Werner & Weber MPC-A User manual

WERNER & WEBER Warenhandelsgesellschaft m.b.H., A1050 Wien, Margaretengürtel18/2, Austria
Tel: [phone], Fax: [phone], e-mail: [email protected]om, www.werner-weber.com
Operation Manual
MPC-A
mobile compactor
MPC-K
MPC-L

The present operation manual for waste compactors of the types MPC-A, MPC-K and MPC- L includes a
detailed product description, instructions for appropriate handling and operational safety, and important
information on accident- and product failure prevention.
Operators are invited to study this manual carefully prior to initial operation of the machine and to consult it
on a regular basis for the sake of compliance with the instructions provided herein. Fail-safe operation and
long product life will be your reward.
No product liability is accepted for damages resulting from inadequate use or handling of our waste
compactors. No claims whatsoever - including claims regarding product design - can be derived from the
contents of this operation manual.
In case of further questions or queries, you are kindly referred to our customer service department.
INTRODUCTION
Warenhandelsges.m.b.H., A-1050 Wien, Margaretengürtel 18/2
Tel.: [phone]
Baujahr:
Type:
Leergewicht:
Ges.Gewicht:
max. Druck:
Leistung:
Spannung:
kg
bar
kW
V
www.werner-weber.com
Serien Nr.:
kg
WERNER & WEBER Warenhandelsgesellschaft m.b.H., A1050 Wien, Margaretengürtel18/2, Austria
Tel: [phone], Fax: [phone], e-mail: [email protected]om, www.werner-weber.com

TABLE OF CONTENTS
Page
1. Safety instructions ....................... 3
Danger- and information signs ....................... 5
2. Description ....................... 6
2.1. Use ....................... 6
2.2. Description of main components ....................... 6
2.2.1. Type MP-A....................... 6
2.2.2. Types MPC-K and MPC-L ....................... 7
2.2.3. Ancillary equipment ....................... 7
2.2.4. Operation panel ....................... 8
2.2.5. Hydraulic power pack ....................... 8
2.2.6. Service opening / ram face ....................... 9
2.2.7. Locking of the discharge door, type MPC-A ....................... 9
2.2.8. Tip bar, type MPC-A ....................... 9
2.2.9. Lifting bar, types MPC-K, MPC-L ....................... 10
2.2.10. Locking of the discharge door,
types MPC-K, MPC-L ...................... 10
2.2.11. Discharge door catch ....................... 10
3. Operation / handling ....................... 11
3.1. Installation instructions ....................... 11
3.2. Initial operation ....................... 12
3.3. Trouble shooting ....................... 13
4. Care and servicing ....................... 14
4.1. Periodical maintenance ....................... 15
5. Annex:
Technical Data ....................... 16
Dimensions ....................... 17
Lubricating scheme ....................... 18
Hydraulic diagram ....................... 19
Circuit diagram standard design ....................... 20
Circuit diagram 3/4 full indication ....................... 21
EC declaration of conformity ....................... 22
Page 02
issue january 2003
WERNER WEBER

1. SAFETY INSTRUCTIONS
Important notes on technical and operational safety are especially highlighted:
DANGER relates to operation procedures requiring strict compliance with
instructions in order avoid hazard to persons and includes remarks on
special worksite hazards.
CAUTION relates to operation procedures requiring compliance in order to rule
out product damage.
1. Prior to initial operation, familiarize yourself with the operation- and maintenance manual. Make
sure to also have read and understood any additional remarks that may apply to special product
features/optionals. A copy of the operation manual must be kept attached to the machine.
2. Operation, maintenance, and repair of the machine is reserved to authorised personnel. Legal
minimum age requirements must be met.
3. Do not employ unskilled or poorly trained staff and clarify competencies in regard to product
operation, maintenance, and repair beforehand.
4. Authorize the responsible operating staff to reject third party instructions that are an apparent safety
hazard.
5. Workshop trainees or apprentices must not operate (or otherwise tamper with) the machine in the
absence of an experienced operator.
6. Perform regular checks to ensure staff˜s compliance with the safety instructions provided in the
manual.
7. Do not operate the machine without proper clothing.
7.a. Avoid rings, wrist watches, ties, scarfs, open jackets, loosely fitting clothes, etc. Do not risk injury by
pulling in or catching on.
7.b. Note that certain procedures require special clothing such as safety shoes, hard hat, gloves, etc.....
8. Check out the location of the nearest fire extinguisher and familiarize yourself/-ves with its
operation. Solicit information on local fire alarm and -fighting possibilities. Avoid the handling of fire
or open light near the charging opening.
Page 03
issue january 2003
WERNER WEBER

