Excel Baler Manual.pdf

HORIZONTAL BALER

EXCEL MODEL EX66 / EX77

Owners Manual

FOR:

EXCEL

CUSTOMER SUPPORT

1-800-475-8812

EX66 / EX77

?eoc’fl a,, CONTENTS

INTRODUCTION 3

1 FEATURES 5

7 CARE AN]) MAINTENANCE 31

SPECIFICATIONS 7

DIAGRAM A 8 CLEANING PLATEN AND REAR COVER 33

BASIC PART IDENTIFICATION 9 FILLING OIL RESERVOIR 33

WEEKLY CARE REQUIREMENTS 34

2 SAFETY PRECAUTIONS 10 MONTHLY CARE REQUIREMENTS 36

SEMIANNUAL CARE REQUIREMENTS 36

GENERAL 10 YEARLY CARE REQUIREMENTS 36

EMPLOYER REQUIREMENTS 10

8 ADJUSTMENTS 37

3 LOCK OUT/TAG OUT PROCEDURE 15 ROTATING CUTTING EDGE 37

PLATEN TO CUTTING EDGE 37GENERAL 15 LIMIT SWITCH ADJUSTMENT 39

EMPLOYER RESPONSIBILITIES 15 ~DRAULIC 40

PROCEDURE 15 PRESSURE SWITCH 40

PUMP COMPENSATOR AND

4 INSTALLATION INSTRUCTIONS 17 RELIEF VALVE 40

PUMP 41

ELECTRICAL REQUIREMENTS 17 PHOTO EYE 41

CHANGING VOLTAGE 17

INITIAL SET UP 18 9 DETAILED PART IDENTIFICATION 43

INSTALLATION SITE 18

BREATHER CAP INSTALLATION 18 MAIN BALER 44

HYDRAUlICS GATHERPLATEN 46

CONNECTING BALER TO POWER SOURCE 19 DOOR 48

REMOVE ATTACHED PARTS 21 RESERVOIR AND FILTER 50

WIRE GUIDE INSTALLATION 21 PUMP AND MOTOR 52

FINAL INSPECTION 22 MAIN CYLINDER 56

CONTROL BOX 58

5 OPERATING INSTRUCTIONS 23 LIMIT SWITCH RAIL 60

START UP AND TESTING 23 PHOTO EYE 62

OPERATING CONTROLS 25 DOOR PHOTO EYE 64

SEMI AUTOMATIC BALER CYCLE 27 MAIN ELECTRICAL BOX 66

BALE TIEING 28 DECALS 70

BALE EJECTION 29

AUTOMATIC BALING (PHOTO EYE APPENDIX A

CONTROLLED) 30 ELECTRICAL SCHEMATIC 72

6 TROUBLESHOOTING AND SERVICE 31 NOTES 87

PREVENTATIVE MAINTENANCE

CHECK LIST 88

WARRANTY 89

EX661EX77

1~••

EX66 / EX77 Page 2 of93

REV B

a

INTRODUCTION

THANK YOU FOR CHOOSING AN EXCEL BALER.

You have selected a precision-engineered product designed with advanced features for modem recycling center baling. The power of intelligent engineering and use of the highest quality components available guarantee many years of maximum performance and reliable service from your baler.

To maintain quality performance, it is important that all personnel involved in the installation, operation, and maintenance of the equipment, carefully read and follow the instructions in this guide until completely familiar with the proper safe operating procedures. This manual is arranged in the order that we anticipate you will use it to operate the equipment.

This manual does not represent an inclusive list of Safety Precautions. It is suggested that owner/operators read the most current publication of American National Standard Safety Requirement No. Z245.5, entitled “Safety Requirement for Baling Equipment.” Copies may be purchased from the AMERICAN NATIONAL STANDARDS INSTITUTE, 11 West 42nd ST, New York, NY 10036, phone (212)-642-4900.

It is also suggested that owner/operators read the most current publication of “Control of Hazardous Energy (Lock Out/Tag Out).” OSHA publication 3120. Available at regional offices of US Department of Labor, Occupational Safety and Health Administration.

Elimination of the hazards listed in this manual does not guarantee that the equipment will meet or exceed all standards or regulations, or will be completely safe to all personnel. The equipment should be inspected before use to assure adequacy in safety for the function for which it will be used.

EX66 / EX77 Page 3 of 93

EX66 / EX77 Page 4 of 93

1 FEATURES

VERSATILE MATERIAL BALING

The EXCEL EX66 / EX77 bales most plastics, cardboard, paper, aluminum cans, and other recyclables.

MAXIMUM SIZE FEED OPENING AND CHAMBER

Because the baler has a large feed opening and chamber, large quantities of material can be fed into the machine by band, conveyor, or machine loader.

REMOVABLE SHEAR BLADE WITH TWO CUTTING EDGES

Material not fitting into the bale chamber, or pieces of material toward the top of the chamber, gets sheared off by the 2 sided removable shear blade, preventing jams or pressure on the baler. After the cutting edge of the shear blade becomes dull, it can be removed, rotated, and reinstalled with a fresh new edge.

43” OF CHAMBER PENETRATION

After the feed chamber is filled, the platen pushes the material into the bale chamber, penetrating 43’ into the chamber, completely compacting all the material with tremendous force.

STATIONARY DOGS

Once the material has entered the chamber, it is prevented from springing back by stationary dogs, until the Automatic Bale Sizing System stops the machine automatically at the proper bale size.

PLATEN WIPER

As the platen retracts to allow more material to fall into the feed chamber, a unique wiper sweeps material from the top of the platen back into the feed chamber.

AUTOMATIC BALE SIZING SYSTEM

When the bale reaches the correct size, the BALE TIE OFF LIGHT will illuminate and the machine will stop cycling with the platen in the correct forward position for tieing the bale. The tie off light is easily seen from all vantage points because of it large size and location on the top of the baler.

FIVE, FULLY GUIDED WIRE TIE SLOTS

Tieing the bale is made easy because the wire is fUlly guided around the bale after it is formed. No prethreading of the wire is required. Tieing the bale with five wires assures that material is held secure in the bale, providing you with a solid, transportable bale.

