CP DEFORMER MANUAL.pdf

MACHINE INFORMATION

Model No:____OD5000__________________________

Serial No:_______________________________

Voltage & Phase:_________________________

TOLL FREE HOTLINE -- 1-800-462-5311

If you have any questions or need any help, please call our Customer Service Hotline, TOLL FREE, between 7:30 a.m. and 4:00 p.m. Monday thru Friday (Pacific Standard or Pacific Daylight Time). Please have the above information ready when you call.

For correspondence, please send your mail to:

CP Manufacturing, Inc.

1300 Wilson Avenue

National City, Ca 91950

WARRANTY PERIOD

CP Manufacturing’s Full Year Warranty is explained in detail on the following pages. YOUR WARRANTY PERIOD IS VALID FROM:

DATE: THROUGH:

WARRANTY POLICY

The following lists CP Manufacturing’s warranty policy concerning components, labor, claims procedures and limitations. During the process of repair or maintenance these guidelines should be followed.

1. CP Manufacturing warrants to the buyer, and buyer only, new equipment manufactured by CP and covered hereby, against defects in material and workmanship for a period of twelve (12) months from the date of delivery or commissioning, whichever occurs first.

2. CP Manufacturing’s Full Year Warranty applies only to equipment that has been properly installed and maintained and subjected to normal use. It does not cover damages caused by abuse, misuse, unauthorized repair, accident, alteration, modification, electrical brownouts, power surges, loose wires, loose screws, nuts or bolts. Also excluded are ordinary service and maintenance items such as replacement belts, light bulbs, tires, wear liners, limit switch adjustments, hydraulic seals, and the like, required as a result of normal wear and tear. Certain components provided to CP for use in the purchased equipment are guaranteed only by the manufacturer of this component. Such guarantees vary from manufacturer to manufacturer. While in such cases CP Manufacturing provides assistance to the Purchaser with warranty claims, CP Manufacturing does not provide independent warranty coverage for such parts.

3. This Full Year Warranty supersedes any representations concerning the equipment sold to the Buyer which may have been made by CP’s agents or employees, or contained in advertisements. If any model or sample was shown to the Buyer, that model or sample was used merely to illustrate the general type and quality of the equipment and not to represent that the equipment would necessarily conform to such model or sample. The Buyer’s sole remedy for any defect of material or workmanship in the equipment sold by CP is as provided by this Full Year Warranty. IN NO

EVENT SHALL CP BE LIABLE FOR ANY CLAIM FOR SPECIAL,

INCIDENTAL, INDIRECT, FORESEEABLE OR CONSEQUENTIAL

DAMAGES RESULTING FROM THE USE, LOSS OF USE, BREAKDOWN

OR MALFUNCTION OF THE EQUIPMENT, INCLUDING LOST EARNINGS

OR PROFITS. CP shall not be obligated to provide any warranty coverage whatsoever for any defect not communicated to CP in writing within the period designated in this Full Year Warranty. Delivery of goods by CP to a common carrier for shipment to the Buyer shall constitute delivery of the equipment to the Buyer. Regardless of freight payment, title and all risk of loss or damage in transit shall pass to the Buyer, and all claims for loss of damage during shipment must be made by the Buyer directly to the carrier.

4. The buyer shall notify CP, or an authorized distributor of CP in writing within thirty (30) days of discovery, within the warranty period, of any alleged defect and permit CP or its representatives to make such investigation, examination and tests as it deems appropriate. If requested by CP, buyer will return the alleged defective product to CP factory, freight prepaid for examination and testing. If CP determines the product is defective, CP will either repair or replace such product with a like item of CP’s manufacture, f.o.b. CP’s factory. The responsibility of CP is limited to repairing or replacing defective material manufactured by it, provided CP examination discloses to its satisfaction that such material has not been altered or repaired, other than by CP approved procedures, subject to misuse, improper maintenance, or normal wear and tear.

5. Any parts or equipment which CP supplies and does not manufacture shall be subject only to the warranties of CP’s vendors to the extents CP can enforce such warranties.

6. Any repairs to, alterations of, or work done on alleged defective products without CP specific written authorization shall void CP warranty applicable thereto.

