TABLE OF CONTENTS. Ram Assembly
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2 TABLE OF CONTENTS DUC Cover Table of Contents SERVICE INSTRUCTIONS Back Panel Side Panel Frame Top Assembly Door Front Panel Insert Drawer Assembly Drawer Latch Mechanism Drawer Handle Drawer Track Kick Board Control Panel Blower Motor Drive Chain Motor Drive Belt Ram Unit Jack Screws Motor Sprocket & Drive Pulley Assembly Motor & Pulley Electrical Power Cord Directional Switch Drawer Front Interlock Switch Interlock Bypass Switch Ram Switch Pictorial Wiring Diagram Schematic Wiring Diagram Service Tips Component Breakdown Unit Cut-A-Way Frame Assembly Container Assembly Ram Assembly
3 SERVICING INSTRUCTIONS NOTE: IT WILL BE NECESSARY TO REMOVE THE UNIT FROM ITS INSTALLED POSITION. NOTE: DISCONNECT ELECTRICAL POWER SUPPLY BEFORE SERVICING UNIT. SIDE PANELS (Fig. 1) 1. Remove top and back panel. 2. Open litter bin door and remove two retaining screws (9). 3. Open drawer and remove remaining front retaining screws (7 & 8). FRAME TOP ASSEMBLY (Fig. 10) 1. Remove top, back panel and side panels. 2. Remove three jack screw retainer nuts (4). 3. Remove two truss head retaining screws (3). 4. Lift off enclosure plate (1). 5. Remove four truss head retaining screws (2). 6. Disconnect the two ram switch leads from start-stop program switch (3) and remove frame top assembly. Top (Fig. 1) 1. Remove three top retaining screws (1) from rear of compactor. 2. Slide top toward rear to disengage from key slots. Lift off top BACK PANEL (Fig. 1) 1. Remove three screws (1) at top. 2. Remove four screws (2) from each side. 3. Remove two screws (3 & 6) from back panel. Remove plate (4) and slide relief (5) up and out of slot. Feed cord through rectangular hole in back panel. DOOR FRONT PANEL INSERT (Fig. 2) 1. Open door and remove three retaining screws from pull handle (1) and remove handle. 4
4 2. Slide panel insert out through opening in top of litter bin door. 1. Remove drawer. 2. Stand drawer on rear and remove the three trim panel retaining screws (1) from bottom of drawer. 3. Remove bottom trim. Slide panel insert out through opening in bottom of drawer front. DRAWER LATCH MECHANISM (Fig. 3) 1. To service the drawer latch rod, springs, and hook assembly, remove the upper three retaining screws (2) from each side of drawer panel. 2. Loosen, but do not remove, the bottom retaining screw (3) on each side of the drawer panel. 3. Pivot drawer front away from storage bin. 4. Disengage latch rod hook from handle and remove latch rod assembly from drawer front. DRAWER HANDLE (Fig. 5) DRAWER ASSEMBLY (Fig. 3) 1. With drawer forward, remove two drawer retaining screws (1), from drawer tracks. 2. Remove drawer from drawer tracks. 1. It is not necessary to remove the drawer front to service drawer handle or hinge & mounting bracket assembly. 2. Use a short handled Phillips screwdriver to remove retaining screws (1) to remove drawer handle. 3. To remove hinge & handle mounting bracket assembly, withdraw the two screws (2) from inside storage cover. DRAWER FRONT PANEL INSERT (Fig. 4) 5
5 7. When installing drawer tracks, first connect springs to frame (spring hooks facing out), then to track mounting brackets. 8. Force the track downward until the hole in the track mounting bracket lines up with the slot in the frame, permitting installation of the bolt, washer and nut NOTE: At reassembly the bolt head should be on the inside of the frame. KICKBOARD 1. Remove drawer. DRAWER TRACK / SPRING (Fig. 6) 1. Remove top. 2. Remove back panel. 2. Stand drawer on rear and remove four retaining screws from kickboard and kickboard support plate. 3. Remove kickboard and support plate. 3. Remove side panels. 4. Remove drawer. 5. Loosen, then remove the two track mounting nuts and washers (1), (two in front and two in back). 6. Remove bolts and washers, then disconnect springs (2) and remove drawer tracks. CONTROL PANEL (Fig. 7) 1. Open litter bin door and remove two retaining screws (1) from inside top of litter bin. 2. Slide console forward to clear unit and disconnect wire leads from charcoal air filter switch, and key lock switch. 3. Remove control panel (2). 6