SAFE , SEMI-AUTOMATIC BALE EJECTION

After the bale is tied, open the door to the baler and eject the bale onto a forklift. The bale is ejected completely from the chamber by fUlly extending the platen.

BALER DOOR SAFETY INTERLOCK SYSTEM

EXCEL’s patented bale door interlock system provides total safety in closed door baling. If an operator attempts to open the door while the baler is in operation, the platen stops then the platen decompresses and backs off the bale.

The door also must be completely open before the platen will extend to eject the bale.

EX66 / EX77 Page 5 of 93

C.

SHORT STROKE CYCLE

This feature enables the ram to cycle with shorter (8”)chamber penetration. The short stroke cycle produces approximately 21 seconds cycle time, allowing material such as corrugated cardboard to be baled at higher production rates.

INTEGRATED CONVEYOR CONTROLS WJCONVEYOR MOTOR STARTER

All conveyor controls are conveniently located on the control panel with the baler controls. Also, no separate electrical disconnect is required for the conveyor. Conveyor power is interlocked with the baler power.

ADVANCED CONTROL PANEL

In addition to normal baler operation controls, advanced controls include an Upper and Lower Photo Eye selector to start and stop the conveyor, and a Conveyor Override switch, which allows the operator to nm the conveyor at any time.

EX66 I EX77 Page 6 of93

SPECIFICATIONS

EXCEL MODEL EX66 I EX77

AUTOMATIC CLOSED END BALING PRESS

GENERAL SPECIFICATIONS

STRUCTURAL

HEIGHT

LENGTH

WIDTH

CHAMBER.

FEED OPENING

SHIPPING WEIGHT

PUMP

DIRECTIONAL VALVE

CYLINDERS

OIL RESERVOIR

VERTICAL DOOR CYLINDERS

84” (214 cm) 186” (475 cm) 88” (224 cm) 4511(11 2.Scm)L x 60” (152cm)W x 30” (76cm) H 5411(1 37cm)W x 35” (89cm)L 15,000 LBS. (6818kg)

34 GAL. (130 liters) PRESSURE COMPENSATED

HORSE POWER LIMITED PISTON PUMP, 3500 PSI RATED

D08 PATTERN HI-FLOW CUSHION SHIFT DESIGN

(2) 6” (lScm)BORE x 74” (185cm)STROKE 4”(lOcm)

HARD CHROME ROD

105 GAL. (399 liters)

(2) 3” (7.5cm) BOREX42”(lO5cm)STROKEX2”(5.1CM)

ROD

I E L E C T R I C A L I

FIVE WIRE TIE SLOTS

REMOVABLE SHEAR BLADE WITH TWO CUTtING EDGES

AUTOMATIC BALE SIZING SYSTEM

FULL BALE EJECTION

FULL PLATEN PENETRATION

SHORT STROKE SELECTOR

PATENTED VERTICAL LIFT DOOR

***DUE TO EQUIPMENT UPGRADES SPECIFICATIONS ARE SUBJECT TO CHANGE***

MOTOR

FNC[ OSI.IRF

CONTROLS

20 HP TEFC 230-460 V 3 PHASE

NEMA 12 RATED

UL/CUL/CE APPROVED NEMA 12 RATED

HYD SYSTEM PRESSURE

OVERALL PLATEN FORCE

PLATEN PSI

CYCLE TIME

BALE

3,200 PSI

162,860 LBS.

94 PSI

29 SEC. -21 SEC. SHORT STROKE

60” (1 52cm)L x 45” (1 22cm)W x 30” (76cm)H

OPTIONAL---- CONVEYOR CONTROLS

*See Diagram A

EXG6 I EX77

C

NOTES:

1) ALLOW 36” CLEARANCE

ON ALL SIDES OF MACHINE.

ALL DIMENSIONS IN INCHES.

4NOT AN INSTALLATION DRAWINO.

I.

Diagram A. EXCEL Model EX6G I EX77 Structural Specifications Diagram.

DOOR

LIFT

HEIGHT

TOP VIEW

2)

3)

SIDE VIEW

L~ III III if

NI III II 62

87 3/4

FRONT VIEW

EX66 I EX77 Page 8 of 93

BASIC PART IDENTIFICATION

Diagram B. EXCEL Model EX66 / EX77 Basic Parts Identification Diagram.

EX66/EX77

BASIC PART iDENTIFICATION

The parts diagram on the previous page shows the location of key parts and baler controls. Some of the parts require installation. These parts have been shipped packed inside the baler. As you read the description of each part and control, find that part on your baler to familiarize yourself with its location.

Page 10 of93

REV B

NO. DESCRIPTION

I BALE CHAMBER

2 REAR COVER

3 FEED OPENING

4 POWER UNIT

5 ELECTRICAL ENCLOSURE

6 BREATHER FILTER

7 OIL FILTER

8 START UP LIGHT- RED

9 START UP LIGHT- BLUE

10 PLATEN

11 WIPER

12 5 WIRE GUIDE SLOTS DOOR

13 5 WIRE GUIDES (UNDER BALER)

14 NONSLIP STEP

15 CLEAN OUT TOOL

K

EX66 I EX77

2 SAFETY PRECAUTIONS/\ The lightning flash symbol within an equilateral triangle is intended to alert the user to the ft presence of uninsulated “dangerous voltage” within the product’s enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of

• important safety reminders, and operating and maintenance (servicing) instructions in the literature accompanying the equipment.

The key and lock symbol are intended to alert the user to the need of Lock Ou~ag Out procedures.

It is the responsibility of all persons involved in the installation and operation of this equipment to completely understand the function and operation of the unit, and to understand and adhere to all safety precautions in this manual. It is important to keep watch for any condition or situation which may affect the safe performance of the equipment. If unsafe conditions are present shut equipment down using the RED EMERGENCY STOP button or normal shut down procedure. Corrective measures, service, or baler repair must be performed by trained and authorized personnel only.

1. READ INSTRUCTIONS

Read all safety and operating instructions before operating the baler.

2. RETAIN INSTRUCTIONS

Retain all safety and operating instructions for future reference.

3. OBEY WARNINGS

Obey all warnings on the baler and in the manual.

4. FOLLOW INSTRUCTIONS

Carefully follow all operating and safety instructions.

