OWNER'S MANUAL HYDRAULIC DRUM CRUSHER/COMPACTOR MODELS HDC-900 & HDC-905
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1 Vestil Manufacturing Corporation 2999 North Wayne Street, P.O. Box 507 Angola, Indiana USA Distributed by Ergonomic Partners Web: PH: FAX: Contents Warnings and Safety Instructions... 1 Receiving Instructions... 1 Warnings and Safety Instructions... 2 Operating Instructions... 3 Installation Instructions... 4 Loading Instructions... 4 Periodic Maintenance Instructions... 5 Exploded Parts Drawings... 6A & 6B Bills of Materials... 6A & 6B Revised A company dedicated to solving ergonomic and material handling problems since OWNER'S MANUAL HYDRAULIC DRUM CRUSHER/COMPACTOR MODELS HDC-900 & HDC-905 Power Unit: Diagram & Parts List...7A-7B Pressure Switch & Valve Settings...7C-7E Electrical Circuit Diagram... 8 Electrical System Specifications... 9 Hydraulic Circuit Diagram Label Placement Diagram Limited Warranty (Standard Units)...12A Limited Warranty (Wash-down Units)...12B E N G L I S H WARNINGS & SAFETY INSTRUCTIONS Read owner's manual completely before operating unit! Do not service unit unless power is disconnected. Do not operate drum crusher/compactor unless all cover plates are in place and all components are in proper working order. Do not clean out drum crusher unless power is disconnected. Do not bypass the safety interlocks. Keep hands and feet outside the unit at all times when operating. Do not allow personnel to stand on drum crusher. Do not stand in front of drum crusher door. Do not operate this unit with loading door open. **(Do not operate if safety switch is not functioning properly.) Do not change pressure relief valve setting. Do not clamp hydraulic cylinder in a vise as you may distort the drum. Use only maintenance parts either supplied or approved by the manufacturer. Do not use brake fluids or jack oils. Use AW-32 Hydraulic oil or equal. Make sure all labels (see Label placement diagram, p. 12) and machine guards are in place & readable or functioning. Report all safety problems immediately. DO NOT modify the drum crusher in any way without first obtaining written authorization from VESTIL. Unauthorized modification(s) automatically void the Limited Warranty and might make the crusher unsafe to use. Page 1 RECEIVING INSTRUCTIONS After delivery, IMMEDIATELY remove the packaging from the product in a manner that preserves the packaging and maintains the orientation of the product in the packaging; then inspect the product closely to determine whether it sustained damage during transport. If damage is discovered during the inspection, immediately record a complete description of the damage on the bill of lading. If the product is undamaged, discard the packaging. SERIAL NUMBER AND CAPACITY The serial number and capacity are inscribed on the nameplate (See p. 12 for location). Please remember to include these numbers in any correspondence with your dealer or the factory. HYDRAULIC DRUM CRUSHER/COMPACTOR MODELS HDC-900 & HDC-905 E S P A N O L F R A N Ç A I S
2 HAZARDS ASSOCIATED WITH USE & GUIDELINES FOR SAFE USE *** Make copies of this page and post in a highly visible location where the unit is being operated and on the company bulletin board. Read Owner's Manual completely before operating or servicing this unit. Do not operate this unit unless all cover plate and guards are in place. Do not operate this unit with loading door open. Do not operate if safety switch is not functioning properly.) Do not stand in front of this unit's door when operating it. Do not allow personnel to stand on this unit. Do not place hands or feet in hopper openings. Keep hands and arms away from all moving parts of this unit. Do not go near leaks - High pressure oil easily punctures skin causing injury, gangrene, or death. Do not service this unit unless power is disconnected. Do not clean out this unit unless power is disconnected. Never use a damaged unit or one that is making unusual noises. Do not change pressure relief valve setting on manifold. Do not clamp hydraulic cylinder in a vise as you may distort the drum. Do not perform any modification to the original equipment without written manufacturer's approval. Use only maintenance parts supplied or approved by the manufacturer. Do not use brake fluids or jack oils. Use AW-32 Hydraulic Oil or equal. Maintenance and repairs are to be done only by personnel qualified to perform the required work. Be sure all safety labels are in place (see Owner's Manual p.12). Report all safety problems immediately. Page 2 For more information: (260) (Fax)
