OverBuilt 10 Instruction Manual

OPERATING AND
SAFETY MANUAL
MODEL 10 AND MODEL 10 HS
PORTABLE AND STATIONARY
CAR CRUSHER
Study this ma ual before operati g the crusher
Huro , South Dakota
[phone]

TABLE OF CONTENTS
Safety Procedures………………………………..……..………………….1 to 3
Start-Up Diesel E gi e…………………………………………………… 4
Start-Up Electric Motor………………………….……….……………… 5
Hydraulic System……………………………..…...….……...…………… 6
Sta dard Speed Cyli der Operatio ………..……...……………………. 6
High Speed Cyli der Operatio ...………….…………………….……… 7
Adjusti g Relief Valves…………………….……………………..……… 8
Adjusti g The High Speed Bypass………….…………………………… 9
Adjusti g Pressure Switches……………….…………………….………. 10
Sta dard Speed Hydraulic Schematic…….…………………….………. 11
High Speed Hydraulic Schematic………….…………………….………. 12
Sta dard Speed Valve Assembly……………..………………….………. 13 & 14
High Speed Valve Assembly………………………..…………….………. 15 & 16
Valve Spool Assembly……..………………………..…………….………. 17
Valve & Pressure Switch Wiri g Diagram.……………..……..………. 18
Cyli der Parts……………………………....…………………….………. 19
Rod E d Fi al Assembly…………………....…………...……….………. 20
Pisto E d Fi al Assembly………………....………………..…..………..21
Cyli der Assembly Sta dard Speed..……....……………..…….……….. 22
Cyli der Assembly High Speed.…………....……………..……..………. 23
High Speed Hydraulic Fitti gs.………..…..………………….…………. 24
High Speed Rege Assembly.…………..…..………………….…………. 25
Crusher Filters & Lubricatio ……..…..……………….…….…………. 26
Crusher Lubricatio Poi ts……..…..…………………..…….…………. 27
Hydraulic Oil Ta k……..…..………………………………….…………. 28
Ma ual Dow rigger Assembly………………………………...………… 29
Hydraulic Dow rigger Assembly……………………………...………… 30
Adva ced Oil Recovery System……………………………..…………… 31
Limit Switch Assembly……………………………………..….…………. 32
Rock Cycle Lift Height Adjustme t……………………...……………… 33
Receiver/Tra smitter Programmi g………………….…….…………… 33
Combi atio Filter/Regulator/Lubricator…………………….………... 34 to 42
Auxiliary Fuel Pump……………………………………………………... 43 & 44
Automatio Receiver Wiri g Diagram…………..……………..………. 45
Trouble Shooti g…………………………….…………….……………… 46 & 47
Warra ty……………………………..……………………….…………... 48

Safety
CAUTION, WARNING &
DANGER: WHAT THEY MEAN
Hazards are identified by the “Safety Alert
Symbol” and followed by a signal word:
Caution, Warning or Danger.
DECALS
he decals on the machine provide instruction
for safe and correct operation.
Never make modifications affecting the safe
operation or capacity without the expressed
written approval of OverBuilt, Incorporated.
When OverBuilt approved modifications are
made, the user is responsible for seeing that
appropriate decals and instructions are
changed.
All plates and decals must be in place and
legible at all times.
OPERATOR QUALIFICATIONS
AND TRAINING
⇒
⇒⇒
⇒ Only trained and authorized persons
should operate the machine. o be
qualified, you must understand the
written instructions supplied by the
manufacture, have training (including
the actual operation of this machine)
and know the safety rules and
regulations of the job site.
⇒
⇒⇒
⇒ Do not operate the machine until you
fully understand the function of all
controls, indicators and instruments.
1