5. MACHINE OPERATING PERSONNEL

a) Only properly trained operators no less than 18 years old shall operate the unit. It is the responsibility of the employer to see that operators are properly trained.

b) Do not wear loose clothing orjewelry which could catch on moving parts. Do wear safety glasses and other safety equipment as required by your employer.

c) Never operate the baler if work ability is impaired by drugs, fatigue, illness or other causes.

d) Do not operate equipment without proper training in Lock Out/Tag Out procedures.

6. EMERGENCY STOP BUTTON

Every unit manufactured by EXCEL has a RED extended head emergency stop button. All personnel should be aware that depressing this button at any time stops the machine from operating. This button shall be installed at a distance from the machine no greater than allowed by applicable codes and local ordinances.

7. SAFETY SWITCHES

Safety switches have been provided at certain doors and access covers. They must not be overridden or removed in any manner which prevents them from functioning properly.

8. ACCESS COVERS

EX66 / EX77 Page 11 of 93

C-..

Access covers must be properly maintained and in place at all times.

9. PINCH POINTS

All moving machinery has pinch points. EXCEL has provided guards on them where possible. Some, because of the operating characteristics, cannot be guarded. Operators must use caution when closing doors, etc.

10. EXPLOSIVE SUBSTANCES

Never attempt to bale volatile or explosive substances. Serious injury or death could result.

11. HOPPER

Under no circumstances is the baler to be operated with EXCEL safety hopper removed.

12. OPTIONAL EQUIPMENT

To prevent hazardous operation, use only attachments and accessories approved by EXCEL.

13. CLEANING BALE CHAMBER OR BALER

The power must be shut off to the machine at the MAIN disconnect, and locked out, when entering the baler chamber to remove debris, or to clean around the power unit and cylinders. Refer to LOCK OUT/TAG OUT PROCEDURE section of this manual for lock out instructions.

14. HYDRAULIC PRESSURE

Hydraulic lines should be considered under pressure at all times. Completely understand the hydraulic circuit before disconnecting any hoses. Personal injury can result from escaping high pressure fluids.

15. BALER POWER DISCONNECT

The BALER disconnect is on the baler’s electrical enclosure. To prevent unauthorized use, turn off and lock out the BALER disconnect. See Diagram 0 located in Connecting Baler to Power Source under INSTALLATION INSTRUCTIONS. Also refer to the LOCK OUT/TAG OUT PROCEDURE section of this manual for lock out instructions.

16. ADJUSTMENTS ANT) SERVICING

Adjustments and repairs to this unit must be performed by qualified and authorized personnel or trained service technicians.

17. SAFETY CHECK

Upon completion of any service or repairs, the service technician should perform safety checks to determine that the unit is operating properly. Do not start or operate equipment which has a malfunction or is damaged.

18. MAKE CERTAIN ALL PERSONS ARE CLEAR OF THE BALER. CONVEYORS, AND RELATED

EQUIPMENT BEFORE STARTING THE MACHINE

19. FIRE EXTINGUISHER

Keep a fully charged fire extinguisher available at all times.

20. SAFETY DECALS

Replace all Safety Decals as they become unreadable or are missing. For proper decal replacement see the Decal list under the DETAILED PART IDENTIFICATION section of this manual and then contact your local Excel representative to obtain replacement safety stickers at no charge.

ç EX661EX77 Page 12of93

EMPLOYER REqUIREMENTS

The employer will establish a procedure for the locking and tagging out of energy sources as required by OSHA.

2. The employer will provide training to all personnel involved in the operation, service and maintenance of the equipment.

3. The employer will monitor the employees operation of the equipment, ensuring that safe practices are being followed.

4. The employer will establish a program of regular inspections as outlined in the section CARE AND

MAINTENANCE.

NOTE

These safety precautions do not imply or in any way represent an all inclusive list. It is the owners and operators responsibility to be familiar with and enforce that the unit is operated in accordance with safety requirements aad codes including all applicable Occupational Safety & Health Act (OSHA) and American National Standards Institute (ANSI) regulations.

These regulations change and therefore, it is impossible to give a reference which will remain current. It is strongly recommended that current OSHA and ANSI standards publications be available and reviewed with operators at all times.

SAVE THESE INSTRUCTIONS

EX66 I EX77 Page 13 of 93

EX66 I EX77 Page 14 of 93

3 LOCK OUT/TAG OUT PROCEDURE

GENERAL

The following is an outline of the OSHA Standard for locking and tagging out equipment from hazardous energy sources. A comprehensive publication of this standard can he obtained from OSHA. The purpose of this procedure is to ensure that the equipment is isolated from its energy sources and rendered inoperative prior to service or maintenance.

Lock OutJTag Out devices shall meet requirements set forth in the OSHA Standard Publication as to durability, standardization and identity.

EMPLOYER RESPONSIBILITIES

The standard requires employers to establish an energy program which includes:

1. Documented energy control procedures.

2. An employee training program.

3. Periodic inspections of the use of the procedures.

Compliance with the development of the Lock Out/Tag Out Procedure shall be the responsibility of the Employer.

PROCEDURE

The suggested procedure to comply with this standard is outlined as follows:

1. Remove the system key.

2. Lock Out the MAIN power disconnect per OSHA requirements.

3. Tag Out all other controls or energy sources not capable of being locked out. Every person affected should know and understand all Lock Out Tags.

4. Veri~’ that all energy sources have been accounted for prior to service ix maintenance work.

5. To restart the equipment, ensure that all Lock Out and Tag Out devices are removed by the employee that applied the device(s).

EX66 / EX77 Page 15 of 93

4 INSTALLATION INSTRUCTIONS

It is the responsibility of the installer of this baler to install it in accordance with applicable codes, local ordinances, and the manufacturer’s recommendations.

/j\ It is important that the installers of this baler follow the installation instructions in the order in which they follow. All persons involved in the installation of this baler should read

• the manual completely before proceeding.

ELECTRICAL REQUIREMENTS

All wiring must be in accordance with local and national electrical code regulations.

Check the voltage and frequency marking at the installation site MAIN supply disconnect box, so it is certain that the electrical current characteristics (voltage, etc.) are compatible with those of the baler.

If not, a qualified electrician must take whatever steps are necessary to make the voltage compatible.