7. Any action for breach of warranty or other action under this agreement must be commenced with one (1) year after such cause of action arises.

THIS FULL YEAR WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,

EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

WARRANTY SERVICE

1. Upon receiving a call for service on any CP Manufacturing equipment still under warranty (within one year from date of commissioning or shipment) and prior to performing service on that machine, the customer or contracted outside service company will call CP Manufacturing with their explanation of the problem. All parts and labor claims must be reported to CP Manufacturing in advance to receive any reimbursement.

2. CP Manufacturing’s Customer Support Department will determine if the machine problem is warranty related and if so, CP Manufacturing will assign a warranty authorization number for that job. CP Manufacturing’s standard warranty is for parts only, however, at CP Manufacturing’s discretion, labor may also be covered under warranty and this will be determined on a case by case basis.

3. If an outside service company is performing the warranty service, a quote must be approved by CP Manufacturing in advance. If the work exceeds the quote, before continuing work, the advised amount must be approved by CP Manufacturing, Inc.

4. All invoices submitted to CP Manufacturing for warranty service should be forwarded to: CP Manufacturing, Inc.

Attention: Customer Service Department 1300 Wilson Avenue National City, CA 91950

RETURN OF GOODS

In the event that the Buyer believes a component manufactured by CP is defective in materials or workmanship during the term of this Full Year Warranty, the Buyer shall promptly notify CP of the problem in writing. Upon receipt of such written notice, CP will issue the Buyer a Return Goods Authorization (RGA) number that must accompany the parts returned to CP for warranty consideration. This RGA number is valid for thirty (30) days. The Company’s warranty parts invoices (mailed separately) automatically become due and payable upon a customer’s failure to return the defective parts within thirty (30) days.

Upon receipt of the defective parts, CP will make an evaluation, or if necessary, forward the defective parts to the original manufacturer for warranty consideration. The Buyer shall then be notified of the determination made. If the part is found to be defective in material or workmanship, the obligations of CP are strictly and exclusively limited to the repair or replacement, at the option of CP, of the defective part. CP agrees to pay all shipping charges, at UPS ground rates, for delivery to the Buyer of repaired or replacement parts provided the submitted parts have provided to be defective and covered by this warranty.

Where expedited delivery of repaired or replacement parts is requested by the Buyer, such additional shipping charges shall be paid by the buyer.

Any questions regarding this policy may be directed to the Customer Service Department at 1-800-462-5311.

TABLE OF CONTENTS

SAFETY 8

OPERATING YOUR MACHINE 10

MAINTENANCE 12

MECHANICAL 19

ELECTRICAL 23

DRAWINGS INSERT 1

THIRD PARTY EQUIPMENT INSERT 2

SAFETY

The safety precautions listed below are recommendations for the safe operation of your OD5000 Ordnance Deformer. Operators must understand and apply them at all times during operation. Careless operation and/or ignoring these precautions may cause injury or death.

This machine is to be used for deforming expended ordnance 20mm and smaller only.

Make sure that you have a properly rated forklift to unload your machine.

Have a qualified electrician make electrical connections to meet local standards.

DANGER: HIGH VOLTAGE IS USED IN THIS MACHINE.

Before electrical power is turned on have a qualified electrician check all electrical connections for tightness.

Also have your qualified electrician verify that the machine that you received is wired for the correct voltage.

NEVER load expended ordnance larger than twenty (20)mm in your OD5000 Ordnance Deformer.

IF YOU HAVE ANY QUESTIONS ABOUT THE SAFETY PRECAUTIONS

OR OPERATIONAL INSTRUCTIONS FOR YOUR MACHINE PLEASE

CALL CP CUSTOMER SERVICE AT 1-(800) 462-5311.

Always turn power off and install a lockout/tagout according to your lockout/tagout procedures when servicing the machine.

Absolutely never operate the OD5000 Ordnance Deformer unless all safety guards are properly installed.

Keep the electrical panel closed at all times. Line terminals are alive when the main switch is off.

Wear eye and ear protection when operating this machine and keep unauthorized personnel away during operation.

SAFETY (cont.)

