VESTIL MANUFACTURING CORP. 2999 N. Wayne St., Angla, IN 46703 Ph: 260-665-7586 Fax: 260-665-1339 E-mail: sales@vestil.cm Website: www.vestil.cm 01/08 HPC-400, 22-126-120, 0108 MODEL HPC-400 HYDRAULIC PAIL CRUSHER Serial number Assembly / Installatin Instructins.. 2 Operatin Instructins. 3-4 Rutine Maintenance & Safety Checks 5 Inspectin & Testing Prcedures (hists)..... 6 Explded Structural Parts Drawing & BOM... 7-8 OWNER S MANUAL Electrical & Hydraulic Diagrams & BOM. 9-12 Pwer Unit s Operatin........ 13 Trubleshting... 14 Safety Label Identificatin...15 Warranty.... 16 IMPORTANT NOTES, WARNINGS AND SAFETY INSTRUCTIONS Ensure that all emplyees understand and fllw the fllwing. Failure t read and understand this wner s manual befre using r servicing the pail crusher cnstitutes a misuse f the prduct. All persns wh will install, use, r care fr this prduct must be familiar with this material. The crushing platen must be secured against drpping befre any wrk is perfrmed n the hydraulic system. Ensure that all infrmatin / safety / warning labels stay in place and remain legible. D nt use the pail crusher if any damage r unusual nise is bserved. Always verify that the cabinet dr is securely clsed befre the crusher is put int peratin. The pail crusher is intended fr crushing steel pails (standard 5-galln and smaller) in nn-classified indr envirnments. D nt use brake fluid r jack ils in the hydraulic system. If il is needed, use an anti-wear hydraulic il with a viscsity grade f 150 SUS at 100 F, (ISO 32 cst @ 40 C), r Dexrn transmissin fluid. Cntact the manufacturer fr any needed MSDS infrmatin. D nt perfrm any mdificatins t the pail crusher withut the manufacturer s apprval. Failure t receive authrizatin fr changes t the equipment culd vid the warranty. Maintenance and repairs are t be dne nly by persnnel qualified t perfrm the required wrk. Cnsideratin will nt be given fr warranty repair charges withut prir written authrizatin by the manufacturer. WHEN ORDERING REPLACEMENT PARTS: We take pride in using quality parts n the equipment we manufacture. We are nt respnsible fr equipment prblems resulting frm the use f unapprved replacement parts. T rder replacement r spare parts fr this equipment, cntact the factry. In any cmmunicatin with the factry please be prepared t prvide the machine s serial number, which is indicated n the machine dataplate. RECEIVING INSTRUCTIONS It is pssible that this prduct culd incur damage during transit. Inspect the unit clsely when it arrives. If yu see evidence f damage r rugh handling t either the packaging r t the prduct when it is being unladed, immediately make a nte f it n the Bill Of Lading! It is imprtant that yu remve the prduct s packaging upn its arrival t ensure that there is n cncealed damage r t enable a timely claim with the carrier fr freight damage. Als verify that the prduct and its specificatins are as rdered. VESTIL MFG. CO. 1
INSTALLATION INSTRUCTIONS HPC-400 Review this entire page befre installing the pail crusher. Cnsult the factry in the event there are any questins r prblems at the time f installatin, r fr infrmatin regarding ptinal features nt cvered by the wner s manual. The pail crusher must be remved frm the shipping wd and securely anchred t a cncrete surface befre use! Mdificatins r additins t the pail crusher withut prir manufacturer s authrizatin may vid the crusher s warranty. The installatin f this machine must be made s that it cmplies with all the regulatins applicable t the machine and its lcatin. The end-user must verify that the supplied equipment is installed s it will be suited t the envirnment in which it will be used. Installatin must be perfrmed by suitably trained persnnel with access t the apprpriate equipment. The electrical aspects f the installatin shuld be perfrmed by an electrician. --------------------------------------------------------------------------------------- Fr a typical installatin f a standard pail crusher, yu will need the fllwing: 1. A frk truck r histing means t unlad the pail crusher frm the freight truck and set it int place. 