Page 04
issue january 2003
WERNER WEBER
9. Note before initial operation (instructions on page 12):
9.a. Never start operation without prior inspection of the machine; check if danger signs are missing or
illegible.
9.b. Note all danger and safety signs.
9.c. Steady all loose machine parts.
9.d. All covers and openings must be closed prior to the start of operation.
9.e. Make sure to close all service openings immediately after servicing/maintenance.
9.f. Prior to any operation, alarm all persons standing or working near the machine and check that
nobody is working on top of it or inside it.
10. For special uses, the machine must be fitted with certain safety components. Start operation of the
machine only with these parts fitted and in good operational condition and with all maintenance lids
closed.
11. Note before care and servicing (instructions on page 14):
11.1. Unless instructed otherwise, proceed as follows in the event of maintenance- and repair works:
11.1.a Stop motor.
11.1.b Switch off main switch and padlock machine against unauthorised operation. Remove key from
padlock and keep it during maintenance. Disconnect supply mains from plug.
11.2. Prior to opening (any repair work), the respective hydraulic parts, including pressure pipes, must be
depressurized.
11.3. Make sure that all supports and protection pads against vibration, friction, and heat build-up are
properly adjusted.
11.4. Check all electrical equipment for defects such as loose connections or worn cables. The repair of
electrical equipment must be reserved to skilled personnel.
11.5. Regularly check all ducts, hoses and screwed connections for leakages and other damages.
Remove leakages immediately and replace damaged parts. Oil leaking through untight spots is a
risk of fire.
11.6. Do not service the hydraulic unit other than in cold condition.
DANGER Oil leaking through untight spots is a risk of fire. Make sure to wear gloves
when looking for leakages.
Note that the hydraulic oil may be very hot even before reaching operating
temperature. Avoid any contact with hot oil or hot lubricated parts.
11.7. Never jump off the machine but use the steps, ladders, and gangboards instead.
12. Never start operation of a defective machine. Have defects repaired on the spot.

13. Note before machine cleaning:
13.a. Handle all process materials with care. Do not use any inflammable liquids for machine cleaning.
13.b. Close, seal or remove all apertures through which no water/cleaning liquid must penetrate during
cleaning with water or water vapour (high pressure cleaner).
14. Note before machine operating:
14.1. Use appropriate hoists (as per DIN 30722 German Industrial Standard). All loads must be carefully
attached to the hoists.
CAUTION Do not exceed the maximum permissible total weight of 12 t (MPC-A) or
15 t (MPC-K, MPC-L) !
DANGER During the operation of hoists, it is strictly forbidden to stand or work
beneath them.
Always wear gloves when working with metal ropes.
14.2. Inexperienced personnel must never be authorized to perform loading or give directions to crane or
truck drivers. When giving directions, remain within each other´s sight or hearing.
14.3. The machine must always be supported in such a way that weight transfers do not cause
unsteadiness. Avoid that steel rests on steel.
14.4. For maintenance/repair works above body height, adequate ladders and/or platforms are necessary.
Never use machine parts for climbing. All handles, steps, rails, platforms, ladders, and the like must
be kept clean and free from dirt, grease/oil, snow, and ice.
15. Do not effect any modifications on the machine, such as rebuilding or adding-on, without the
supplier´s prior approval. This also applies to the mounting and adjustment of safety installations
and -valves and to the welding of supporting structures.
16. Danger- and information signs:
at the chargebox at the discharge door
Page 05
issue january 2003
CLEAN CHARGEBOX
EVERY WEEK
DISCONNECT FROM
POWER SUPPLY BEFORE
OPENING THE FLAP
CHARGEBOX
DANGER OF LIFE
DO NOT ENTER!
CUT OFF POWER PRIOR TO
ANY MAINTENANCE WORK!
DANGER
KEEP CLEAR OF
THE DOOR
WHEN FLAP
OPENS!
WERNER WEBER