Never override or bypass emergency stop switches.

Absolutely never put hands or other body parts close to any moving part of this machine.

Never stick anything into the rotor chamber while the machine is on.

Never attempt to remove objects from moving parts of the machine while the machine is on.

Do not modify or change any part of this machine. To do so may cause the machine to become hazardous to operate.

OPERATING YOUR MACHINE

Your OD5000 Ordnance Deformer is designed to process 5000 lbs. of ordnance (up to 20mm) per hour. Ensure that a qualified electrician has connected the proper electrical service with a voltage and current rating sufficient for your machine. Ensure that the rotation of the deformer blades is counter-clockwise facing the front (drive) end.

Before starting your machine, perform a visual inspection of all moving parts to ensure that a jam will not occur. Ensure that the emergency stop switch is pulled out.

1. Load the hopper with expended ordnance 20mm or smaller.

2. Turn the power on at the Main Disconnect.

3. Turn the crusher on.

4. Close the flow control gate.

5. Turn the conveyor on.

6. Meter the expended ordnance flow with the flow control gate to control the volume of ordnance on the conveyor (refer to figure A).

Main Disconnect

Crusher

Switch

Conveyor

Switch

Emergency stop Switch

Fault Light

OPERATING YOUR MACHINE (cont.)

SHUT DOWN

You can stop your machine at any time, however the sequence of shut down is very important.

1. Stop the conveyor

2. Allow the expended ordnance to clear the deforming drum.

3. Stop the deformer.

NOTE: The emergency stop should only be used to turn off the ordnance deformer in an emergency situation.

You can load the hopper at any time during operation. Your best production will be achieved if you keep the hopper full.

FIG. A Meter the expended ordnance flow with the flow control gate to control the volume of ordnance on the conveyor.

MAINTENANCE

CP Manufacturing has designed the OD 5000 for efficient operation with a minimum of maintenance. In order to keep your machine running at its optimum level, please maintain your machine in accordance with the following maintenance procedures.

WARNING: BE SURE THAT YOUR MACHINE IS TURNED OFF AT THE

MAIN SWITCH AND A LOCKOUT/TAGOUT HAS BEEN APPLIED BEFORE

SERVICING THE MACHINE.

Schedule

Clean the area around the machine. Daily Fig. 2 Remove debris from the conveyor head and tail pulleys.

Daily Fig, 4

Check the crusher drive belt tension. 40 hrs. Fig. 3 Check the conveyor belt for loose ordnance and debris.

40 hrs. Fig. 4

Grease the crusher shaft bearings. 40 hrs. Fig. 5, 5A Grease the conveyor head and tail pulley bearings.

40 hrs Fig. 6, 6A

Grease the oscillator rod end bearings.

40 hrs. Fig. 7

Check the oil in the motor speed reducers.

40 hrs Fig. 8, 8A

Tighten all electrical connections in the electrical panel.

150 hrs Fig. 10

Check the condition of the rotors and rotor shaft

150 hrs Fig. 9

Replace the oil in the speed reducers.

First 250 hours

Fig. 11

Replace the oil in the speed reducers.

2500 hrs Fig. 11 Grease motor bearings. Annually

FIG. 1 Load your expended ordnance (under 20mm) into the hopper.

FIG. 2 Clean the area around and under the machine daily.

Fig. 3. Check the crusher drive belt tension

Fig. 4. Check the conveyor belt for loose debris or ordnance. Be sure to check the head and tail pulley areas.

FIG. 5, 5A Grease the crusher shaft bearings

FIG. 6 Grease the conveyor head pulley bearings

FIG. 6A Grease the conveyor tail pulley bearings

FIG. 7 Grease the oscillator rod end bearings.

FIG.8A Check the oil in the motor speed reducers.

FIG. 8 Check the oil in the motor speed reducer.

FIG. 9 Check the condition of the rotors and rotor shaft.

FIG. 10 Tighten all electrical connections.

FIG 11. In addition to your regularly scheduled maintenance, change the oil in the motor speed reducers every six months, or every 2500 hours of use, whichever comes first.