2
IMPORTANT
EYE AND EAR PROTECTION
Safety Devices
Valves are enclosed in a lockable cabinet.
his allows you to secure the valves from
unauthorized or unintentional use.
Safety lock can be placed on both ends of
the crusher. hey are located on the uprights
and must be manually placed under the slides.
To lock the lid i the upright
positio .
 Make sure the top lid is all of the way up.
 Remove the yellow safety lock located on
the uprights.
 Place the lock under the lid slides.
 Repeat on the other end.
The top lid is ow blocked from falli g.
NO E: his safety lock is to prevent the top
lid from falling under its own weight. It may
not stop the lid from falling if you apply
downward hydraulic pressure to the cylinders.
Putting downward hydraulic pressure
on the lid with one or both of the safety
lock mechanisms in place may damage
the mechanisms or a cylinder rod.
Remove keys and do not run engine
when the safety locks are in place.
Always inspect the safety locks to
make sure they have not been damaged.
LOCKOUT PRECEDURE
Crusher lid may fall a d death or serious
i jury will occur if the followi g precautio s
are ot observed before getti g o or i to
the crusher:
1. Raise lid to full height.
2. Shut off crusher e gi e a d remove
key.
3. Lock cabi et co tai i g hydraulic
valves a d remove key.
4. Carry all sets of keys with you.
5. Remove the yellow safety lock located
o the uprights.
6. Place the safety lock u der the lid
slider.
7. Repeat o the other e d.
8. Whe fi ished, remove safety locks
before loweri g the lid.
Importa t: Never leave the crusher lid i a
raised positio while the crusher is
u atte ded.
CRUSHER LOCATION
Lid rises higher than the frame of the
machine. Operating this equipment near
or below power lines may cause serious
injury or death.
Machine should be positioned on level
hard ground.
Never move crusher unless the crushing
chamber is completely empty and the
crusher lid is in the closed position.
Safety glasses and ear protectio
n
should be used at all times when
operating or standing near the
crusher.

Safe Operatio of this crusher is the operator’s respo sibility. Listed below are some basic
rules that ca make a operator aware of da gerous practices to avoid a d precautio s to take
for his ow safety a d the safety of others. Observa ce of these rules i additio to freque t
exami atio s a d periodic i spectio s of the equipme t may preve t i jury to perso el a d
damage to equipme t.
• 1. DO study this manual before operating the crusher. If your crusher is equipped with a remote
control, refer to that part of the manual for additional precautions.
• 2. DO make sure that all persons stay clear of the crusher during operation.
• 3. DO promptly report any malfunctions, unusual performance, or damage of the crusher.
• 4. DO inspect the crusher regularly, replace damaged or worn parts, and keep appropriate
records of maintenance.
• 5. DO inspect the hydraulic system for leaks, worn or damaged hoses.
• 6. DO inspect the fluid levels prior to starting the engine.
• 7. DO keep the crusher clean, paying special attention to the electrical and hydraulic systems.
• 8. DO immediately repair or replace any worn or damaged parts prior to operating the
crusher.
• 9. DO follow the LOCKOUT PROCEDURE (see page 1) prior to getting on or in the crusher.
• 10. DO lower the lid and shut off the engine prior to doing maintenance on the crusher.
• 11. DO NOT at anytime get in or reach in the crusher chamber while the engine is running. he
lockout procedure must be strictly followed.
• 12. DO NOT operate the crusher without visually inspecting in and around the crusher for other
personal.
• 13. DO NOT operate the crusher unless you have a clear view of the machine.
• 14. DO NOT reach in or across moving parts.
• 15. DO NOT operate the crusher near or under power lines.
• 16. DO NOT move the crusher unless the crushing chamber is completely empty and the lid is in
the down position.
• 16. MOST OF ALL use common sense when operating this or any other piece of equipment.
Safety o the job begi s with you
3