Motor Horsepower Line Voltage Motor Amps

20 HP 3 Phase 230 Volts 54 Amps Full Load

460 Volts 27 Amps Full Load

CHANGING VOLTAGE

The baler has been shipped from the factory wired for the correct voltage. Changing voltage is to only be done by a qualified electrician.

/N ///“SS\\ Observe proper Lock OutlTag Out procedures before changing voltage. Make sure¶ that the MAIN disconnect switch is padlocked in the OFF position. Place an a appropriate waraiag tag, “UNDER REPAIR, DO NOT USE,” on the switch so that

-‘ it will aot be energized without notifring the person making wiring corrections.

1. When changing voltage on a baler, the complete baler disconnect panel box needs to be changed. Also, the wires from the disconnect box to the motor need to be changed. Contact EXCEL Manufacturing Customer Support for further details.

2. Change the motor wiring to match the voltage required. See Diagram C for 230 volts and Diagram D for 460 volts. A plate on the motor will also show the correct wiring.

Diagram C. 230 Volts. Diagram 0. 460 Volts

DIAGRAM C DIAGRAM D

A Li AL2 AL3 A Li AL2cT~i ~3 J~i J~2

EX66 / EX77 Page 16 of 93

3. Set the motor overload at the proper setting listed in the following chart.

230 VOLTS 460 VOLTS

Set at 68 Amps Set at 34 Amps

The motor overload for both 230 volts and 460 volts must be set in the MANUAL mode only.

4. Place an appropriate voltage decal on the outside of the box which indicates either 230 Volts or 460 Volts.

5. Follow the START UP AND TESTING instructions in this manual to assure that the baler will operate properly.

INITIAL SET UP

After the baler arrives, inspect the overall condition of the baler for damage during shipping. Remove all the loose parts and information papers.

Make sure that all parts required for assembly have been received. If any items are missing or appear damaged, contact your EXCEL Manufacturing representative immediately.

INSTALLATION SITE

CarefUl consideration should be given to the site selected for the baler, to determine the amount of room required to operate the baler. Ample room must be provided to load the baler feed opening, remove a bale from the baler, and obtain access to the back and sides of the baler for maintenance work and servicing.

Use extreme caution when moving the baler into position. Watch for all persons who may be in the path of the baler and moving equipment

BREATHER CAP INSTALLATION

Remove the Breather Cap from the baler’s accessories box in the chamber Remove the shipping plug from the oil reservoir and install the Breather Cap.

HYDRAULICS Diagram E. Temperature/Sight Gauge

EX66 / EX77 Page 17 of93

The hydraulic system has been completely operated and tested at the factory. Check all hydraulic connections to insure that no leaks have developed during transit.

Check the oil level within the reservoir. The oil in the temperature/sight gauge on the side of the reservoir should be even with the oil level arrow when the platen is thEy retracted.

CONNECTING BALER TO POWER SOURCE

OIL LEVEL

~i

All wiring must be in accordance with local and national electrical code regulations.

Observe proper Lock Out/Tag Out procedures before connecting power to the baler.

Make sure that the MAIN disconnect switch is padlocked in the OFF position. Place an appropriate warning tag ,“UNDER REPAIR, DO NOT USE,” on the switch so it will not be energized without notifying the person making wiring connections.

See the APPENDIX section of this manual for the wiring diagram and electrical schematic.

1. Open the electrical enclosure. Refer to Diagram F for operation and lock out procedure of the BALER power disconnect. Also, refer to LOCK OUT/TAG OUT PROCEDURE section of this manual.

Diagram F. Operating and Lockout Procedure of Baler Power Disconnect.

REV B

C

2. Drill or punch a hole in the electrical enclosure to allow the electrical power line to enter the box. Protect parts from metal chips.

/4\ After drilling or punching holes in the electrical box, extract all metal filings or chips from the box.

Do not use forced air to remove fillings or chips or premature contactor failure will result!

3. Run electrical power lines from the customers MAIN disconnect switch to the electrical box.

4. Connect the electrical power line as shown in Diagram G on the next page.

REV B

Diagram C. Connecting Electrical Power to Disconnect Inside Box.

5. Close the electrical box.

/4\ Do not close the MAIN power supply switch or turn the handle to ON until instructed to do so in the START UP AND TESTING section of this manual.

REMOVE ATTATCHED PARTS

Open baler door and remove clean out tool from inside tube at top front of chamber. Remove the grease gun attached to inside of bale door. Remove any other parts located inside chamber.

WIRE GUIDE INSTALLATION (INSTALLED AT FACTORY)

Parts Required:

5 - Wire Guides

10- 3/8” Flat Washers

10- 3/8-16 UNC x 3/4” Hex Bolts

10- 3/8’ Split Lock Washers

Page 20 of93

REV B

[4 v— INCOMING POWER

I _______ PROVIDED BY

CUSTOMER

EX66/EX77

INSTALLATION STEPS

1. Block up front end of baler one foot off from floor.

2. From underneath the baler, place a wire guide into a slot, sliding the front of the wire guide to the front of the baler.

3. Push the guide into the slot completely, so that the front of the guide rests on the tube at the front of the baler, and so that the holes in the guide are aligned with those on the baler. See Diagram H.

Diagram H. Wire Guide Installation.

4. Use 2 - 3/8-16 UNC x 3/4’! bolts, 2 - 3/8” flat washers, and 2-3/8” split lock washers to secure the guide.

5. Repeat the previous steps until all guides are in place.

FINAL INSPECTION

As a final check, carefully inspect for leaky hydraulic connections, loose electrical connections, and loose or missing bolts and nuts.

REV B

CHAMBER FLOORB ALE

ONT OF BALER

WIRE GUIDE

3/8 FLAT W

3/8 LOCK

3/8—16 UNC

ASH ER

WASHER -~

X 3/4” HEX BOLT -~

TOP OF WIRE GUIDE

5 OPERATING iNSTRUCTIONS

START UP AN1~ TESTING

Do not test this baler until all involved persons have completely read and understood this manual.

/I\ Make sure that all access covers are in position and that the baler chamber door is closed and secured with the latch. Before proceeding with this test, make sure that all persons are clear of the

• baler.