With a capacity of 8-25m 3, waste compactors of the types MPC-A, MPC-K and MPC-L are suitable for all
major skip and roll-on/off container handling units. These waste compactors compact your waste down to a
fifth of its original volume and are suitable for any kind of household and industrial waste such as wooden
cases, packaging material, paper, cardboard, etc. They are not suitable for sand, gravel, rumble, hot ashes,
inflammable, acidic or alkaline substances, or heavy metal parts (such as profiles, beams).
Waste compactors of the types MPC-A, MPC-K and MPC-L are designed for a temperature range of
-20 to +60 degrees Celsius.
2. DESCRIPTION
2.1 USE
2.2 DESCRIPTION OF MAIN COMPONENTS
2.2.1. WASTE COMPACTOR of the type MPC-A
(Skip loader unit)
issue january 2003 Page 06
Overall view with
optional side walls
and hopper lid
4 ....... lifting pins
5 ....... discharge door lock
1 ....... hydraulic cabinet
2 ....... hopper lid
3 ....... operation panel

2.2.2. WASTE COMPACTOR of the types MPC-K and MPC-L
(Roll on/off unit)
Page 07
issue january 2003
1.......... hydraulic cabinet
2...........hopper lid (optional)
3...........high-voltage connection
4...........information sign
5...........type plate
6...........operation panel
7...........lifting bar
8...........discharge door lock
Overall view with
optional side walls and
hopper lid
2.2.3. OPTIONALS
Waste compactors may be equipped with the following optionals:
- Hoppers
- Hoppers with lid
- Hydraulic container dumping system
- Container liquid sealed
- Bilateral braces for container handling systems
- Supplementary rolls (front)
- 95% or 100% container full warning
- Limit stop switch for ram face (open or closed position)
7
45
6
3
8
1
2
WERNER WEBER

2.2.4 OPERATION PANEL
Control of the machine is via the operation panel, mounted next to the charging opening:
1...........The main switch serves for switching the
power supply on and off.
2.......... By pushing the start button, the compaction
process is started.
3.......... The machine may be switched off by pushing either
of the two EMERGENCY-OFF buttons on its lateral
faces. For restarting, both EMERGENCY-OFF
buttons must be unlocked.
4.......... The release switch serves for gradual opening
of the ram face in case of emergency.
5......... The power cable is connected to the socket
by means of a CEE-standard plug.
2.2.5. HYDRAULIC POWER PACK
The hydraulic power pack is located above the
charging opening and comes in closed design with
maintenance lid. The power pack serves for the control
and supply of the two hydraulic cylinders behind the
ram face.
The hydraulic unit consists of the following
components:
1 ......... motor with hydraulic pump
2 ......... control valve
3 ......... oil tank
4 ......... oil filler
5 ......... oil filter
6 ......... oil level gauge
7 ......... control cabinet
Page 08
issue january 2003
24
3
15
2
3
6
5
1
4 7
WERNER WEBER

The service opening is situated below the charging opening and is closed by means of a maintenance lid
with limit switch protection. The compaction box accommodates the ram face, which is operated by means
of two hydraulic cylinders.
2.2.6. SERVICE OPENING / RAM FACE
issue january 2003 Page 09
DANGER Never enter the charge box
without pushing the
EMERGENCY-OFF button,
switching off the main switch
and padlocking against
unauthorised operation.
Remove key from padlock and
keep it during maintenance.
Disconnect supply mains from
plug!
2.2.7. Locking of the DISCHARGE DOOR, type MPC-A
The discharge door is fitted with a special locking mechanism.
Secure locking mechanism always with the safety lever.
DANGER Note that the discharge door must be
closed and locked before starting the
compaction process.
2.2.8. TIP BAR, type MPC-A
All waste compactors fitted with skip vehicle attachments
come with an adjustable rail (adjustment depending on
vehicle type) for catching on of the tipping hook.
CAUTION Do not exceed the maximum permissible total wheight of 12 t (MPC-A)!