4
START-UP – DIESEL ENGINE
 Before starting the engine, read the
manufactures engine operator’s manual.
 Check all fluid levels, engine oil, coolant and
hydraulic reservoir.
 urn the ignition key until the starter engages.
 Allow the engine to warm up for a couple of
minutes.
 Flip the throttle toggle switch to run at high
RPM.
 You are now ready to run the lid up and down.
 Raise the lid by pulling the valve handle
toward you.
 Lower the lid by pushing the valve handle
away from you.
 NOTE: Operate the crusher manually to get
familiar with it and to test its operation prior to
using the remote control.
 Although the machine was tested at the factory
it is always a good idea to check for oil leaks.
 Cra k La di g Gear: Block the front of the
machine with a railroad tie. he Manual Crank
Landing Gear Is For ransportation Use Only.
Using it to stabilize the machine while
crushing may cause damage.
 Hydraulic & Ma ual La di g Gear: Pull
safety pins on landing gear legs. Adjust the
landing gear to the desired height using the
hydraulic valves (if so equipped) or manually
using an appropriate sized jack or the air
system on the semi-tractor. Replace safety pins
when you are done adjusting legs.
 COLD WEATHER STARTING: 1. Start
diesel engine and run at idle for 5 – 10
minutes. 2. urn high idle switch on to
help circulate oil through pump. 3. Move lid
up and down manually or with switches on
transmitter (hand held) to help warm hydraulic
oil.
Note: Allow at least 30 minutes for steps 1–3.

5
START-UP – ELECTRIC MOTOR
 Before starting the engine, read the
manufactures motor installation and
maintenance manual.
 Check the fluid levels of the hydraulic
reservoir.
 Push the start button to engage the motor
 Check motor rotation.
 Check the power plant for leaks or other
problems.
 You are now ready to run the lid up and down.
 Raise the lid by pulling the valve handle
toward you.
 Lower the lid by pushing the valve handle
away from you.
 NOTE: Operate the crusher manually to get
familiar with it and to test its operation prior to
using the remote control.
 Although the machine was tested at the factory
it is always a good idea to check for oil leaks.
 COLD WEATHER STARTING: 1. Start electric motor and run for 5 – 10 minutes to help
circulate oil through pump. 2. Move lid up and down manually or with switches on transmitter
(hand-held) to help warm hydraulic oil. Note: Allow at least 30 minutes for steps 1 and 2.
 MANUAL/AUTOMATIC SWITCH: Operating the crusher in the manual position deactivates
the 20-minute safety shutdown timer (for cold weather warm up) and the remote start/stop
function from the transmitter. When the crusher is operating, turn the switch to auto to activate
the 20-minute safety timer and the remote start/stop feature.

6
6-1 THE HYDRAULIC SYSTEM
here are really two separate hydraulic
systems. he hydraulic tandem pump contains
two sections that draw oil from the tank through
two 100-mesh screen filters located inside the
tank. Each section pumps oil into one of the two
4-way control valves. he valves can be
electrically or manually controlled. he two
valves, in turn, control two separate 10” cylinders.
o raise the lid, pull the valve handle
toward you, oil is then sent to the bottom port of
the cylinder, which will force the lid to go up. he
oil in the top of the cylinder is sent through a 10-
micron filter and then to the tank
o lower the lid, push the valve handle
away from you, oil is then sent to the top port of
the cylinder, which will force the lid down. he
oil in the bottom of the cylinder is sent through a
10-micron filter and then to the tank.
When the valve handles are in the center
position oil is sent through a 10-micron filter and
then back to the tank.
here are two safety pressure valves
located on each system. A Main Relief on the
control valve restricts the valve operating pressure
to 2600 psi. he Cylinder relief valves restricts
the cylinder operating pressure to 2800 psi and
protects the cylinders from extreme pressures that
could damage them.
6-2 STANDARD SPEED CYLINDER OPERATION
On our standard hydraulic system, to raise the lid we pump 32 gallons of oil into the bottom
of each cylinder. he 27 gallons of oil in the top goes back to the tank. he 5-gallon difference is
equal to the area of the rod.
o lower the lid we pump 27 gallons of oil into the top of each cylinder. he 32 gallons of oil
in the bottom goes back to the tank.

