Harris Baler Manual.pdf

OPERATOR

SERVICE

MANUAL

HARRIS

HORIZONTAL~_

CLOSED DOOR

BALER

© Copyright Harris Waste Management Group Inc., July 1, 1995 f~.t~Li~~J GirL -3k~i - Cod~c\c.. 72fi~—7JI 3-2-500

FORWARD

HARRIS Balers are quality built machines engineered to operate with a minimum of moving parts and maintenance and built for long service We.

Each Baler is factory tested to ensure it operates correctly and will pailonn to the design standards.

The use of non-standard1 counterfeit or substitute parts may affect the performance and operational safety of your machine. Insist on genuine HARRIS replacement parts.

This manual was prepared for your use with the intention of providIng clear. anase instructions to aid in the safe, efficient operation of HRB Balers.

Operator Safety is of the utmost importance to us at HARRIS. We strongly recommend that all persons operating or working around HARRIS Bale’s read this manual carefully far safety rea sons. Only persons literate in the English lan guage should be considered as potential opera-torn for HARRIS Balers.

The baler operator must know and observe the capabili ties and limitations of the baler. It is important to keep alert and watch for any condition or situation which may affect the normal performance of the baler, such as over charged feed hopper, oversized bale, machine malfunc tion or personal safety in the work area If a problem or unsafe condition does anse, shut the baler down by using the emergency stop push button or the prescribed shut down procedure. Notify the proper authority immediately.

Corrective measures, service or baler repair must be per formed only by trained authorized personnel. If at any time there is a question regarding safety~ the operator should consult the manual, supervisor or HARRIS to ensure all precautions are taken before proceeding.

1W~ This manual is pnnted on recycled paper.

If You Cannot Do It Safely Don’t Do It

NOTE

TABLE OF CONTENTS

Forward Table of Contents Definition of Terms Decals and Warning labels

OPERATION

Terms You Will Need to Know Decal Application Chart Hydraulics Electncal Systrnes Safety Precautions Baler Functions Description of Operating Controls Pre-operation Inspection Baler Start Up Procedure Baler Operation Shut Down Jam at the Shear Knife and

Corrective Measures

PREVENTIVE MAINTENANCE

General Maintenance Records Hydraulic Fluid Recommendations for

Hydraulic Systems Hydraulic Oil Viscostly Index Low Temperature Neutralization Number Contamination Recommended Hydraulic Fluid Hydraulic Fluid Testing Ofl Sample Collection Procedure Lubncation Electric Motor Bearing Lubrication Lifting Instructions Filter Replacement Suction Strainer Replacement Service Inspection and

Cleaning Requirements

ADJUSTMENTS

II

IV

.IV

1—1 1-2 1-4 1-4 1-5

TROUBLESHOOTING

2-2

Electric Solenoid Valve Test For Internal Leakage of Cylinder Main Motor(s) Will Not Start Pump Noise Maximum Hydraulic Pressure

Not Obtained Platen Will Not Move Forward Platen Will Not Retract Bale Will Not Eject Machine False Cydes in Auto Mode Bale Exit Door Will Not Open Bale Exit Door Will Not Close Fatse Bale Complete Shut

2-2

2-2 REPAIR

Platen And Cylinder Removal Platen and Cylinder Installation Platen Hold Down Liner Replacement Platen Guide Bar Replacement Platen Wearstnp Replacement Platen Welded Wearstnp

Liner Replacement Cylinder Repair Bale Door C~,linder

.3-5

.3-6

.3-7

.3-8

-3-9

.3-10

.3-10

4-1 4-1 4-2 4-2

4-2 4-3 4-3 4-4 4-5 4-5

.5-1

.5-2

.5-3

.54 -5-5

.5-5

.5-6

.5-7

Platen Hold Down Hydraulic System Pressure Unloading Valve Pressure Pilot Pressure Limit Switches Naten Retract Stop Limit Switch