6 1. Connect electrical power supply and run ram to bottom position. 2. Disconnect power supply. 3. Remove back panel. 4. Disconnect two lead wires from blower motor. 5. Remove two blower motor mounting screws (1). 6. Remove blower motor and fan from housing. NOTE: The nylon blower motor fan is lightly pressed onto the motor shaft. This is removable for service replacement. CHAIN TENSION REGULATOR (Fig. 9) 1. Remove top and top frame cover plate. 2. Remove chain tension regulator spring (2). 3. Remove retaining nut (1) and lock washer from idler arm. 4. Remove screw (5) from idler plate assy. (4). Shift idler plate to allow idler arm (3) to clear sprocket cover. 5. Lift off idler arm (3). DRIVE CHAIN 1. Remove top, back panel, side panel and frame top assembly. 2. Remove chain tension regulator spring (2, Fig. 9). 3. Pull drawer half way open. locate ram on top of drawer. Ram can be operated manually by using the 5/8 hex socket on the motor sprocket (6, Fig. 11). 4. Remove the four sprocket cover and brace screws from the ram top brace. Then loosen (only) the two remaining screws in the ram top brace. Remove the drive sprocket covers (1, 3 and 6, Fig.10). 7
7 5. Remove chain (5, Fig.10) from sprocket. 6. Install replacement chain making certain chain is properly positioned onto drive and idler sprockets. Install tension regulator spring (4, Fig.10). CAUTION: All three drive sprockets must be level (same height). Measure distance from top of each jack screw to top of drive sprocket. 7. Adjust drive chain for correct tension by loosening the four motor sprocket bracket mounting blots (7, Fig.10), and moving the sprocket in the proper direction to the distance from the center of the two idler sprocket retaining screws is 6 ¼ minimum to 6-1/2 maximum as shown (see Fig. 9). It is IMPORTANT this distance is maintained. 8. The four sprocket bracket mounting bolts (7, Fig.10) must be securely tightened. Check the two side flange bearing mounting bolts (8, Fig.10) and if necessary, retighten. Recheck the chain adjustment. 9. Reinstall drive sprocket covers and ram top brace 10. Manually rotate motor sprocket clockwise to check for free operation of ram drive mechanism. MOTOR DRIVE BELT To remove: 1. Remove top and top frame cover plate. 2. Locate ram approximately 4 inches from top position. Ram can be operated manually by using the 5/8 socket on the motor sprocket (6, Fig.11). 3. Remove chain tension regulator spring (4, Fig.10). 4. Loosen four motor mounting bolts (2, Fig.10). Slide motor toward sprocket drive pulley and remove belt. To replace: 5. Position belt around motor sprocket drive pulley. 6. Move belt toward motor and around motor pulley making certain teeth in belt are meshed in both sprocket drive pulley and motor pulley. 7. Slide motor toward front and finger tighten mounting blots (2, Fig.10) 8