MECHANICAL

CP Manufacturing has designed the OD 5000 for efficient operation with a minimum of maintenance. If your machine is properly maintained it will operate at peak efficiency with a minimum of down time for many years. It is necessary to follow the prescribed maintenance schedule as described in the maintenance section of this manual.

WARNING: BE SURE THAT YOUR MACHINE IS TURNED OFF AT THE

MAIN SWITCH AND A LOCKOUT/TAGOUT HAS BEEN APPLIED BEFORE

SERVICING THE MACHINE.

LUBRICATING THE BEARINGS

There are a total of eight bearings on your OD5000 Ordnance Deformer (refer to FIG. 5, 5A, 6, 6A, & 7.

Two are located at the conveyor head pulley.

Two are located at the conveyor tail pulley.

Two are located at the rotor drum shaft.

Two are located at the oscillator rod ends

For optimum results grease the bearings weekly using the zerk fittings provided. Clean the tip of each fitting and inject a general purpose lithium grease with a standard automotive grease gun. Wipe the excess grease off the fittings and bearings to prevent dirt build up.

CHANGING THE OIL IN THE SPEED REDUCERS

There are two speed reducers on your OD5000 Ordnance Deformer (refer to FIG. 8, 8A).

One is located at the conveyor head pulley

One is located at the agitator motor at the base of the hopper

The speed reducer takes approximately one quart of Mobil SHC 634 synthetic gear oil, or the equivalent. It is very important to use the proper type of oil. Check the oil level monthly by removing the inspection plug. If oil drains out when the plug is removed, it is full. If not, remove the breather plug and, using an oil pump, fill the gearbox with oil until it drains out of the inspection hole.

MECHANICAL (cont.)

Replace the inspection plug and breather plug to protect the oil from contamination.

Change the oil in the speed reducer after the first 250 hours of operation. Then change it every six months, or 2500 hours, whichever comes first.

ADJUSTING THE CONVEYOR BELT

After approximately 250 hours of use, and periodically thereafter, the conveyor belt tension may need to be adjusted. Remove the guards covering the tail pulley bearings.

Also, remove the cover over the oscillator rod so that the belt is visible on the tail pulley.

Using the adjusting screws, move the tail pulley bearings toward the rear of the machine to increase tension on the belt. Adjust the bearings evenly, and run the conveyor to make sure the belt is tracking centered on the tail pulley. Increase the tension only enough to take up slack in the belt, and to prevent slipping. Excess tension will cause the belt to wear out prematurely, and may damage other drive components.

FIG. 12 Loosen the locknut.

TROUBLESHOOTING AND REPLACING THE

CONVEYOR MOTOR GEAR REDUCER

To replace the motor gear reducer, first unbolt the torque arm from the conveyor body, then loosen the Allen set screws holding the head pulley shaft. Pull the gear reducer off of the shaft, saving the key stock from the head pulley shaft. Unbolt and pull the gear reducer off the motor, saving the key stock from the motor shaft. Manually try to turn the gear reducer input shaft. If the output shaft will not turn, the gear reducer is bad.

Bolt the torque arm to the new gear reducer. Install the motor onto the new reducer with the key stock from the motor shaft properly aligned in the keyways. Lubricate the head pulley shaft with anti-seize lubricant and push the motor/speed reducer onto the head pulley shaft, taking care to align the key stock. Bolt the torque arm back into place and then tighten the Allen set screws. Check the oil level in the new reducer, and add oil if necessary.

FIG. 13

Adjust the take-up bolt in or out to loosen or tighten the belt.

REPLACING A DRIVE BELT

To remove a drive belt, first lower the motor by loosening the four nuts just below the motor mount plate to allow slack in the belts. Next, remove the yellow drive belt guard.

Then, grab the outside belt and pull it off while turning the pulley. Next, repeat the procedure on the inside belt. ALWAYS replace both belts at the same time with matched belts.

To replace a drive belt, first lower the motor sufficiently to allow you to fit the new belts over both drive and rotor pulleys by loosening the four nuts below the motor mount plate.

Install the new belts, then raise the motor until you can deflect the belt no more than 3/8” under 30 lbs. of force.

REPLACING THE CRUSHER ROTOR BLADES.