.3-1

.3-2

.3-2

.3-3

.3-3

.34

LS-2 Platen Forward Stop Limit Switch Pressure Switch Processor Unit— SLC15O

Tern’s You Will Need to Know Expansion Unit — SIC 150

Terms You Will Need To Know Bale Complete lime Delay

Procedure (JEAT) Platen Forward Delay Time

Procedure (TCAT) Platen Forward lime Delay

Procedure (RELAY)

1-9 1-10 1-10 1-12

1-12

2-1 2-1

2-2

2-2 .2-3 2-3 .24 .2-5 .2-5 2-5 2-6 .2-6

2-7

II

TABLE OF CONTENTS CONTINUED

7-

III

DEFINITION OF TERMS

The temis DANGER1 WARNING, CAUTION and NOTE appear throughout this manual and denote the following.

I

ADANGER

The word DANGER precedes information pertaining to specific immediate hazards which, if disregarded, WILL result in SEVERE INJURY or DEATh of the user orothets.

IAWARNING I

The word WARNING precedes information pertaining to hazards or unsafe practices which COULD result in PER SONAL INJURY or DEATH.

IAWARNINGI

Failure to follow prescribed practices and requirements may result in SEVERE INJURY or DEATh

DECALS AND WARNING LABELS

See the accompanying illustrations for the location and label content of all safety decals.

Make certain warnings are obeyed at all times.

Make certain decals are in place and readable at all times.

Report any damaged or missed decals to the proper authority immediately

Replacement decals carl be ordered tree of charge from your local distributor or from:

HARRIS WASTE MANAGEMENT GROUP Inc.

RO. Box 406, Jekyll Road axley,GA 31513

ACAUTION

his word CAUTION precedes information pertaining to potential hazards or unsafe practices which, if disre garded, may result in personal INJURY or DAMAGE to the equipment

NOTE

The word NOTE precedes information which is vital to the proper operation or maintenance of the equipment

Iv

TERMS YOU WILL NEED TO KNOW

SECTION 1 - OPERATION

CYLINDER

FEED HOPPER

BALE EJECT

LIMIT SWITCH

HOPPER DOOR INTERLOCK

DRIVE MOTOR

ELECTROCAL RRNEL

MAIN POWER

SWITCH

BALER SAFETY GUARDS

BALE EXIT

DOOR

COOLER (WHEN APPLICABLE)

COOLER PUMP

(WHEN APPLICABLE)

DOOR CYLINDER

REAR WIPER CLEAN

OUT DOOR

1—1

DECAL APPLICATION CHART

A PELIGRO

Nunca en’rc en ía empaquetadora a menas que Ia tuenle de potencia este apa gada yet area de tra baja este segura

IACUJDADOI

AcAW1ONADANbER ~

Do Not Enter Baler unless main power is off and work area is secured.

~ PELIGRO

ALTO VOLTAJE

Cc, a a cot Dma tic pa! aacguic ci iniciluptor anita dD C cmcfltar cc al quip’ ira t310 Cc man lenin, crib.

FOR SERVICE OR

BALING WIRE U.S. 1400-447-352G

861,110 BALERS

S land crear *~tfl opening dooM and C CC? to be a IC gace a a to a Cunita, data Ia pattia ci atop, ~MERICk

~DANGER

HI CS VOLTAGE

Turn main power oil and tcture,witchtr lore ptrlorrii,ng atiy matntrnancc

ANSI Z245 SCLEAN OUT DAILY

I!]

INSTRUCCIONES SAFETY

DE SEGURIDAD INSTRUCTIONS

INSTRUCCIONES SAFETY

CE SEGURIDAD INSTRUCTIONS

Ii~I

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ACUIDADO

ACALJTION

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AMUCHO

CUIDADO

iai -~

AWARNING(

Do not operair unit with salciy guard ron,oved.

~ao oprro a un dad £ fl a guarda de sogusidad.