Page 10
issue january 2003
2.2.9. LIFTING BAR, types MPC-K/MPC-L
The lifting bar for the roll on/off unit are hinged and adjustable for both standard hook heights.
CAUTION Do not exceed the maximum
permissible total weight of 15 t
(MPC-K/MPC-L)!
Any handling of the compactor requires bolting of
the hook (with supplied bolts)!
2.2.10. Locking of the DISCHARGE DOOR,
types MPC-K/MPC-L
The discharge door is provided with a ratchet locking
mechanism. Turn the lever for opening or closing locking
mechanism.
DANGER Note that the discharge door must
be closed and locked before
starting the compaction process.
2.2.11. DISCHARGE DOOR CATCH
The discharge door has a mechanism designed for fastening the
open door during the discharge operation.
DANGER Make sure that the open discharge
door is fastened before starting the
discharge operation.
WERNER WEBER

3. OPERATION / HANDLING
3.1. INSTALLATION INSTRUCTIONS
DANGER Read and follow these and the safety instructions of chapter 1 !
1. Note the following safe-floor loads:
a. for skip units not less than 13.000 N/m 2 ,
b. for roll on/off units not less than 17.000 N/m 2 .
2. Provide sufficient space at the installation site for transportation with the skip unit or roll on/off unit.
3. If charging of the waste compactor is done from a loading dock or platform(s), make sure that the
hopper is at least 1 m above ramp height (i.e. operator´s location)!
4. Note that the floor for installation of the compactor should be even.
5. If required, provide additional lighting at the installation site (in accordance with AAV).
6. Protect installation site against accessing by unauthorized personnel.
7. Note that the power supply at the installation site must be protected by means of a safety switch
(with a sensitivity of 30mA) and a 16A fuse.
8. The supply cable must have a cross-section of 5 x 2.5 mm 2 and should be fitted with a
16A CEE-standard socket.
9. Movable supply cables require a solid (rubber) hose pipe of the type HO/RN-F according to
VDE 0100.
Page 11
issue january 2003
WERNER WEBER

Page 12
issue january 2003
3.2. INITIAL OPERATION
The machine is ready for operation after a test run. The following safety checks are necessary prior to initial
operation of the compactor:
DANGER The operating personnel must be familiar with machine handling and observe
the safety instructions !
All service openings must be closed !
Make sure there is no person inside the charge box before starting
operation !
The discharge door must be locked !
The maintenance door of the hydraulic unit must be closed during operation !
1 ........ Connect the compactor to electrical supply.
2 ........ Switch on main switch.
3 ........ Unlock the EMERGENCY-OFF button (on both sides).
4 ........ Push start button.
The ram face must move backward within 5 seconds.
Immediately switch off the motor if it fails to do so, since
the pump will not be lubricated once the motor takes the
wrong direction. Reverse poles of the plug in the machine
socket by switching the pole changer.
5 ........ After starting the motor, the ram face will alternately move
forward and backward. For this purpose, two hydraulic cylinders
alternately move up and down. The movement of the hydraulic
cylinders is reversed by means of a hydraulic control unit. For protection of the hydraulic unit, the power
unit is equipped with a time lag relay, which automatically stops the hydraulic operation after a set period of
time, at any point bet-ween 0 and 12 minutes.
6 ........ Charging of the waste may continue up to the point where the ram face fails to clear the charging
opening.
CAUTION Never leave the operation panel unattended during the compaction process;
the machine must be switched off immediately in case of emergency !
The panel may be left unattended only after operation is discontinued !
34
21
WERNER WEBER

Page 13
issue january 2003
3.3. TROUBLE SHOOTING
PROBLEM SOURCE SOLUTION
machine cannot be switched on power supply - check mains supply
- switch on main switch
- release both EMERGENCY-OFF switches
- close maintenance lid of charge box
- check fuse and motor protection in
power unit
- check safety switch and fuse of mains
supply
motor defective - replace motor
motor runs, ram face does not polarity - change 2 of the 3 phases of plug
operate connection
too little hydraulic oil - check oil level and refill if required
main valve defective - main valve defective
hydraulic pipes and
hydraulic unit leak - hydraulic unit leak
pump defective - replace pump
ram face toes out during operation ram face guide loose - call service
telescope plates do not stay - call service
within guides
CAUTION Call a service technician for all problems operating personnel cannot handle
and for problems not listed above !
WERNER WEBER