2. A smth, level, and adequately strng cncrete surface n which t munt the pail crusher. 3. Cncrete anchrs, a masnry drill, a masnry bit, and hand tls. Cnsult the building s architect r facility engineer t determine the best size and type f hardware with which t anchr the machine t the flr. 4. An apprpriate pwer supply circuit and electrical discnnect matching the mtr vltage and current requirements. Refer t the machine s dataplate, t the labels n the cntrl enclsure, and t the electrical sectin in this manual fr mre infrmatin. The end-user is respnsible fr supplying the branch circuit s required grund fault and shrt-circuit prtectin. (Standard units have a 115V mtr with verlad prtectin prvided by a built-in thermstat, and have an 8 lng pwer crd with a mlded 3-prng plug.) --------------------------------------- T install a standard pail crusher: 1. Mve the pail crusher t the lcatin at which it is intended t be perated. Use care t avid damaging the pwer unit s electrical and hydraulic cmpnents. Cautin: Once it is unbanded frm the skid, the pail crusher will be tp-heavy and can fall ver. Nte: The pail crusher s legs can be remved t allw the pail crusher t be used n tp f a heavy wrk table, cuntertp, wrk bench, etc. If the legs are remved, the unit des nt need t be anchred. 2. Anchr the frame t the flr (3/8 max.) thrugh the hles lcated in the bttm flange f each leg. 3. If applicable, make permanent cnnectin t the pwer supply, using an apprpriate wiring methd. 4. Operate the pail crusher thrugh several full crush cycles. Verify that the crush platen s upper travel limit switch and the dr limit switch functin prperly. 5. Check the hydraulic il level. It shuld be filled t within abut 1 f the reservir s fill hle. If il is needed, use an anti-wear hydraulic il with a viscsity grade f 150 SUS at 100 F (ISO 32 at 40 C) r a nn-synthetic autmatic transmissin fluid. 6. Clean up any debris r spilled il, and verify that all f the infrmatin/safety/warning labels are in gd cnditin. VESTIL MFG. CO. 2
OPERATION INSTRUCTIONS HPC-400 Ensure that all emplyees invlved in the peratin f this crusher understand and fllw these instructins! The standard mdel pail crusher is suitable fr use indrs in mst nn-classified industrial and cmmercial lcatins. It is intended t be used t crush empty metal and fiber pails measuring up t 17½ high and 12½ in diameter. [Ntes re: applicatins invlving static, temperature (esp. extremes), washdwn, classified areas, etc.?] Lading: Warning: D nt attempt t crush sealed pails r pails that are nt cmpletely empty. Nte: The riginal cntents f the pail must be taken int accunt t ensure that a hazardus r unhealthy cnditin will nt be created (frm airbrne dust and vaprs, etc.) when it is crushed. Place an empty, unsealed pail n the flr f the cabinet. Center the pail s that there is a gap all the way arund the pail t allw fr the pail s diameter t increase as it crushes. Operatin: Warning: The cabinet dr must be clsed and securely latched befre cycling. Injury t persnnel r permanent damage t the pail crusher culd result frm perating it with the cabinet dr unsecured. Cautin: Keep persnnel away frm the frnt f the machine when it is in peratin. Press and release the CYCLE START pushbuttn. The mtr will turn n and the crushing platen will lwer t crush the pail. When the pail is flattened, the platen will autmatically raise back t the tp f the cabinet and the crusher will turn ff. Open the dr and remve the crushed pail. Warning: D nt attempt t pen the cabinet dr when the crusher is in peratin. Cautin: Never use the pail crusher if any damage r unusual nise is bserved, if it is in need f repairs, r if it seems t be malfunctining. Ntify yur supervisr r maintenance persnnel if yu ntice anything ut f the rdinary. Ensure that all infrmatin/safety/warning labels stay in place and are legible. Refer t the labels page in this manual. VESTIL MFG. CO. 3