ACIJIDADO

Cat iiiat it or lao ‘Sri

P pa trla’u on MI! “tibia dub pain isisa ~a If Pit p • pea a T It t Ca Mi uTh,,bo 0;’ taut, p t.npuaIttt

Liii rianaca tie I 3- ~ II, 3 Id Ii ii 4ar,pdId roan a

IIU tub

~PELIGRO I~~DANGER

Operate switch Sc debe Sc opaqar to OFF position Ia palanca y and remove key remover Ia a Have Before antes de nacer pertormlng any cualquier tipo de maintenance mantenimiento en a maqulna

ACAUTION

Cc o y airgu c a p rn, anira Cr opcrar ‘a cmpaqurlaoala

1-2

DECAL APPUCAUON CHART

I..

‘S

AMIJCHO

CUIDADO

MANTENSASE

AP~.9T4DO

LaM

&t~tE •a

CCLCli

BALERS

NAJ~ B4XLEY GEORGIA

El m

AWARNINGI IACUIDADOIIACAUTION_I

Esta maquina arranca This machIne is auto auto mat’ c amen te. maticatly controlled. IT

FUNCIONARENCUAL ~1AY START AT ANY

OUtER MOMENTO

Ill

1-3

HYDRAULICS

Hydraulic fluid operates under high temperatures. Avoid contact with piping, hoses or cylinders to prevent the pos sibility of bums.

I AWARNINãJ Never use hands to check hydraulic fluid leaks. Fluid escaping under pressure may cause severe injuiy. In the event of injursc seek medical treatment immedlatel~

ELECTRICAL SYSTEM

EAtERS require a high voltage external power supply.

Each unit has two electrical circuits: main power and control powen The high voltage circuit lumish es power to operate the drive motors; a transformer converts the high voltage to 120 volts to operate the control circuit.

For the main power circuit the high voltage enters the Main Electrical Control Panel and goes directly to a disconnect, which is connected to the motor cir cuit. For the control circuit, high voltage coming into the main electrical control panel is converted to 120 volts by means of a transformer.

For the electrical system to function correctly, elec trical components must be kept clean and free from moisture.

In order for the unit to operate property, all limit switches must be property adjusted and free from foreign material to prevent the switches from giving false signals to the control circuit a DANGER

HIGH VOLTAGE

High voltage, any service to the electrical system should be performed only by trained, authorized personnel.

Co a S

1-4

SAFETY PRECAUTIONS

NOTE

only trained authonzed personnel familiar with the safe operating and maintenance procedures should be allowed to inspect operate, or service the baler.

ADANGER

Never place any portion of the body, head or limbs into a potential pinch point unless the machine is locked out in accordance with OSHA regulations before any service or inaintainence is attempted.

Obey all warning decals and labels.

Never allow anyone to enter or nde on a feed conveyor.

Always wear hand and proper eye protection when work-wig with lie wire, Be certain all safety guards and access doors are main-tamed and secured in place while the machine is in oper ation.

Make certain all warning signals and interlock devices we working before operating the machine.

Be alert and aware of those persons who may be working in the vicinity of the baler.

Know emergency shutdown procedures and where to gel help in the event of an emergency.

Never attempt to operate any equipment, perform service or maintenance without the proper training.

Never operate the baler while under the influence of intoxicants or narcotics. Working under the influence of intoxicants or narcotics presents a m~or hazard to one self and others in the work area.

Never operate the baler while weanng jewelry or loose clothing which may catch on moving parts or controls.

Always wear proper safety equipment as specified by the employer. Hams strongly recommends head, eye, loot protection and in noisy installations, heanng protection.

I AWARNINÔ1

Failure to follow prescilbed practices and requirements may result in SEVERE INJURY or DEATh.

Do not start or operate equipment which has a malfunction.

Do not attempt to remove or dislodge inatenal above waist level unless proper eye protection is worn.

Never remove covers on any electncal component unless the main electncal power supply is OFF and secured with a padlock. Make sure the machine is locked out in accordance with OSHA regu lation before any service or maintenance is attempted.