Page 14
issue january 2003
4. CARE and SERVICING
Waste compactors require very little servicing. However, compliance with the following instructions is
recom-mended to ensure failsafe operation and long machine life.
Conclusion of a service agreement is optional, yet recommended. Under such agreement, our service staff
will service your plant twice a year. Our specialists will identify potential problems hands-on, thus avoiding
major failures.
Service range:
1. inspection of hydraulic unit
2. adjustment (if required)
3. inspection of power unit
4. lubrication
5. filter cleaning
6. oil change (once a year))
7. overall inspection
DANGER During all maintenance work, compliance with the following safety
instructions (also see chapter 1) is required:
1. Switch off main switch and padlock machine against unauthorized operation.
Remove key from padlock and keep it during maintenance.
2. Push the EMERGENCY OFF button and disconnect supply mains from plug!
3. Do not remove or deactivate protections!
4. Do not change setting of the hydraulic control unit (sealed). In case of replacement, original spare
parts suitable for an operating pressure of 250 bar must be used!
WERNER WEBER

Page 15
issue january 2003
4.1. PERIODICAL MAINTENANCE
Weekly:
- Clean box behind ram face. Maintenance intervals will
depend on the kind of waste processed and frequency
of compaction.
- Check all parts of the hydraulic unit for tightness.
1 ........ Clean back flow oil filter. Remove cover of hydraulic
cabinet and open screws for taking out filter and
subsequent cleaning.
2, 3 ..... Check oil level and refill hydraulic oil (HLP 22)
via the filler.
- Check all electric parts for possible damage.
DANGER Do not service the hydraulic
unit other than in cold condition !
Close charging opening (safe to step on) before
servicing.
Quarterly:
- Check hydraulic unit for tightness. Lubricate guides with Signum LM grease.
- Lubricate nipples of the rollers, hydraulic cylinder and door hinges with Signum LM
(see lubricating scheme).
Once a year:
- Change hydraulic oil (HLP 22).
132
WERNER WEBER

Page 16
issue january 2003
ANNEX: TECHNICAL DATA
Handling system Dim Skip unit Roll on / off unit
Type MPC10A MPC12AMPC16-K MPC18-K MPC20-K MPC25-K MPC16-L MPC18-L MPC20-L MPC23-L
Effective capacity (m3) 10 12 16 18 20 25 16 18 20 23
Ram force (cylinder) (kN) 230 230 330 330 330 330 330 330 330 330
Total lenght (A) A(mm) 452051705370 5770 6220 7220 6260 6660 7110 7860
Total width B(mm) 199019902420 2420 2420 2420 2420 2420 2420 2420
Height C(mm) 236023602650 2650 2650 2650 2650 2650 2650 2650
Opening lenght D(mm) 144014401440 1440 1440 1440 2330 2330 2330 2330
Opening height E (mm) 130013001340 1340 1340 1340 1340 1340 1340 1340
Opening width F (mm) 163016301948 1948 1948 1948 1948 1948 1948 1948
Roller distance G (mm) 2160 2160 2160 2160 2160 2160 2160 2160
Ram stroke H (mm) 1230 1230 1230 1230 1230 1230 1980 1980 1980 1980
Stand width J (mm) 1280 1280
Roller width K (mm) 300 300 300 300 300 300 300 300
Empty weight (kg) 334035604070419043204650458047004830 5080
Gross weight (kg) 12000 12000 15000 15000 15000 15000 15000 15000 15000 15000
Min. cycle time forw/backw.(sec) 222230 30 30 30 50 50 50 50
Motor (kW) 5,5 5,5 5,5 5,5 5,5 5,5 5,5 5,5 5,5 5,5
Power supply 380 V, 50 Hz - standard plug CEE-form 16 A, 5-pole
Change of technical data reserved.
WERNER WEBER

issue january 2003 Page 17
ANNEX: DIMENSIONS
Types
MPC-K and MPC-L
Type MPC-A

issue january 2003 Page 18
ANNEX: LUBRICATIONS SCHEME MPC-K and MPC-L
S
S
S
S
ANNEX: LUBRICATIONS SCHEME MPC-A
S
S
S
S
S
S
S

issue january 2003 Page 19
ANNEX: HYDRAULIC DIAGRAM MPC-A, MPC-K AND MPC-L
Compactor
rear end
position
full indication
BF/PZ