1. With the MAIN disconnect switch OFF, visually inspect all hydraulic, mechanical and electrical connections. All connections must be ti~t.

2. Check oil level in the reservoir to be sure it is adequate.

3. Close the MAIN disconnect switch. Turn the BALER power disconnect located on the electrical enclosure to

ON.

A\ Be alert for smoking, electrical arcing, or fuse failure. If any irregularity is observed, open the MAIN supply switch immediately. Find the source of the trouble and make the necessary corrections.

4. Have an assistant stand so that they may clearly view the fan end of the motor. This person should be instructed to observe the rotation direction of the motor. The motor must turn in the direction of the arrow located on the motor housing when viewed from the fan end. If the direction arrow is missing, the motor must turn in same direction as indicating arrow on pump.

5. Insert the key into the key switch located on the control panel.

6. Turn the key clockwise to the START position, hold until the buzzer stops and the motor starts.

7. If the observer indicates that motor rotation is incorrect, depress the EMERGENCY STOP button IMMEDIATELY and go on to step 8. If motor rotation is correct, skip to step 10.

8. Place the key switch in the OFF position and remove the key./\ Observe proper Lock OutlTag Out procedures before changing motor rotation.

ft ..Q Make sure that the MAIN disconnect switch is padlocked in the OFF position. Placecj~’ an appropriate warning tag, “UNDER REPAIR, DO NOT USE”, on the switch so that it will not be energized without notifying the person making wiring connections.

9. To change motor rotation for 3 phase motors, switch any two motor wires. Switch the wires where the incoming wires connect to the disconnect. Do not change factors’ wiring.

,4\ Make sure the motor wires are reconnected securely if it was necessary to switch them to correct motor rotation.

Retum to step 4 and repeat the rotation testing procedure to assure proper motor rotation.

10. Leave the motor running, turn selector switch to AUTO.

EX66 I EX77 Page 22 of 93

11. Depress the green FORWARD button. The platen will move forward and then reverse automatically after reaching full extension into the bale chamber. It will return to its retracted position and the motor will continue to rum

12. Cycle the baler again by depressing the green FORWARD button. When the baler is part way through its cycle, depress the EMERGENCY STOP button. The motor should stop running and the platen should stop moving.

13. Test the optional hopper door interlock and emergency stop arm on the conveyor to ensure they are functioning properly.

Employer Responsibility Regarding the Operation of EXCEL Balers.

The employer shall provide properly maintained baling equipment that meets all applicable regulatory safety standards.

The employer must insure that the installation of balers is in conformance with local codes, ordinances, and the manufacturer’s recommendations.

The employer must provide instruction and training in safe methods of work to employees before assigning them to operate, clean, service, maintain, or repair the equipment. Such instruction and training shall include procedures provided by EXCEL Manufacturing.

Employers are responsible for repairing, prior to placing baler equipment into service, any mechanical malfunctions or breakdowns that affect the safe operation of the equipment.

Employers are responsible for establishing and following a program of periodic and regular inspections of the baling equipment to insure that all parts, component equipment, and safeguards are in safe operating condition and adjusted in accordance with the manufacturers

— recommended procedures. This shall include keeping detailed malfunction reports and records of inspections and maintenance work 3 erfonned.

/j\ Before operating, check to see that the loading chamber is empty and free to operate.

All operators of this baling equipment must read this manual and be at least 18 years old.

OPERATING CONTROLS

The operating controls are located on the control panel on either side of the baler, depending upon how the baler is equipped. Following is a brief description of the function of each control and its intended use.

~iagram K. Operating Controls.

EX66 / EX77 Page 23 of 93

START UP ALARM

When the baler disconnect switch is turned on, the emergency stop switch is released and the key switch is turned to the START position, the buzzer will sound and the red light will flash for 15 seconds before the baler and conveyor controls are unlocked and the motor starts. Any time the baler disconnect switch is fumed off then back on or any emergency switch is depressed then released or the key switch is turned to the offposition, the start up sequence will need to be initiated again.

BALER POWER DISCONNECT SWITCH - Electrical Enclosure This switch controls the main power to the baler. See Diagram F in the INSTALLATION INSTRUCTIONS section of this manual. Turn the switch to the OFF position and lock it out when baler is not in operation.

EMERGENCY STOP - Red Extended Head Push Button and conveyor emergency stop Depressing this button stops all baler fhnctions in the event of an emergency. When pushed, the button remains depressed and the baler will not operate. To restart the baler, twist the EMERGENCY STOP clockwise and follow the proper start up procedure.

Each conveyor is equipped with an emergency stop arm which when activated will stop both the baler and conveyor, when released this arm will return to original position.;

SYSTEM - 3 Position Key Switch The key switch in the START position will start the motor when baling is initiated. The key switch in the ON position allows the baler to operate in either manual or automatic after the motor is running. Turn the key switch to OFF and remove the key to discontinue baling.

HAND I AUTO - 2 Position Selector Switch When in HAND POSITION, the baler will extendlretract only when the appropriate controls are activated. When in AUTO POSITION and the PHOTO EYE control is ON, the baler will activate completely automatically.

SHORT STROKE -2 Position Selector Switch When set to ON, the platen partially penetrates into the chamber, approximately 8”. When set to OFF, the platen has full chamber penetration.

BALER PHOTO EYE - 2 Position Selector Switch

EX66 I EX77

C.

DOOR OPEN DOOR CLOSED DALER PHOSO EYE CONVEYOR

Oil On DIR Oooofl

SHORT STROKE CONVEYOR

OH On OVERRIDE

HOPPER OVER

HAND AUTO FILL LIMIT

LOWER UPPER

I &WARNING &PRLcAucION I .nennEs,,SsnI,VDSHALLY CCC. mORN EVE CC ISO

When set to ON, and the SYSTEM is set to AUTO, the photo eye is activated. The baler starts and cycles automatically when the photo eye beam is broken after the baler feed chamber becomes fbll. Turn the switch to OFF to bale or for semiautomatic operation.

FORWARD - Green Push Button When the SYSTEM is set to AUTO, depressing the FORWARD button activates auto cycle and starts the platen moving forward.

When the platen reaches ftill extension into the bale chamber, it reverses automatically and returns to its original starting position.