3 OPERATING INSTRUCTIONS The HDC-900 is equipped with a momentary contact control. This relieves the operator from having to hold the "Start" button while the unit cycles. Sequence of Operation: To operate the crusher: 1) select the appropriate platen configuration (see "Platen configurations" on p. 4); 2) place a drum inside the crusher; 3) close the door; 4) lock the door latch handle; 5) turn the key switch to the appropriate mode; 6) select CRUSH or COMPACT ; 7) pull out the Emergency Stop button; 8) momentary press the cycle START button to activate the crush/compact cycle. The direction of the platen's travel will be determined by its starting position -- if it is fully raised to the top of the cabinet, the platen will move down to crush a drum; otherwise, the cylinder will raise the platen until it finally is all the way up and in its starting ("home") position, at which point the power unit will turn off. Pressing the cycle start button again will cause the platen to move downward. The operator must hold the button for a few seconds to latch the circuit. When the crusher is in its "home" position and the cycle start button is pressed, the cylinder pushes the platen down onto (or into) the drum. In order to achieve a short cycle time, both sections of the pump in the power unit drive oil to the cylinder until the cylinder pressure reaches approximately 1000 PSI. At that time, the higher-displacement section recycles oil to the reservoir while the low-displacement, high-pressure section continues to pump oil to the cylinder, i.e. a typical High-Low circuit. As the platen crushes or compacts the drum to a height of about 6 inches, the cylinder pressure increases until it reaches the set-point of the appropriate pressure switch. The valve shifts to center and a timer activates to control the period of decompression. Once the period ends the directional valve shifts and reverses the direction of oil flow to the cylinder. Reversing the flow of oil raises the platen to its starting, or "home" position. When the cylinder returns the platen all the way to the top of the cabinet, the power unit turns off. At this point, the cabinet door can be opened to remove the drum. If the unit needs to be stopped at any point during its cycle, the operator can depress the red emergency stop button located on the control panel. This stops the motor and prevents the unit from cycling any further. To return the platen to its starting ("home") position, pull the emergency stop button out to release it and depress the cycle start button again. This will cause the platen to ascend back to the starting position. To cycle the unit again, simply depress the cycle start button. RESPONSIBILITIES OF OWNERS/USERS It is the responsibility of the owner/user for the following: 1.) Inspected and maintain this product according to the guidelines in this manual. 2.) Any unit not in normal operating condition should immediately be removed from service and remain out-of-service until it is returned to normal operating condition. Unsafe conditions include, but are not limited to, the following: hydraulic fluid leakage, missing pins, or fasteners, any cracked or deformed structural members, cut or frayed hydraulic or electric lines, and damaged controls or safety devices. All repairs and maintenance must be performed by qualified personnel. 3.) Unit should only be used by authorized personnel. All operators must read and understand all operating procedures and safety guidelines in this manual prior to using the crusher for the first time. 4.) Operator should verify that all safety features function properly before each use. 5.) Any modifications to the unit must be approved in writing by the manufacturer. Ordering Replacement & Spare Parts Our company takes pride in using the finest available parts for our equipment. We are not responsible for equipment failure resulting from the use of unapproved replacement parts. To order parts for your equipment, contact Customer Service (see contact information on the cover page). In any correspondence with the factory please include the Serial Number which is included on label 287 (see "Label placement diagram" on p. 11). Use only the part numbers provided in this Owner's Manual. When ordering parts for AC power units, please indicate the motor phase as well as the operation voltage of the equipment. Page 3