Know the location and function of all emergency stop buttons, control switches, instru ments, guages and protection devices.

NOTE

Publication of these safety precautions does not imply or in any way represent an all inclusive list It is the opera tor’s responsibility to be familiar with the unit to ensure that the unit operation is in accordance with safety requirements and codes, including all applicable Occupational Safety & Health Act (OSHA) and Amencan National Standards Institute (ANSI) regulations, These regulations change and therefore, it is impossible to give a reference which will remain current It is strong ly recommended that current applicable OSHA and ANSI standards to be available to operators at all times.

IAWARNING (

The machine cycles automatically.

1-5

BALER FUNCTIONS

There are four basic functions in the operation of the Horizontal Closed Door Baler - loading, compaction, tieing, and qection.

LOADING

Material is loaded into the baler chanter by a feed conveyor.

A feed hopper is used to assist in the loading process. The electric eye measures the material and determines when the baler is cycled in the automatic mode.

COMPACTION

The platen compresses material in the hal ing chamber, excess matenai is cut by the shear blade as the material is compressed.

Material type and density will determine the number of cycles necessazy to form a bale.

BALE TIEING

EJECTING THE BALE

When lb bale is complete and lied, the bale door is opened and the platen is used to push the bale out of the chamber, as the next bale is formecL

Alter a bale is completed, wire ties are applied to the bale manually by the operator. E

1-6

DESCRIPTION OF OPERATING CONTROLS

The follOWing information is for descriptive purposes only to aid the operator in locating the control and understanding what they do. It is not to be misconslnied as operating instructions. For operating instn,ctions~ refer to OPER~11NG PROCEDURES later in this section.

NOTE:

This section contains a descnption of the BALER con trols covenng the control buttons for most SELCO EAtERS.

MAIN POWER SWITCH [1]

Controls the electrical supply to the baler control panel. The baler will not operatewhile the switch isin the off postion. For safety purposes, this control can be padlocked in the off posi tion.

EMERGENCY STOP BUTrON [2] This button, when depressed, slops all operating functions and shuts the machine down in the event of an emergency.

The unit will not operate with this button depressed.

Emergency stop button locations for closed door models:

A. Operators control panel B. Hopper C. Feed conveyor

POWER ON LIGHT [3]

(Located on man electrical panel) A Red tight, when illuminated indicates there is electrical power to the control panel and the baler is functional.

BALER MODE SELECTOR

SWITCH [4]

A. 3-position selector switch controls the mode at operation [or the baler~ When set in the tIf’ position, the baler will not func tion. When set in the “manual” position, the platen must be cycled manually by the operator: When set in the “auto” posi tion, the baler will cycle automatically, controlled by the elec tnc eye on the feed hopper.

NOTE:

This switch controls the baler cycle system only and has no control over the baler motor. The baler motor is con trolled by the baler motor selector switch.

SECTION 1 - OPERATION

0Q 0 a.

1-7

BALER MOTOR

SELECTOR SWITCH

[5] (located on operator’s control console) A 3-position selector switch that controls the electrical power supply to the main pump motor. When turned to the “OFP position, power to the main pump motor is turned off. When set on “MANUAL” the main pump motor will run continuously.

When set on “AUTO” the main pump motor will start and stop automatically, allowing the baler to cycle as required to bale material.

CONTROL RESET BUTION

[6] (located on operator’s control console) When depressed this button activates the power to aD baler controls.

PLATEN FORWARD BUTFON

[7] (located on the operator’s control console) In the ‘MANUAL” mode, the button must be depressed and held to move the platen forward. When released, the platen movement will stop.

PLATEN REVERSE BUIrON [8] (located on operator’s control console) In the ‘MANUAL” mode, the button must be depressed and held to retract the platen. When released, the platen move ment will stop.