When the SYSTEM is set to HAND, depress and hold the FORWARD button to manually move the platen forward. The platen will stop when the FORWARD button is released while in hand.

REVERSE - Yellow Push Button When the SYSTEM is set to AUTO, depressing the REVERSE button activates auto cycle and starts the platen moving backwards and retracts filly. When the SYSTEM is set to HAND, depress and hold the REVERSE button to manually back the platen up. The platen will discontinue moving when the REVERSE button is released while in hand.

CONVEYOR OFF-ON - 2 Position Selector Switch In the ON position, the conveyor starts and stops automatically and is controlled by the baler photo eye. The conveyor does not operate when set in the OFF position. Upon first start up or after an emergency stop has been depressed, the override button must be depressed in order to initiate the conveyor.

CONVEYOR ON OVERRIDE - Push Button Depressing this button activates conveyor auto cycle. Also, depressing this button starts and operates the conveyor, overriding the baler photo eye function. The CONVEYOR OFF-ON must he set to ON for this switch to operate the conveyor.

EX66 / EX77 Page 25 of 93

C.

HOPPER OVER FILL LIMIT -2 Position Selector Switch

Photo eyes are placed at high and low positions in the hopper to regulate incoming material. This switch selects which photo eve is active. The lower photo eye operates the baler and the conveyor. The upper photo eye operates the conveyor only. When the HOPPER OVER FILL LIMIT is set to LOWER, the chamber fills for one charge, the baler cycles and the conveyor stops. When the HOPPER OVER FILL LIMIT is set to UPPER, the conveyor will continue filling the hopper until material reaches the upper photo eye, so that another charge is ready when the platen reverses.

DOOR OPEN - Green Push Button When in HAND POSITION and after the bale is tied off, depressing this button will open the door completely. Prior to depressing this button, retract the platen about 4” to relieve pressure off the door. This will allow the door to open smoothly.

DOOR CLOSE - Yellow Push Button When in HAND POSITION and after the bale is ejected, depressing this button will close the door completely.

SEMI AUTOMATIC BALER CYCLE

1. Turn the BALER power disconnect switch to the ON position.

2. Set the selector for SHORT STROKE to OFF or ON.

3. Set the selector for BALER PHOTO EYE to OFF.

4. Turn the key switch to START. For 15 seconds, the red light will flash and the buzzer will sound.

5. Turn the selector switch to AUTO.

6. Load the feed chamber until it is thU.

Before depressing the FORWARD button, clear all unauthorhed personnel from the area.

6. Depress the FORWARD button. The platen will move forward, compacting the material in the bale chamber. After the platen reaches full extension into the bale chamber, it will reverse automatically and return to its original starting position.

7. Follow steps 5 and 6 until the blue BALE TIE OFF LIGHT at the top of the baler illuminates. After a complete bale is formed, follow the directions for Bale Tieing and Bale Ejection.

8. If you wish to stop baling before a bale has been completed, retract the ram and tum the key switch to the OFF position and remove the key. Turn the BALER power disconnect switch to the OFF position.

To prevent unauthorized use of the baler, always Lock Out the BALER power disconnect and remove the key when the baler is not in use.

BALE TIEING

EX66 I EX77 Page 26 of93

After a complete bale is formed, the blue TIE OFF LIGHT at the top of the baler will illuminate. The baler and conveyor will stop automatically with the platen in the correct forward position for tieing the bale.

1. Turn the key switch to the HAND position. Turn the BALER PHOTO EYE SWITCH to OFF.

2. From the top of the baler, thread the end of the wire which is not looped down through the five slots in the front of the platen. See Diagram L.

3. If the wire does not feed smooth through the wire guides, the slots may have blockage in them, use the clean out tool to clean slots.

SAFETY GLASSES REQUIRED. Do not insert wire when persons are in front of the baler. Injury could result.

Diagram L. Threading Wire Ties Around the Bale.

1. PUSH UNLOOPED END DOWN

THROUGH SLOTS IN PLATEN,

CONTINUING TO FEED THROUGH

WIRE GUIDES AS SHOWN.

2. FEED LOOPED

END OUT SLOTS

IN TOP OF DOOR.

3. SECURE ENDS

OF TIES AT

FRONT OF

BALER.

3. Push the wire until it comes out the bottom of the corresponding slot in the door.

4. Pull the wires through to allow enough slack for securing the two ends together.

5. Thread the looped end of the wire ties through the corresponding slots on the top of the bale and then out the same slot in the top of the bale chamber door.

6. Center the wire in the guide on the underside of the bale to assure that the wire will pull up completely and out of the slot when the two ends are secured together. See Diagram M. This will prevent the wires from being cut by the edge of the wire guide.

Diagram M. Centering Wire Ties in the Guides.

r

7. Standing in front of the baler, tie the two ends of each of the five wires together.

BALE EJECTION

The hale is ready to be ejected from the chamber after the machine has stopped with the BALE TIE OFF LIGHT illuminated and the bale has been tied following the previous instructions.

All persons must be clear from the front of the baler when the bale is being ejected. Serious injury could result from the bale falling onto the pallet.

1. Turn the SYSTEM key switch to the HAND position.

2. Depress the REVERSE button and retract the platen 3” to 4” (75 mm to 100 mm) from the bale.

3. Depress the DOOR OPEN button, at this point the platen will also backup.

The bale chamber door is under pressure and may spring open suddenly when the door latch is opened.

Stand clear of the swing path of the door as it is being opened.

4. Open the bale chamber door completely to activate the safety interlock system.

5. Place a fork lift in front of and lower than the door opening for the bale to land on and be moved away with once it is ejected.

6. Push the FORWARD button. Keep depressing it until the platen reaches fill extension and the bale is ejected.

7. Depress the REVERSE button and hold to filly retract the platen.

8. Turn the SYSTEM key switch to the OFF position. Turn the Baler power disconnect switch OFF and lock out.

Observe proper Lock Out/Tag Out procedures before cleaning the baler.

9. After the bale has been removed, clear the inside of the baler chamber and the area of debris.

EX66 I EX77

BALER FLOOR

WIRE

WIRE GUIDE

WIl )

10. Clean wire guides if necessary using the clean out tool provided.

11. Restart Baler using KEYSWITCH

12. Close and secure the bale chamber door, by depressing the DOOR CLOSE button, to activate the safety interlock system.