4 INSTALLATION INSTRUCTIONS Read the entire manual before installing the crusher. Installation requires the following: 1.) A fork truck. 2.) Lag bolts, masonry drill, masonry bit, and wrench for lag bolt, grout, and steel shims. 3.) A power circuit with the specified voltage, including fuses and disconnect or circuit breakers. (See p. 8-9). Reference NEC ) Minimize voltage drop by using adequate wire size. Reference NEC 70. Read all warning labels on the unit (see "Label placement diagram" on p. 11) and confirm that each label shown in the diagram is on the unit. Move the crusher to its installation location, e.g. with a fork truck by lifting the crusher via the fork tubes on the frame. Anchor the crusher to the floor before using it for the first time. Connect the power source as shown in the electrical circuit diagram on p. 8 and described in "Electrical system specifications" on p. 9. Cycle the unit a few times; then check the oil level and add more oil, if necessary. (See oil specification on page 5). LOADING INSTRUCTIONS The Hydraulic Drum Crusher/Compactor (HDC-900) is designed to crush standard, ribbed steel drums of 55 gallon size or smaller. DO NOT use the crusher to compact smooth-walled drums, i.e. drums that lack ribs. The crusher can be used to compact standard, ribbed steel drums that contain soft materials. When loading the crusher, always apply these suggestions: 1.) Before using the crusher, confirm that the platen is properly installed; 2.) Carefully center the material/item to be crushed under the platen, because an offset or uneven load might damage the cylinder rod; 3.) DO NOT fill drums with scrap metal, paint cans, etc. which will exceed the crushing capacity of the unit and significantly damage the crusher. NOTE: The crusher is designed to compact standard, ribbed steel drums. However, the crusher might not compact a particular drum. It is also possible that the crusher might sustain minor damage during the compaction process. PLATEN CONFIGURATIONS Configure the platen to match the application: The compactor platen is shown in blue in the drawing at right; the crusher platen is shown in grey. To compact materials, remove the crusher platen by sliding it off of the circular compactor platen. The crusher platen is heavy; at least 2 people should work together to remove it. Lower the ram to position the platen at a comfortable level; then press the red emergency stop button. Remove the crusher platen. To crush drums, install the crusher platen by sliding it unto the compactor platen. Center the crusher attachment on the circular platen as shown in the graphic. Page 4
5 PERIODIC INSPECTIONS & MAINTENANCE INSTRUCTIONS ALWAYS EMPTY THE CRUSHER BEFORE INSPECTING OR PERFORMING MAINTENANCE ON IT. (A) Before each use, inspect the crusher and remove it from service if any of the following issues are observed: 1.) Frayed wires; 2.) Oil leaks; 3.) Pinched or chafed hoses, loose fittings; 4.) Structural deformation of frame; 5.) Unusual noise or binding (B) Monthly Inspections 1.) Check oil level. Oil should be 2" to 2½" below the top of the tank with the cylinder in the fully retracted position. Add as necessary. 2.) Check for oil leaks. 3.) Check for worn or damaged hydraulic hoses, electrical wires, and cords. Repair as necessary. 4.) Cycle the crusher and listen for unusual noise. 5.) Make sure all warning labels are readable and in place according to the diagram on p ) Remove dirt and debris. (C) Yearly Inspection Change the hydraulic oil at least once per year. However, because the oil should be changed as soon as it darkens, looks milky, or becomes gritty, oil changes might be required more frequently than every 12 months. After draining the oil from the reservoir, flush the reservoir before refilling it. If the oil looks milky, water is present and the oil should be changed immediately. Recommended hydraulic oil: Purity ISO AW-32 hydraulic fluid or equivalent. Page 5
6 2 8 fork tube FIG. 1: HDC-900 Exploded parts Diagram & Bill of Materials /2"-13 NYLON INSERT LOCK NUT HHCS #2 Z PLATED, 1/2-13 UNC x 2 1/4 LG HEX NUT Z-PLATED, Ø5/8-11 UNC CYLINDER, 4 X 36 X WELDABLE PEAR LINK LOCK, ADJUSTING ROD ADJUSTABLE YOKE END GUARD, PLASTIC COVER, POWER UNIT RESERVOIR, PLASTIC ROUND/SQUARE DRUM CRUSHER OPTION FRAME, SUBASSEMBLY 1 ITEM NO. PART NUMBER DESCRIPTION QTY. Page 6A
7 fork tube Page 6B 8 7 ITEM NO. PART NUMBER DESCRIPTION QTY /4-10 X 4 1/2 HHCS #2 PLAIN /4 lock washer /4-10 HEX NUT /2"-13 NYLON INSERT LOCK NUT Ø1/2 USS FLAT WASHER PLAIN HHCS #2 Z PLATED, 1/2-13 UNC x 2 1/4 LG Ø5/16-18 NYLON LOCK NUT, Z-PLATED, # HHCS #2 Z PLATED, Ø 5/16-18 x 1 LG Ø5/16 LOCK WASHER Z PLATED Ø 5/16 USS Flat Washer Z Plated ROUND/SQUARE DRUM CRUSHER SUB-ASSEMBLY GUARD, PLASTIC COVER, POWER UNIT RESERVOIR, PLASTIC CYLINDER, 4 X 36 X FRAME, SUBASSEMBLY 1 4 FIG. 2: HDC-905 Exploded Parts Diagram & Bill of Materials