7
HIGH SPEED CYLINDER OPERATION
It is important to understand the principle of how your high-speed crusher works. If you are
new to this type of equipment you should run the lid up and down a few times to get acquainted with
it. You will find it is totally different than standard speed crushers.
he speed is achieved through the use of 2-1\2” oil bypass valves (Please see illustration on
page 24) located on the main cylinders. It’s quite simple; a cylinder is always full of oil. he bypass
system transfers that oil between the top and bottom cylinder ports, eliminating the need to send oil
all the way back to the tank. he oil is transferred directly to the other end of the cylinder. his
means to raise or lower the lid we only need to move 5 gallons (rod area) of oil in or out of each
cylinder, not the full 32 gallons like the standard system
o raise the lid we take the 27 gallons of hydraulic oil that is in the top of the cylinder and
transfer it to the bottom through the 2.5” bypass valve, adding only 5 gallons of oil from the pump.
Now in about 8 seconds we have put 32 gallons in the bottom of the cylinder. Putting our actual
cylinder port oil flow at over 200 gallons per minute.
When you lower the lid, the oil in the bottom of the cylinder transfers to the top through the
bypass valve. Since there is more, oil in the bottom than the top only the excess 5 gallons goes back
to the tank. It will retract the full 8 feet in just 8 seconds. Putting our actual cylinder port oil flow at
over 200 gallons per minute.
When you raise the lid the bypass valve opens automatically, giving you high-speed operation
on the full up stroke.
he length of time the lid falls in high-speed mode is adjustable. When you lower the lid the
bypass valve will start to close, you can adjust how long it takes the valve to close using the needle
valve (Please see instructions on page 9 – illustration on 24 part # 8) located on the bottom port of the
bypass valve.
As an example you could set it to close in 4 seconds, this means the top lid will lower about 4
feet in the high-speed mode. After the valve closes the lid will slow to the standard speed.
If the lid can fall only 2 feet before landing on the load, it will just sit there for the additional
2 seconds until the valve closes, and then the crusher lid will operate at standard speed and pressure.
AGAIN: When the lid is coming down, you can adjust how far you want it to fall in the high-
speed mode. Using the needle valve to adjust the time is takes for the valve to close. Once closed the
cylinders work at standard speed and pressure.
NOTE: During the down stroke, the cylinders do not operate at high pressure in the high-
speed mode. Only when the bypass valve closes can the cylinders create high pressure.
You will create high pressure on the up stroke after the cylinders top out.

8
ADJUSTING RELIEF VALVES
8-1 Mai Relief
he main relief valves are located on the main control valves and are set at 2600 psi. he main relief
(Please see illustration on page 15 part # 5) will limit the amount of pressure that can be built up in
the system.
o check the main relief setting.
 Lower the lid.
 Push the valve handle away from you to build pressure.
 he valve needs to be all of the way open.
 Read the pressure gauge on the valve.
 his pressure is the main relief pressure and should read 2600 psi.
o adjust the pressure, follow these steps. You will need a 3/4-inch wrench and a 1/4-inch Allen
wrench. - he valve adjustment is located on the back-left side of each control valve.
 Remove the dust cap with ¾ inch wrench.
 Loosen the nut with ¾ inch wrench.
 Hold the valve all the way open.
 o adjust the relief to 2600 psi, turn it with a 1/4-inch Allen wrench.
 urn in (clockwise) to i crease pressure.
 urn out (counterclockwise) to decrease pressure.
 ighten the nut while holding the Allen wrench in place to keep the setting from changing.
 Check the setting after the nut is tight, in some cases it will have changed and you will have to
adjust a second time.
8-2 Sta dard Speed Cyli der Relief
he cylinder relief valves are located on the back of the main control valves and should be set at 2800
psi. (Please see illustration on page 13 part # 14)
his relief allows the cylinder to extend during the rock cycle, when the opposite end is pulling down
and teeter-tottering the lid over the load
As lo g as the mai co trol valve ca achieve 2600 PSI the bypass wo ’t eed to be adjusted
o adjust the pressure, call the Factory.
8-3 High Speed Cyli der Relief
he cylinder relief valves are located on the side of the bypass valve and should be set at 2800 psi.
(Please see illustration on page 24 part # 5)
his relief allows the cylinder to extend during the rock cycle, when the opposite end is pulling down
and teeter-tottering the lid over the load
As lo g as the mai co trol valve ca achieve 2600 PSI the bypass wo ’t eed to be adjusted
o adjust the pressure, call the Factory.