13. Turn the SYSTEM key switch to AUTO and begin forming another bale..

AUTOMATIC BALING (PHOTO EYE CONTROLLED)

1. Turn the BALER power disconnect to ON.

2. Tum the SYSTEM key switch to AUTO.

3. Turn the PHOTO EYE CONTROL switch to ON.

4. Depress FORWARD or REVERSE to activate auto cycle.

5. Load the feed chamber.

/j\ When photo eye beam is broken, the baler starts and cycles automatically, without warning.

The baler cycles automatically when the feed chamber becomes full.

6. Continue filling the chamber. When a complete bale is formed, the blue BALE TIE OFF LIGHT at the top of the baler illuminates.

1. After the blue BALE TIE OFF LIGHT illuminates, turn the PHOTO EYE CONTROL switch to OFF. Follow the Bale Tieing and Bale Ejection instructions earlier in this section.

8. If you wish to stop baling before a bale is completed, turn the PHOTO EYE CONTROL switch to OFF, then the SYSTEM key switch to OFF.

Never leave the baler unattended with the Photo Eye Control On.

EX66 / EX77 Page 29 of 93

6 TROUBLESHOOTING AND SERVICE

Troubles sometimes are caused by simple faults that can be easily corrected without the help of a service technician by first checking a few basic remedies.

Before you call an authorized EXCEL Manufacturing service representative, look below for the type of trouble you are experiencing. Then perform the check and adjustments listed for the trouble.

If your baling equipment is still in warranty, these checks and adjustments could save you time and the cost of an unneeded visit from a service representative. They also could save you the cost of a diagnosis not covered by your warranty. (Refer to the warranty on the inside of the back cover to veri~’ what is covered.)

If your baling equipment is out of warranty, these checks and adjustments could save you the cost of an unneeded diagnosis.

For your nearest authorized EXCEL Manufacturing service representative, yhone 1-800475-8812.

Please have baler model and serial number ready before calling.

Electrical trouble shooting is to be performed by qualified electricians only.

Page 30 of93

REV B

4-

TROUBLE POSSIBLE PROBLEM SOLUTION

Material jams under cutting edge. Cuffing edge to platen tolerance exceeds See Cutting Edge Adjustment.

1/16’.

Cutting edge is not cutting. Edge is dull. Remove or replace cutting edge and rotate as needed.

Wire slots do not line up. Side clearance adjustment. Add side shims.

The platen is in extended position Rear limit switch. Foreign object holding Rear limit switch arm and will not return, open.

Pressures out of adjustment. Check pressure settings.

Bale tie position is not correct. Bale Tie Limit Switch out of adjustment. See Limit Switch Adjustments.

Motor runs hot. Blocked ventilation. Clean external and intemal ventilation systems.

High ambient temperature of over 105 Provide outside sources of cooler air or reduce degrees F. number of cycles per hour.

Motor does not run. Emergency Stop button depressed. Twist to release.

Key Switch in OFF position.

Disconnect in OFF position.

Blown fuse. If blown, replace.

Blown Control Voltage fuse. Replace.

TROUBLE POSSIBLE PROBLEM SOLUTION

Motor does not run. (cont.) Thermal overload tripped. Press Reset button.

Main switch open. Close switch.

Motor won’t start or makes growling Very low voltage. Check power source.

noise. Check motor nameplate.

Single Phased. Check power source. Must have all three phases.

Open motor leads. Check continuity. Clean and tighten.

Rotor or bearings locked. Check shaft for freeness of rotation.

Starter coil burned out. Replace starter coil.

Thermal overload relays tripped or Incoming leads to incorrect terminals. Correct lead terminal locations.

tripping.

Low voltage at motor terminals. Improve power supply andlor increase line size.

Single Phased. Check power source, Must have all three phases.

Loose wires from fuses to starter/ from Tighten wire connections.

overload to motor.

Incorrect amp setting. Correct amp setting on overload.

Excessive vibration. Motor mounting. Check aligmrieni between motor arid pump.

Be sure motor mounting is tight and solid.

Pump. Disconnect pump from coupling and restart motor. If vibration stops, the unbalance is in the pump. Replace the pump.

Coupling. Remove coupling and restart motor. If the vibration stops, the unbalance is in the coupling. Replace the coupling spider.

Motor. If the unbalance does not stop after checking the other possibilities above, the unbalance is in the motor. Check the bearings.

Motor runs noisy. Bad bearings. Disconnect from pump coupling and check. If noise does not stop, replace bearings.

Bad pump or coupler. Disconnect from coupling and check.

Pump makes noise. Low oil level. Add oil.

Restricted intake pipe. Flush the system. Clean intake pipe.

Defective bearing. Replace pump.

Air getting in the pump. Check condition and tightness of intake hose.

EX66 /EX77 Page 31 of 93

7-...

C

TROUBLE POSSIBLE PROBLEM SOLUTION

Motor and pump run but baler does Low oil level. Add oil.

not 11111.

Incorrect pump and motor rotation. See Start Up and Testing section for checking motor rotation.

Key sheared on pump or motor shaft. Replace key and any damaged parts.

Noise like stones in the pump - Air leak in suction system. Replace 0-ring on suction end of pump.

usually intermittent. Check all connections for possible leaks.

Motor continues to nan and fails to Front Limit Switch out of adjustment. See Limit Switch Adjustments.

retum platen.

Relief Valve out of adjustment. See Relief Valve Adjustments.

Baler continues to cycle with empty Photo Eye and/or Photo Eye Reflector Clean Photo Eye and/or Photo Eye Reflector.

chamber. dirty.

Photo Eye and/or Photo Eye Reflector See Photo Eye Adjustments.

out of adjustment.

Motor runs but the platen does not Door not opened or closed completely. Open door to activate door safety switch or move, close door and latch completely to activate door safety switch.

Motor to pump coupler loose. Check motor to pump coupler tightness.

Wires don’t feed easy. Not in position. Move main ram to tie position.