8 Page 7A
9 FIG. 4: Detailed Parts Breakdown of Manifold Assembly (Item No. 21 on p. 7A) Item no. Part no. Description Quantity Manifold Filter Unloading valve 1 4 SHD-03G-3C60-A24D 4-way valve Relief valve Pressure switch PO check Check valve H-04 Plug psi check valve Fitting way valve VAC coil Fitting O-ring ¼ in. 20 x 1 ½ in. SHCS bolt Fitting /10/6802 Fitting Pressure switch 1 14 Page 7B
10 Adjusting Pressure Switch and Hydraulic Valve Settings The manifold assembly shown in Figures 1 4 below corresponds to item no. 21 on p. 7A & 7B. Filter Pressure switch #2 (port PS2) Set screw on knurled knob of pressure switch 1 [NOTE: The knurled knob of PS1 also has a set screw.] Pressure switch (port PS1) Gauge port (GA); install 3,000psi pressure gauge FIG. 5: Front view FIG. 6: Rear view Directional valve Sequence valve Upper pressure switch (PS2) Filter Directional valve Adjustment hex flats of relief valve Gauge port (UL GA); install 3,000psi pressure gauge Lower pressure switch (PS1) FIG. 7: Left side view FIG. 8: Right side view Page 7C
11 Procedures for adjusting hydraulic valves and pressure switches: 1. Install pressure gauges in ports GA and UL GA (see FIGS. 6 & 7 respectively on p. 7D): [NOTE: Hose fittings and adaptors might be necessary to connect the gauges to these ports.] a. Remove the cap plugs from port GA and install a 3000psi gauge into the port. The port is located under the directional valve; then b. Remove the cap plug from port UL-GA and install a 3000psi gauge into the port, which is located under the sequence valve (pointed towards the motor). 2. Prepare the pressure switches: a. Using a standard (flathead) screw-driver, loosen the set-screws through the knurled knobs on both of the pressure switches (see FIG. 6, p. 7B); then b. Turn the knurled ring of each pressure switch clockwise until they can turn no farther. 3. Turn the adjustment hex flats on the relief valve (See FIG. 7 on p. 7D; labeled RV) out all the way, by turning it counterclockwise. 4. Turn the selector-switch on the control box to COMPACT. 5. Press the cycle start button on the control box. a. Hold the button until the motor engages. b. While the motor operates, the hydraulic cylinder extends and the platen descends towards the bottom of the enclosure. 6. Adjust the unload valve: a. When the cylinder is fully extended and while the motor continues to run, adjust the unload valve (in port SV) until the UL GA pressure gauge reads 1000 psi. Typically, adjustment requires turning the valve clockwise rather than counterclockwise. 7. Adjust the relief valve: a. With the motor running, observe the reading on the gauge connected to the GA port. b. Begin turning the adjustment hex of the relief-valve ( RV ) clockwise. [Note: As pressure approaches 1000 psi, you will hear a change in sound as the unload valve--adjusted in step 6-- shifts into the unloaded position.] c. Continue to increase the RV setting until the GA gauge displays 1500 psi. 8. Adjust the upper pressure switch (in port PS2): a. With the power unit now adjusted and operating at 1500 psi pressure, decrease the setting on PS2; b. Rotate the knurled knob counterclockwise until it clicks. The click indicates that the directional valve shifted. Consequently, the cylinder will retract and lift the platen to the raised position and the power unit will turn off. 9. Adjust the lower pressure switch (PS1): a. Turn the selector switch on the control box to CRUSH. b. Press the cycle start button and hold it until the motor engages. c. While the power unit runs, i. Increase the RV valve setting until the gauge displays 3000 psi. ii. Turn the knurled knob on the pressure switch in port PS1 (lower pressure switch) counter-clockwise until it clicks. The click indicates that the switch is open. Simultaneously, the valve shifts and the platen will rise. iii. Turn the knob counter-clockwise an additional 1/8 turn. 10. Return the crusher to service: a. Run the crusher through a complete cycle in each mode (COMPACT and CRUSH) to confirm that the machine is functioning normally. b. Remove the pressure gauges and reinstall the cap plugs into ports GA and UL GA. c. Tighten the set screws to fix the positions of the knurled knobs of PS1 and PS2. Page 7D