Your machine was assembled with two sets of rotor blades in the deformer drum. These are sufficient for most applications. However, you may add two more sets of rotor blades to the drum. For your convenience two additional sets of rotor blades were shipped with your machine in the hopper. To remove a crusher rotor blade, first loosen the four clamps, and move them aside so that the door swings downward. Next, remove the two mounting bolts for each of the rotor blades that you wish to remove. Remove the rotor blades. Always remove and replace the rotor blades three (3) at a time to keep the drum in balance. To replace a rotor blade, first install the new blade to the right of the mounting disk. Then, install the two mounting bolts and tighten with two NEW

“Nylock” nuts. Tighten the mounting bolts to 120 Ft./Lbs. of torque. Swing the drum hatch up and tighten the clamp bolts.

FIG. 14 To remove a crusher rotor blade, first loosen the four clamps and swing the access door downward.

ELECTRICAL

Your OD5000 will operate at 208VAC, 230VAC, 460VAC, or other power as specified at time of purchase.

There are three fuses located inside the control panel. If a fuse blows, have a qualified electrician determine the cause of the blown fuse prior to installing a new one. ALWAYS USE THE CORRECT AMPERAGE AND

MODEL/TYPE FUSE WHEN REPLACING FUSES!!!

There are three overload devices inside the control panel, refer to FIG. 15, &

16. One for each motor. When an overload trips, the Fault Light on the front of the control panel will be illuminated. To reset the overload, turn the handle to the vertical “I” position. Each overload has an adjustable amperage range that is factory preset to match each motor. Only a qualified electrician should change the setting of the adjustment dial. Keep in mind that most overload trip problems are the result of a mechanical problem with the conveyor or crusher.

Loose terminal screws can cause electrical failures. Check the electrical connections if an overload trips, or if a motor does not energize after pressing the start button. ALWAYS TURN OFF POWER AT THE MAIN

DISCONNECT AND INSTALL A LOCKOUT/TAGOUT PRIOR TO

SERVICING THE ELECTRICAL PANEL.

If a fuse keeps blowing, or if an overload keeps tripping, call CP Manufacturing Technical Support at (800) 462-5311.

FIG. 15 To reset an overload, turn the handle to the vertical “I” position.

FIG. 16 The overloads have an adjustable amperage range.

Only a qualified electrician should change the setting.

PARTS LIST

CP PART #

NAME

QUANTITY

5-550223 DRIVE BELT, B60 2

5-003025 MOTOR, 7 1/2HP, 3PHASE 1725

RPM

5-010928 FUSE, FNM 1 1

5-043530 SHEAVE, 2TB80 1

5-043538 SHEAVE, 2TB40 1

5-043546 BUSHING, Q1 x 2 3/16 1

5-405227 BUSHING, P1-1 3/8 1

5-413216 MOTOR, 3/4 HP 1

4-502551 ROTOR BLADES 12

5-041524 HEX BOLT, GRADE 8, 1/2-20x1.50 24

5-012823 WASHER, 1/2 F(SAE) 48

5-029475 HEX NUT, 1/2-20 STOVER 24

5-6348-004 CONVEYOR BELT 1

4-6063-094 BELT FLAP 1

5-454059 REDUCER, SF726-505 B5-G 1

5-043514 BEARING FB900X 2 3/16 2

5-031542 FUSE FNQ-R-8/10 2

3-00027-01 CASTER 8” 2

3-00027-02 SWIVEL CASTER 8” 2

5-550026 BEARING, UCP207-23 2

5-027006 SWITCH, MANUAL PKZM 1-4 1

5-027022 SWITCH, MANUAL PKZM 1-1.6 1

5-028125 SWITCH, MANUAL PKZM 1-25 1

5-029165 CONTACTOR DIL 00 M-10 1

5-029173 CONTACTOR DIL 0 M 1

5-029211 CONTACTOR AUX 10 S DIL M 1

5-029807 CONTACTOR AUX NHI 10-PKZM

1-NA

CP MANUFACTURI NG I NC.

1300 Wilson Ave.

National City, CA 91950 619-477-3175 www.cpmfg.com http://www.cpmfg.com

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