ROUTINE MAINTENANCE & SAFETY CHECKS HPC-400 Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Warning: Fully lwer the crushing platen and remve all hydraulic pressure befre beginning any wrk n the hydraulic system. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment (A) Inspect daily fr: 1.) Frayed r damaged wires. 2.) Oil leaks. 3.) Pinched r chafed hses. 4.) Damage r structural defrmatin t the cabinet, legs, r dr latching mechanism. 5.) Unusual nise r binding, r evidence theref. 6.) Prper functining f the upper travel and dr switches. (B) Inspect mnthly fr: 1.) The hydraulic fluid level. It shuld be maintained abut 1-1½ belw the reservir s fill hle with the crushing platen in the fully raised psitin. See belw fr the hydraulic il specificatin. 2.) Wrn r damaged hydraulic hses and electrical wires. 3.) Bending f the crushing platen s hydraulic cylinder rd. 4.) The integrity f the legs anchr blts, and fr cracks in the cncrete arund them. 5.) Cnditin and tightness f the pushbuttns. 6.) Unusual nises r mvement during peratin. 7.) All the infrmatin/safety/warning labels being in place and in gd cnditin. 8.) The need t clean ff dirt and debris. The il shuld be changed if the il darkens, becmes gritty, r turns a milky clr (indicating the presence f water). Replace with an anti-wear hydraulic il with a viscsity grade f 150 SUS at 100 F, (ISO 32 at 40 C). Ex: AW 32 r HO 150 hydraulic il, r a nn-synthetic transmissin fluid such as Dexrn III. Yu may use a synthetic transmissin fluid if yu flush the system with the synthetic fluid befre filling the reservir. VESTIL MFG. CO. 4
EXPLODED PARTS VIEW & BOM -- HPC-400 Item n. Part number Descriptin Qty. 1 22-514-013 Sub-assembly, frame and dr 1 2 22-014-037 Leg, frame, frmed 3 3 22-514-015 Weldment, leg brace, frame, right 1 4 22-514-016 Weldment, leg brace, frame, left 1 5 22-021-006 Cylinder, 2½ x 18 (1½ rd) 1 6 22-514-014 Weldment, frame, push plate 1 7 22-01-022 Bracket, guide, push plate 2 8 A/L Screw, hex head, 3/8 16 UNC x 1 lng 4 9 A/L Washer, flat, 3/8 ID 4 10 A/L Blt, hex head, 3/8-16 UNC x 1½ lng 6 11 A/L Blt, hex head, 5/8-11 UNC x 4¼ lng 1 12 A/L Nut, hex, 5/8-11 UNC 1 13 A/L Blt, hex head, 1/2-13 UNC x 1¼ lng 4 14 A/L Nut, hex, 1/2-13 UNC 4 15 A/L Blt, hex head, 1/4-20 UNC x ¾ lng 8 16 A/L Nut, hex, 1/4-20 UNC 8 VESTIL MFG. CO. 5
MOTOR & TRANSFORMER CONNECTION DIAGRAMS CAUTION! If the mtr vltage is changed, the wire n the cntrl transfrmer s primary wire has t be changed t match the new mtr vltage als. VESTIL MFG. CO. 6
ELECTRICAL LADDER DIAGRAM -- HPC-400 Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Verify that all system pressure and pwer have been remved befre attempting t wrk n the electrical r hydraulic systems. Warning: The platen must be fully lwered and the hydraulic pressure remved befre wrking n the hydraulic system. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment. VESTIL MFG. CO. 7
ELECTRICAL INTERCONNECTION DIAGRAM -- HPC-400 Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Verify that all system pressure and pwer have been remved befre attempting t wrk n the electrical r hydraulic systems. Warning: The platen must be fully lwered and the hydraulic pressure remved befre wrking n the hydraulic system. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment. VESTIL MFG. CO. 8
HYDRAULIC DIAGRAM LIFT-HOLD-LOWER CIRCUITS Warning: Care shuld be taken t identify all ptential hazards and cmply with applicable safety prcedures befre beginning wrk. Fully lwer r secure the crushing platen, and verify that all system pressure and pwer have been remved, befre attempting t wrk n the hydraulic system. Only qualified individuals trained t understand mechanical devices and their assciated electrical and hydraulic circuits shuld attempt trubleshting and repair f this equipment Cautin: D nt use brake fluid r jack ils in the hydraulic system. If il is needed, use an anti-wear hydraulic il with a viscsity f 150 SUS at 100 F (ISO 32 @ 40 C), r nn-synthetic transmissin fluid. VESTIL MFG. CO. 9