8 8. Rotate motor sprocket manually approximately two revolutions to align belt. 9. Loosen motor mounting bolts (2, Fig.10), slide motor toward front until belt is taut (approximately 30 to 40 lbs.). 10. Replace chain tension regulator spring (4, Fig.10). RAM UNIT 1. Remove top, back panel, side panels and frame top assembly. 2. Pull drawer out half way. 3. Locate ram on top of drawer. Ram can be operated manually by using the 5/16 hex socket on the motor sprocket (6, Fig.11). 4. Remove Drive Chain (5, Fig.11). 5. Unscrew all three drive sprockets (1, Fig.12) from jack screws (2, Fig.12). 6. Remove drive sprocket grease retainers (Fig.13). CAUTION: DO NOT INTERCHANGE jack screw sprocket assemblies. On reinstallation be certain to return each sprocket assembly to its original jack screw location. 9
9 7. Remove drawer interlock actuator bracket from rear of upper ram housing. 8. Loosen main wiring harness by removing strain relief bushing (1, Fig.14) from frame and harness retainer (4, Fig. 17) from idler plate. 9. Move wiring harness aside. Grasp side of ram and lift from jack screws. NOTE: Should further disassembly be requested for the ram, disconnect all ram wiring connections. JACK SCREWS CAUTION: At reassembly of jack screw make certain square end of jack screw (1, Fig.16) extends through square hole and is flush with bottom of screw retainer plate (2, Fig.16). Screw retainer plate (2, Fig.16) must be drawn up tight against the mating face of the jack screw retainer nut (3, Fig.16). 1. Remove ram. (Jack screws are now accessible for removal). 2. Remove hex mounting bolts (2, Fig.15). 3. Pull jack screw (1, Fig.15) down through hole in frame and withdraw jack screw retainer out (3, Fig.15) and screw retaining plate (4, Fig.15) from underside of cross member of frame. 10
10 MOTOR SPROCKET AND DRIVE PULLEY ASSEMBLY (Fig.17) 1. Remove top, top frame cover plate and one side panel. 2. Ram must be located in top position (if necessary, use 5/8 hex socket wrench to manually raise ram). 3. Remove drawer. 4. Tape the ram spacer to ram top for holding spacer in place before removing ram bottom. (Use 6 or 8 strips of masking tape.) 5. Remove four retaining screws from ram bottom. NOTE: To reassemble ram bottom, masking tape should again be used to hold ram bottom in place (6 or 8 strips are necessary). Start one of the front retaining screws to secure the ram bottom. Install remaining screws. Tighten securely and remove tape. 6. Loosen four mounting bolts (1) and slide motor sprocket bracket toward motor. 7. Remove chain tension regulator spring (2). 8. Disengage chain (5) from motor sprocket. 9. Remove four motor sprocket bracket mounting bolts (1) and lower the drive pulley assembly. NOTE: Repairs to the motor sprocket and drive pulley assembly should not be attempted. If unit is faulty, replace with complete new unit. MOTOR AND PULLEY (Fig.17) 1. Remove top and top frame cover plate. 2. Remove drawer. 3. Locate ram in down position. (If necessary, use 5/8 hex socket to manually lower ram.) 4. Remove four retaining screws from ram bottom. 5. Remove ram bottom and the ram spacer. 6. Disconnect motor lead wires. 7. Loosen motor mounting bolts (3) and slide motor toward motor drive sprocket assembly. 8. Remove motor drive belt. 9. Insert ram bottom and spacer and place as support under motor. Remove motor mounting bolts (3). Slightly raise ram manually to clear top of motor. Lower and remove motor. 11
11 SWITCHES-CONTROL PANEL (Fig.18) [Filter switch (1), Key lock switch (2)] 1 Remove control panel. 2 Remove lead wires from switches. 3 Remove filter switch by depressing tabs together and pulling switch out of panel. 4 Remove key switch, retaining nut and then the switch. CAUTION: Leak wire identifications MUST correspond with switch terminals. ELECTRICAL POWER CORD 1. Remove L.H. side panel. 2. Remove back panel. 3. Remove ground screw, wire connector from white neutral lead and disconnect two switch terminal connections from drawer front interlock and bypass interlock switch. 