12 Electrical controls sequence of operation: 1) Press Cycle start button - 1M energizes; - Aux. contacts 13 and 14 close; - Terminal 8 energizes; - Power at CR2 9&1; - Power reaches 2LS normally open, held closed switch (NO, HC); - Power on 11 to CR1, 13 and 14; - CR1, 5 and 9 close (latch); - CR1, 2 and 10 open (timer); - Energize 2 SOL H (4-way, 3-position); - Ram and platen descend. 2) As the ram and platen descend: - 2 LS normally closed, held open switch (NC, HO) closes; - 2 LS NO, HC opens. 3) At the bottom of the cylinder (ram) stroke: - PS1 (if in CRUSH mode) or PS2 (if in COMPACT mode) make; - Energizes CR2, 13 and 14; - CR2, 9 and 1 open; - 2 SOL H de-energize; - CR1, 13 and 14 de-energize; - CR1, 2 and 10 close and the timer starts. 4) Timer cycle: - CR1, 3 and 11 close; - Power reaches decompression valve 3 SOL H; second delay; - CR3, 2 and 10 open; - 3 SOL H de-energizes and closes; - CR3, 5 and 9 close; - Power to 1 SOL H causing the ram and platen to ascend. 5) As the cylinder retracts, causing the ram and platen to return to the ready position: - 2 LS normally closed switch opens; and - 1M de-energizes. Page 7E
13 Page 8 FIG. 9: Electrical system diagram
14 Electrical System Specifications: This hydraulic drum crusher, model HDC-900 or HDC-905, was tested at the factory at the voltage specified at the time of order. For applications that require voltages that differ from original specifications, the motor and control transformer must be rewired for the appropriate voltage. Failure to do so automatically voids the Limited Warranty (see p. 12A & 12B) and might significantly damage the electrical system. Motor wiring: The table below indicates how to wire 3-phase motors of specified voltages VAC, 3-Phase Motor wires 1 & 7 Connect to contactor lead T1 Motor wires 2 & 8 Connect to contactor lead T2 Motor wires 3 & 9 Connect to contactor lead T3 Motor wires 4, 5 & 6 Tie together with a wire nut Motor wire 1 Motor wire 2 Motor wire 3 Motor wires 4 & 7 Motor wires 5 & 8 Motor wires 6 & 9 460VAC, 3-Phase Connect to contactor lead T1 Connect to contactor lead T2 Connect to contactor lead T3 Tie together with a wire nut Tie together with a wire nut Tie together with a wire nut Transformer: If the supply voltage to the motor is changed, the primary wires of the transformer must also be changed (refer to Electrical system diagram on p. 8; also refer to the label on the transformer to properly connect to the supply voltage). Page 9
15 Page FIG. 10: Hydraulic System Diagram M
16 Label placement diagram: By Oil Fill Data Label Page 11
17 Rev. 11/20/2014 LIMITED WARRANTY Vestil Manufacturing Corporation ( Vestil ) warrants this HDC-900 (excluding Washdown model HDC-905- WD, which is covered by a separate warranty) to be free of defects in material and workmanship during the warranty period. Our warranty obligation is to provide a replacement for a defective original part if the part is covered by the warranty, after we receive a proper request from the warrantee (you) for warranty service. Who may request service? Only a warrantee may request service. You are a warrantee if you purchased the product from Vestil or from an authorized distributor AND Vestil has been fully paid. What is an original part? An original part is a part used to make the product as shipped to the warrantee. What is a proper request? A request for warranty service is proper if Vestil receives: 1) a photocopy of the Customer Invoice that displays the shipping date; AND 2) a written request for warranty service including your name and phone number. Send requests by any of the following methods: Mail Fax Vestil Manufacturing Corporation (260) sales@vestil.com 2999 North Wayne Street, PO Box 507 Phone Angola, IN (260) In the written request, list the parts believed to be defective and include the address where replacements should be delivered. What is covered under the warranty? After Vestil receives your request for warranty service, an authorized representative will contact you to determine whether your claim is covered by the warranty. Before providing warranty service, Vestil may require you to send the entire product, or just the defective part or parts, to its facility in Angola, IN. The warranty covers defects in the following original dynamic components: motors, hydraulic pumps, electronic controllers, switches and cylinders. It also covers defects in original parts that wear under normal usage conditions ( wearing parts ): bearings, hoses, wheels, seals, brushes, batteries, and the battery charger. How long is the warranty period? The warranty period for original dynamic components is 1 year. For wearing parts, the warranty period is 90 days. The warranty periods begin on the date when Vestil ships the product to the warrantee. If the product was purchased from an authorized distributor, the periods begin when the distributor ships the product. Vestil may, at its sole discretion, extend the warranty periods for products shipped from authorized distributors by up to 30 days to account for shipping time. If a defective part is covered by the warranty, what will Vestil do to correct the problem? Vestil will provide an appropriate replacement for any covered part. An authorized representative of Vestil will contact you to discuss your claim. What is not covered by the warranty? 