Wire slot restricted. Use clean tool to clean slots

Page 32 of93

7 CARE AN]) MAINTENANCE

EXCEL Manufacturing recommends that users of our baling equipment adopt a program of regularly scheduled maintenance procedures. The following schedule should be followed to insure against premature failure of mechanical or hydraulic components. A PREVENTATIVE MAINTENANCE CHECK LIST is provided in the APPENDIX of this manual, which may be copied for your convenience, Warranty coverage is dependent upon your maintenance records.

Employer Responsibility Regarding the Maintenance of EXCEL Balers

It shall be the responsibility of the employer who uses baling equipment to insure the proper caring for, cleaning, inspection, and maintenance of the equipment. In the case of employers who maintain their own equipment, the employer will provide training to competent iiersonnel for this purpose.

It is also the responsibility of the employer to establish and follow a program of periodic and regular inspections of baling equipment, and to insure that all parts, auxiliary equipment, and safeguards are in safe operating condition and adjusted in accordance with the manufacturer’s recommended procedures. The employer must maintain records of these inspections and of maintenance work performed.

The employer is Responsible for providing adequate work area around the baler to permit safe maintenance, servicing, and cleaning practices. The employer must insure that all surrounding floors are free from obstructions, and from accumulation of water, grease or oil.

CLEANING OUT BEHIND PLATEN ANT) REAR COVER

All balers tend to accumulate material behind the main platen as the machine is cycled. This is due to the built in clearance along the sides and bottom of the platen which allows material to migrate to the area behind the platen.

Allowing this material to build up may cause baler malfunction and even lead to structural failure. Therefore, it is necessary to clean out this area on a regular basis as part of a routine maintenance program. This procedure should be performed every 40 hours, or as necessary.

To avoid personal injury, observe Lock Out/Tag out procedures per OSHA

. ____________ :;~:i~meh1t5 before cleaning ont this area. Wear safety glasses to keep debris out of

Lock out power and put on safety glasses. Remove rear cover and sweep out all material on floor. Also, clean debris from limit switch rail.

FILLING OIL RESERVOIR

EXCEL recommends the use of a premium grade antiwear hydraulic oil in our systems. The following table lists specifications for Mqbil and Conoco products recommended by EXCEL. Other brands of oil are acceptable if th~y meet the specifications and oil cleanliness code listed in the oil selection table on the next page.

Initial oil selection, cleanliness and on going maintenance procedures are vital to the trouble free operation and longevity of your baler. Regular oil filter and air breather changes are a necessary part of care and maintenance. Yearly oil sampling and testing by your local oil distributor can help determine if there is a need to change the oil or replace the oil additives. The advice of your local oil distributor is also invaluable when selecting the oil for a new machine.

When filling the system, DO NOT pump oil directly from the barrel or bulk truck. Filtering of new oil is required.

EX66 I EX77 Page 33 of 93

When filling the system it is not acceptable to pump the oil directly from the barrel or bulk truck without filtering it. New oil rarely meets the cleanliness codes required by pump and valve manufacturers. New oil should be filtered with a maximum 10 micron filter as the tank is filled.

OIL SELECTION TABLE

Conoco ISO Grade MV 32 Product Number MV32 Oxidation Control (ASTM D-943, hr) 4500 hours Pour Point, (° F), max. -45 Flash Point, (°F), mm. 400 Viscosity SUSat100°F 164 SUSat21O°F 47 cStat40°C 32 cStatlOO°C 6.2 ISO viscosity Grade 32 Viscosity Index, mm. 145 Rust Test, ASTM D665 A @ B PASS Foam Test, ASTM D892 I, II, 1II,mllml, max. PASS

Alternate Oils include: Exxon Univis M32, Texaco Randall HD-36, Mobil DTE-13M

WEEKLY CARE REOUIREMENTS

1. Check the baler disconnect switch for fUnction. Make sure a padlock is available for servicing.

2. Check the hydraulic reservoir oil level. The oil level in the sight gauge on the side of the reservoir should be at the oil level arrow when the platen is fully retracted. If it is not, add oil as specified in the table above.

3. Grease the six nylatron wear pads at the sides (three per side) of the baler. Also grease the two door guides. See the Diagram L. on the next page for grease point locations. Lubricate the baler every 35 to 40 hours of operation.

High use will require lubrication more often.

/I\ Use cardboard or wood to search for suspected leaks. Do not use hands. High pressure fluid flow can penetrate skin and cause serious injury.

4. Check hydraulic pump, valve, cylinders and hoses for leaks. Check for any damage, kinks, etc.

5. Inspect the power unit. Remove dust and dirt from outside of the reservoir, control box, and electrical enclosure.

Wipe off any grease, oil, or moisture. Inspect motor for excessive dirt, friction, or vibration. Keep the ventilation openings clear to allow free passage of air.

6. Remove the rear cover and clean out behind the platen. Clean off the limit switch rail.

7. Inspect the limit switches and rail. Make sure the arms are 90 degrees from the body and that all connections are secure. Inspect the cylinders, cylinder pins, etc.

8. Test all the baler controls and make sure each is operating properly. Check the photo eye operation. See the description of each control under Operating Controls in the OPERATING INSTRUCTIONS section.

EX66 I EX77 Page 34 of93

Diagram N. Lubrication Chart.

WEAR PAD

(BOTH SIDES)

9. Test the thnction of the Upper and Lower Photo Eyes. Make sure conveyor stops, baler cycles, etc.

10. Check that the bale tie light functions when a bale is complete. Check that the start up light and alarm function on start up.

11. Inspect the door cylinders condition. Make sure bolts are secure.

12. Inspect the door of the baler. Check general condition, welds, structure and function.

13. Lock out the baler power disconnect, open the baler door and clean the wire tie slots in the front of the platen.

14. Clean the wire guides or more often as needed.

15. Check the clean out tool, this may be required more often for high usage situations.

16. Inspect the platen wiper condition and make sure it pivots freely.

17. Check all nuts and bolts. Make sure all are tight and secure.

18. Walk around baler and inspect overall condition of equipment, including decals and structural. Make sure overall baler is clean and free of debris.

19. Check to see that all access covers are secured in place.

20. After the first week of use, check the tightness of all the wires and monthly thereafter. This check should be done by a qualified electrician.

Page 35 of93

____________ (..MONTHLY…