BILL OF MATERIALS -- HPC-400 ELECTRIC / HYDRAULIC BOM -- HPC-400 Item #: Descriptin Part number Qty. 1 Reservir 06-023-001 1 2 Plug, breather BV-38 1 3 Clamp HS64 1 4 O-ring 568-340 1 5 Valve, check 99-153-011 1 6 Valve, 4-way, 2-psitin directinal 99-153-008 1 Slenid, 24VAC 99-034-008 1 7 Plug, cavity CPO8-20-N 1 8 Fitting, hydraulic, 90 6801-06-06N-WO 2 9 Valve, pressure relief 99-153-004 1 10 SHCS, 5/16-18 UNC x 1 lng 23255 4 Washer, lck, high cllar, 5/16 ID 33687 4 11 SHCS, 3/8-16 UNC x 1 lng 23305 2 Washer, lck, high cllar, 3/8 ID 33688 2 Washer, flat, 3/8 ID 33008 2 12 Filter, hydraulic, 3/4 x 3 5/8 lng, 20 mesh 01-031-005 1 13 Pump, hydraulic,.06 in³/rev 01-143-905 1 14 Mtr, electric, 3/4HP, 115V 99-135-003 1 15 Manifld, hydraulic 17-127-001 1 16 O-ring 568-015-BN70 1 17 O-ring 568-011-BN70 1 18 Plug, cavity (prts 2 t 3 pen) CP08-30-N-X 1 19 Switch, pressure, adjustable, 3000 psi 99-022-004 1 VESTIL MFG. CO. 10
THE POWER UNIT S OPERATION HPC-400 The electric / hydraulic pail crusher utilizes an electric mtr directly cupled t a gear-type hydraulic pump t prduce the needed fluid pressure and flw t allw the cylinder t perfrm the wrk f crushing pail. A hydraulic manifld huses the hydraulic cntrl cmpnents, and is blted directly nt the gear pump. The pwer unit s hydraulic cmpnents are all rated fr 3,000 psi wrking pressure. Imprtant parts f the pwer unit include: The electric mtr. Available fr all nminal vltages and phases f pwer supply. The gear pump. Its shaft is cupled directly t the shaft f the electric mtr. The check valve. Its purpse is t prevent the backflw f fluid thrugh the pump. When stpped befre a cycle is cmpleted, the crushing platen will hld its psitin. The pressure relief valve. Its jb is t pen a path fr fluid t flw back t the reservir in the event that the fluid pressure built up by the pump exceeds 3,000 psi. The slenid-perated directinal valve. This is an electrically-perated cartridge valve. It cntains a screen t keep cntaminants frm entering the valve. The pressure-cmpensated flw cntrl spl. This rests under the lwering valve, and regulates the fluid flw back t the reservir when the valve pens. It allws the frks t always lwer at the same rate regardless f whether there is a lad n the frk carriage r nt. The hydraulic cylinder. This is a duble-acting cylinder. The hydraulic fluid. The system uses HO150 hydraulic fluid. Any anti-wear hydraulic fluid with a viscsity grade f 150 SUS at 100 F (ISO 32 @ 40 C) such as AW-32 r Dexrn transmissin fluid are acceptable. When a pail is laded and the cabinet dr is clsed, press the CYCLE START pushbuttn. The mtr turns, and in turning it spins the hydraulic gear pump. Hydraulic fluid is pumped thrugh the check valve, thrugh the energized directinal valve, and t the cylinder, which extends t lwer the crushing plate. When the cylinder either strkes ut r the pail is crushed cmpletely, a pressure switch causes the directinal valve slenid t de-energize, the pilt-perated check valve in the hydraulic manifld pens, and the cylinder retracts t raise the crushing platen. VESTIL MFG. CO. 11
TROUBLESHOOTING GUIDE -- HPC-400 Warning: Always secure the platen by blcking it up r lwer it fully, and discnnect the pwer supply, befre pening the hydraulic system. Cnsult the factry fr prblems at time f installatin, r fr any prblems nt addressed belw. Prblem: Pssible cause(s): Actin: Mtr desn t run when CYCLE START buttn is pressed. Mtr runs, but platen des nt lwer. Mtr hums nticeably r is therwise nisy, but the platen des nt mve dwnward, r mves dwnward nly slwly. Crushing platen cycles up and dwn a few inches rapidly when the CYCLE START buttn is pressed and held. Crushing platen lwers, but nly while the CYCLE START buttn is pressed. Platen lwers, but wn t return t the tp. Pails are nt crushing cmpletely. Platen returns t the tp. Crushing platen drifts dwnward when the crusher is nt being used. Stp buttn is engaged. Dr switch is nt engaged. N utput frm the transfrmer s secndary winding, r the in-line fuse is blwn. N supply vltage. Bad cnnectin in the cntrl circuit. Open mtr relay cil r mtr thermstat. If three-phase, wrng mtr rtatin. N pump utput. Fluid level is lw. Supply vltage is t lw. Mtr is single-phasing (threephase mtrs nly). Mtr s start capacitr r centrifugal switch is pen (single-phase mtrs nly). Lw fluid level in the