DOOR OPERATION

SELECTOR SWITCH

[9] (located on operator’s control console) This switch operates the ‘Bale Door The unit must be set on manual and the platen reverse button must be depressed and held. A three position switch opens the bale door when rotat ed counter clockwise, doses the bale door when rotated clockwise and automatically returns to neutral or lock when released.

BALE DENSITY

SELECTOR SWITCH

[Optional] A 2 position selector switch operating only in the automatic baling mode. Regutated by a pressure switch, this switch acgusts low and high bale density at predetermined pressure setting.

CONVEYORS

SELECTOR SWITCH

[Optional] A 3 position selector switch controls the teed conveyors.

When set on “manual” the conveyors will run continuously.

When set on “auto” the conveyor will stop automatically when matenal in the hopper breaks the beam of the electnc eye.

When turned “ofr’ the conveyors will not operate.

COUNTER RESET

[Optional] ‘This push button is depressed to reset the bale length counter to its predetermined setting.

LOW OIL

WARNING LIGHT

[Optional] A red indicator light which will illuminate to show the oil in the hydrauho reservoir has dropped below the acceptable operat nig level.

COOLING SYSTEM

SELECTOR SWITCH

[Optional] A 2 position selector switch, when turned to the “on” position, activates the cooling pump to pump the hydraulic fluid through the cooler unit.

1-8

This inspection is essential for the safe and efficient operation of your HARRIS Horizontal baler. It should only be made by trained personnel who are familiar with safe operating proce dures. While items listed are standard, there may be other checks required for some baler installations.

IAWARMNG I

Before perfonnmg pre-operation inspection, make sure cartain the baler has been shut down end locked out in accordance with OSHA standards.

ITEMS TO INSPECT AND CHECK

1. Working area around baler~ A. Keep walk area clean.

B. Remove flammable materials.

C. Remove any oil or fluid spills.

2. Check behind platen for rnatenal build-up; clean out If necessajy. before operating.

3. Check hydraulic lines, hoses and fittings for fluid leaks.

4. Look for worn, broken and damaged parts such as:

A. Hydraulic hoses.

B. Broken cc missing cap screws, pins and keepers.

C. Wear Strips.

0. Welds broken or cracked.

E. Structural damage.

6. All warning signs, safety guards and interlock switches must be in place and functional.

WARNING: Never override a safety interlock switch.

6. Check wlpei dean out door for material build-up.

7 Make sure all electrical panels are closed and secure.

8. Check hydraulic reservoir oil level, add the coned fluid, if nece$saiy.

9. See that the main power supply is on.

10. Bale di~harge area is not obstructed.

11. Make sure feed hopper access door is closed.

12. On auto-He models, make sure the tie wires and spools are not damaged or obstructed.

13. Lighting is adequate for safe operation. All pails of the machine should be visible dunng pre-operation inspection.

14. Note the position of tire extinguisher and make sure it is fully charged.

15. Have emergency telephone numbers available.

SECTION 1 - OPERATION

PRE-OPERATION INSPECTION

c

II

C C

C 1-9

BALER START UP PROCEDURE

AWARNING1

Make certain all persons are clear of the charging hopper, bale chamber, ejection area, and conveyor before starting the machine

1. Set the baler on manual mode by moving the selec tor switch to “MANUAL”

2. Unlock the %iAIN POWER” switch and rotate the lever to the “ON” position.

3. Turn the “DRIVE MOTOR” selector switch to “MAN UAL” arid depress the push to start button to start the dnve motoit

4. Manually cycle the platen and retract It lo the home position.

5. Set the baler and drive motor selector switch to “AUTOMATIC” or “MANUAL”

6. Start feed conveyors (if applicable.).

GENERAL

The Closed Door Baler bale matenal against the door, when the baler is empty, in a continuous baring process. Wire is inserted through the platen face slots at the start of a new bale.

ACAUTION I

Hand and eye pmtectlon should be used when handling tie wires L

-. 12 —‘

IAWARNING I

The machine cycles automatically. Never attempt to load or handle wire unless the machine is shut down and locked out in accor dance with OSHA standards.