1. Labor; 2. Freight; 3. Occurrence of any of the following, which automatically voids the warranty: Product misuse; Negligent operation or repair; Corrosion or use in corrosive conditions; Inadequate or improper maintenance; Damage sustained during shipping; Accidents involving the product; Unauthorized modifications: DO NOT modify the product IN ANY WAY without first receiving written authorization from Vestil. Modification(s) might make the product unsafe to use or might cause excessive and/or abnormal wear. Do any other warranties apply to the product? Vestil Manufacturing Corp. makes no other express warranties. All implied warranties are disclaimed to the extent allowed by law. Any implied warranty not disclaimed is limited in scope to the terms of this Limited Warranty. Page 12A
18 LIMITED WARRANTY Vestil Manufacturing Corporation ( Vestil ) warrants this HDC-905-WD drum crusher to be free of defects in material and workmanship during the warranty period. Our warranty obligation is to provide a replacement for a defective original part if the part is covered by the warranty, after we receive a proper request from the warrantee (you) for warranty service. Who may request service? Only a warrantee may request service. You are a warrantee if you purchased the product from Vestil or from an authorized distributor AND Vestil has been fully paid. What is an original part? An original part is a part used to make the product as shipped to the warrantee. What is a proper request? A request for warranty service is proper if Vestil receives: 1) a photocopy of the Customer Invoice that displays the shipping date; AND 2) a written request for warranty service including your name and phone number. Send requests by any of the following methods: Mail Fax Vestil Manufacturing Corporation (260) sales@vestil.com 2999 North Wayne Street, PO Box 507 Phone Angola, IN (260) In the written request, list the parts believed to be defective and include the address where replacements should be delivered. What is covered under the warranty? After Vestil receives your request for warranty service, an authorized representative will contact you to determine whether your claim is covered by the warranty. Before providing warranty service, Vestil may require you to send the entire product, or just the defective part or parts, to its facility in Angola, IN. The warranty covers defects in the following original dynamic components: motors, hydraulic pumps, electronic controllers, switches and cylinders. It also covers defects in original parts that wear under normal usage conditions ( wearing parts ): bearings, hoses, wheels, seals, brushes, batteries, and the battery charger. How long is the warranty period? The warranty period for original components is 30 days. The warranty period begins on the date when Vestil ships the product to the warrantee. If the product was purchased from an authorized distributor, the period begins when the distributor ships the product. Vestil may extend the warranty period for products shipped from authorized distributors by up to 30 days to account for shipping time. If a defective part is covered by the warranty, what will Vestil do to correct the problem? Vestil will provide an appropriate replacement for any covered part. An authorized representative of Vestil will contact you to discuss your claim. What is not covered by the warranty? 1. Labor; 2. Freight; 3. Occurrence of any of the following, which automatically voids the warranty: Product misuse; Negligent operation or repair; Corrosion or use in corrosive conditions; Inadequate or improper maintenance; Damage sustained during shipping; Accidents involving the product; Unauthorized modifications: DO NOT modify the product IN ANY WAY without first receiving written authorization from Vestil. Modification(s) might make the product unsafe to use or might cause excessive and/or abnormal wear. Do any other warranties apply to the product? Vestil Manufacturing Corp. makes no other express warranties. All implied warranties are disclaimed to the extent allowed by law. Any implied warranty not disclaimed is limited in scope to the terms of this Limited Warranty. Page 12B
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