4. Remove strain relief bushing from left front vertical frame upright. 5. Remove electrical power cord. 6. When reinstalling electrical power cord, feed cord through cord clamps. DIRECTIONAL SWITCH (Fig.18) 1. Remove top and top frame cover plate. 2. Disconnect lead wires from switch (3). CAUTION: At reassembly, lead wire identification MUST correspond with switch terminals. 3. Remove switch retaining screws and the switch. DRAWER FRONT INTERLOCK SWITCH 1. Remove top and left side panel. 2. Remove interlock switch lead wires. 3. Remove switch mounting screws and the switch. 12
12 INTERLOCK BYPASS SWITCH (Fig.10) 1. Remove top and side panel. 2. Remove interlock switch lead wires. 3. Remove switch mounting screws and the switch (2). RAM SWITCH (Fig.19) 1. Remove top and top frame cover plate. 2. Disconnect two lead wires from switch (1). 3. Remove switch retaining screws and the switch. 4. In reassembling switch make sure it is correctly adjusted. Rotate in slot as necessary. 13
13 PICTORIAL WIRING DIAGRAM 14
14 SCHEMATIC WIRING DIAGRAM 15
15 VIKING COMPACTOR ** SERVICE TIPS ** CONDITION POSSIBLE CAUSE REMEDY Motor runs but 1. Motor pulley, motor sprocket, 1.1 Replace pin(s) ram inoperative drive sprocket or drive pulley 1.2 Replace drive belt is inoperative 1.3 Replace drive chain 1.4 Replace pulleys or sprockets Ram stuck in down 1. Malfunction of directional 1.1 Replace directional switch Position switch. Ram operates continuously 1. Malfunction of ram switch 1.1 Adjust or replace ram switch 2. Misalignment of start 2.1 Realign start switch button. Switch button Drawer will not close 1. Drawer latch mechanism 1.1 Adjust latch rod for proper alignmisaligned. ment with drawer track hooks. 2. Drawer track malfunction 2.1 Clean and loosen or replace drawer track. 2.2 Replace drawer spring. 3. Drawer latch rod will not slide 3.1 Apply a small amount of lubriover cam on drawer slide hooks. cant (grease) on the drawer slide Hook cam surface to allow drawer Latch to slide on cam surfaces. Drawer will not open 1. Drawer kickboard drags on floor. 1.1 Adjust leveling legs. 1.2 Replace drawer springs. If required. 2.Malfunction of directional switch 2.1 See Ram stuck in down position. 3. Drawer latch mechanism 3.1 Adjust or replace malfunction malfunctions. Parts. 4. Trash jamming drawer. 4.1 Remove trash 5. Malfunctioning tracks. 5.1 Clean, lubricate or replace as required. 6. Track spring inoperative. 6.1 Correct or replace. Compactor will not operate 1. No electric power to compactor 1.1 Make sure compactor is plugged in. 1.2 Check fuse or circuit breaker. 2. Drawer not completely closed 2.1 Close drawer. 3. Key in locked position. 3.1 Turn key to unlock. Motor will not operate 1. Improper electrical connections. 1.1 Check and correct. 2. Motor inoperative. 2.1 Replace motor. Odor 1. Fully absorbed charcoal air filter. 1.1 See Use and Care Guide. 2. Inoperative blower motor. 2.1 Check electrical connection. 2.2 Replace motor. Clearance between drawer 1. Improper drawer and /or litter 1.1 Align as needed. and litter bin door uneven bin alignment. **A properly operating compactor will smash 3 #2 size cans to ¼ their original height with cans placed on a 6 wood block. When making this test the cans should have their lids removed. #2 size cans are approximately 3 ½ in diameter and 4 ¼ high. 16
16 DUC180 CUT-A-WAY 17
17 DUC180 FRAME ASSY. 18
18 DUC 180 CONTAINER ASSEMBLY 19
19 RAM ASSEMBLY 20
20 Viking Range Corporation 111 Front Street, Greenwood, Mississippi (MS) USA (662) Viking products are marketed under the Ultraline brand name in Canada F90199 Specifications subject to change without notice (LP10/02)
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