A few timely steps prevent downtime, boost productivity and prevent big issues down the road.
Kirk Warren
Without a doubt, compactors are a wise investment for any business that generates large volumes of waste and/or recycling materials. By compressing and crushing waste, fewer hauls are required鈥攔esulting in significantly lower collection costs. But compactors work hard. They are typically used on a daily basis in all sorts of extreme environments. And, like any heavy equipment, there are electrical systems, controls, switches and hydraulic systems鈥攏ot to mention constant abrasion of metal against metal.
Unexpected downtime is aggravating as well as costly. However, simply performing regular maintenance tasks and attending to the early warning signs of poor compactor performance can typically avoid compactor downtime.
Just like your favorite sports car, compactors need a little well-timed care to keep them running strong. A regular preventative maintenance plan is the best way to keep your compactor running efficiently, and following a recommended maintenance schedule will protect against premature failure and/or wear of hydraulic and mechanical components, significantly extending the compactor鈥檚 life cycle.
Always operate a compactor within the rated capacity and follow a maintenance and lubrication program. A qualified service technician should always perform preventative maintenance. A compactor should always be disconnected from power supply, locked and tagged out before performing any maintenance. It is also advised that the control circuit fuse is removed as a secondary precaution to prevent the compactor from being started accidentally. Double-check circuit breakers to make sure that they are off.
The age and type of equipment plays a role in determining maintenance needs, but a good program infuses weekly, monthly and yearly maintenance tasks, such as checking pressure relief valve settings, checking hydraulic fluid level, changing oil and filters, inspecting hoses and fittings for leaks, applying grease to grease fittings and inspecting cylinders.
Recommended Weekly Maintenance
- Check fluid level in hydraulic oil tank. Add oil as necessary.
- Check hydraulic hoses and fittings for leaks. Tighten fittings or replace hoses as needed.
- Remove dust and dirt from outside of the control box.
- Wipe off any grease, oil or moisture on power unit.
- Observe one complete cycle to verify proper operation.
Recommended Monthly Maintenance
- Perform all recommended weekly maintenance tasks.
- Visually inspect condition of compactor for potential problems.
- Clean refuse from behind ram.
- Ensure compactor is securely anchored to floor.
- Apply grease to all grease fittings as applicable.
- Lubricate ram contact surfaces.
- Check condition of hydraulic oil. Change if discolored (milky or dark) or dirty, or if it contains water, smells burnt, or lacks lubricity when rubbed between the fingers.
- Check cylinder pins and retaining bolts.
- Check turnbuckles and marriage hooks for stress fractures and wear.
Recommended Yearly Maintenance
- Perform all recommended weekly and monthly maintenance tasks.
- Drain, flush and refill hydraulic oil tank.
- Replace oil filter.
- Check all fasteners and tighten as required.
- Replace air breather.
- Check structure of compactor for potential trouble areas.
- Check anchor bolts and tighten as necessary.
Some compactors have an automatic maintenance scheduler to alert you when preventative maintenance is due. Large volume waste generators can reap all of the benefits of a compactor by choosing the correct model, meeting all installation requirements, and scheduling regular maintenance. With proper use and maintenance, compactors should last for many years, reducing collection costs while safely storing waste and recycling materials.
Kirk Warren is the Director of Product Management for Wastequip鈥檚 Container and Compactor Division. Wastequip (Charlotte, NC) is a leading North American manufacturer of waste and recycling equipment. Wastequip鈥檚 broad range of waste and recycling equipment and systems is used to collect, process and transport recyclables, solid waste, liquid waste and organics. The company鈥檚 brands include Wastequip, Toter, Galbreath, Pioneer, Accurate, Cusco, Mountain Tarp and Go To Parts. For more information, call (877) 468-9278 or e-mail [email protected].
Sidebar
Preventing A Commonly Overlooked Problem
Most closed-lid compactors have hydraulic operating pressure gauges that determine when a compactor is full. One common issue that is often overlooked, but very easy to address, is a faulty and damaged pressure gauge. If the gauge indicates false pressure readings, one of two things typically happens: you pay hauling costs for transportation of a less-than-full compactor; or worse, a false low pressure reading causes a compactor to over-compact waste and potentially damage a compactor or container.
To prevent false pressure readings, a qualified service technician should measure the compactor鈥檚 hydraulic operating pressure with an independently calibrated gauge each time basic preventative maintenance is performed. He/she should measure the reading against a compactor鈥檚 hydraulic pressure gauge both before and after maintenance to capture trend data and alert when a gauge is reading false high or low operating pressures.