reservir. Cylinder Raised limit switch is staying engaged when the platen is fully raised. Operatr is nt hlding the buttn lng enugh. The mtr relay s auxiliary cntact is dirty r is pen. The pressure switch setting is higher than the system pressure. The pressure switch setting is t lw. System check valve is leaking. Verify that the buttn peratr is pulled cmpletely utward. If s, test its cntact blck with an meter. Verify that the dr switch plunger is pushed in far enugh t clse the switch. Test the fuse, and fr 24VAC at the secndary winding; replace cmpnents if bad. Test fr line vltage at the mtr relay s line terminals. Test all cmpnents and wiring with a meter. Test with a meter; replace if bad. (Mtr thermstat can be bypassed.) Verify mtr rtates CCW when viewed frm the shaft end. Check fr fluid flw by lsening the hse fitting at the tp end f the cylinder t check fr fluid flw. The fluid level shuld be within 1½ f the tp f the reservir when the platen is fully raised. Verify the supply vltage at the mtr relay s lad terminals while the mtr is n. If vltage drp is 10% r mre, install a prperly sized dedicated supply circuit. Verify that all phases are present. Determine cause f lss f vltage n ne phase, and crrect. Test bth cmpnents with a meter. Lsen the hse fitting at the tp end f the cylinder t check fr fluid flw. Inspect fr the cause f the hangup. Verify that the limit switch s arm and the switch s actuatr blt bth mve freely. Hld buttn dwn lng enugh fr the platen t drp a cuple f inches. Test with a meter. If defective, replace the relay. Place a pressure gauge in the hydraulic system t verify that the pump is develping adequate pressure (3,000 psi). Run the crushing platen dwn fully, then remve, inspect, clean, and replace the check valve (item #5). VESTIL MFG. CO. 12
SAFETY LABEL IDENTIFICATION * Prduct safety signs r labels shuld be peridically inspected and cleaned by the prduct users as necessary t maintain gd legibility fr safe viewing distance -- ANSI 535.4 (10.21). Cntact the manufacturer fr replacement labels. VESTIL MFG. CO. 13
PRODUCT WARRANTY ONE YEAR LIMITED WARRANTY The manufacturer warrants fr the riginal purchaser against defects in materials and wrkmanship under nrmal use fr ne year after date f shipment (nt t exceed 15 mnths after date f manufacture). Any part that is determined by the manufacturer t be defective in material r wrkmanship and returned t the factry, shipping csts prepaid, will be, as the exclusive remedy, repaired r replaced at ur ptin. Labr csts fr warranty repairs and/r mdificatins are nt cvered unless pre-apprved by the manufacturer r dne at the manufacturer s facilities. Any mdificatins perfrmed withut prir written apprval f the manufacturer may vid warranty. This limited warranty gives purchaser specific legal rights which vary frm state t state. All specificatins are subject t change withut ntice. LIMITATION OF LIABILITY T the extent allwable under applicable law, the manufacturer s liability fr cnsequential and incidental damages is expressly disclaimed. The manufacturer s liability in any event is limited t, and shall nt exceed, the purchase price paid. Misuse r mdificatin may vid warranty. Warranty des nt cver labr r cnsequential damages including, but nt limited t, business interruptin csts, lst prfits, r lst business pprtunities. WARRANTY DISCLAIMER The manufacturer has made a diligent effrt t accurately illustrate and describe their prducts. Hwever, such illustratins and descriptins are fr the sle purpse f identificatin, and d nt express r imply a warranty that the prducts are merchantable r fit fr a particular purpse, r that the prducts will necessarily cnfrm t the illustratins r descriptins. The prvisins f the warranty shall be cnstrued and enfrced in accrdance with the Unifrm Cmmercial Cde and laws as enacted in the State f Indiana. DISPOSITION Our cmpany will make a gd faith effrt fr prmpt crrectin r ther adjustment with respect t any prduct that prves t be defective within the Limited Warranty Perid. Warranty claims must be made in writing within said year. VESTIL MFG. CO. 14