BALER OPERATION

1. When the baler isenlpbc insertthe tie wues in the bale chamber slots just back of the bale door. Leave approximately IT extending out to the end loop.

BALE CHAMBER

SLOTS

1-10

2. Set the baler on “AUOTMATIC’ and start feed conveyor and allow rnatenal to feed and baler to cycle until the bale is complete.

3. The bale complete alarm will sound and the baler will shut down when the bale is complete, to inform the operator bale ties are needed.

4. Set the baler control on “MANUAL” turn the feed convey ors”OFP Shut the baler down.

6. Pull the wire down the side of the baler, run it through the end loop on the tie wire.

7 Pull the wire back and wrap it around itself.

a. Insert new tie wires in the slots on the platen face, leaving approximately 12” extending out to the end loop.

9. Start the baler, fully retract the platen.

10. Release the door latch hydrauliclmechanical and open the bale door.

12. Set the baler to “AUTOMATIC” start the feed conveyors and continue the baling process.

13. The alarm will sound, the baler will shut down, informing the operator the bale needs to be removed.

14. Shut the baler down, turn off teed conveyors.

15. Remove the bale length rod and return it to the stor age position.

Remove the bale, close and latch the door.

17 Start the baler and the feed conveyors and allow the baler to continue bating in the automatic mode.

NOTE:

THIS COMPLETES ONE FULL BAUNG CYCLE.

NOTE:

When baling in the “MANUAL” modç, the operator will operate the “PLAThN FORWARD” and “REVERSE” to make the bala All shut downs and horn do not function as in the “AUTOMATiC” mode.

SECTION 1 - OPERATION

11. Rotatethebalelength rod down in front of the bale.

5. Run the wire ties down the side of the baler, insert each tie wire in the coned slot on the face of the platen and pull them through.

SLOTS ON ThE FACE

OF THE PLATEN

1—11

SHUTDOWN

1. Turn off matenal feed system.

2. Turn baler selector switch to off position.

3. Turn baler motorselector switch to “OFF position.

4. Turn man power supply off and ladc out bale~

5. Perform any house cleaning. If necessa~

JAM AT THE SHEAR KNIFE AND

CORRECTIVE MEASURES

The high pressure alarm will notify the operator when an unusually large amount of malenal, foreign o1~ect or comb-nation of both may prevent the shear knife from cuffing the matenal allowing the platen to enter the bale chamber.

1. Stop the feed conveyor or material lead process.

2. Turn the baler to the manual mode.

3. Retract the platen halfway, observe the material in the hopper to see If it falls away from the shear knife.

4. Cycle the platen forward to see it the ~am clears and the platen enters the bale chamber.

5. If the jam falls to clear:

A. Retract the platen approximately halfway.

8. Shut the mahcine down and lock out in accordance with the recommended SELCO shutdown procedure and OSHA ANSI requirements.

C. Remove obstruction.

4DANGER

SERIOUS INJURY or DEATh will occur If the baler is start ed and operated with someone is inside the machine. To prevent senous injuty or death, you must follow HARRIS recommendations and 05114 requirements on lockout procedures. Neverallow anyone to place any part of their body in the machine unless all shutdown and lockout procedures have been followed. If you have any ques tions about the procedure for machine lockout, check with your supervisor before you or anyone else enters the machine.

1-12

PREVENTIVE MAINTENANCE

GENERAL

SECTION 2- PREVENTIVE MAINTENANCE

The main objective of preventive maintenance program is to anticipate and prevent operational malfunctions before they require extended shutdown for malor repairs.

Careful attention to proper preventive maintenance Will insure and extend trouble-free operation of the uWit. Particular atten tion and care given to the hydraulic system will extend the ser vice life of the inathine.

MAINTENANCE RECORDS

Prepare and adhere to a regular maintenance schedule.

Keep accurate records of all maintenance pedormed. A reg ular review of all maintenance records may provide an Lndloa Von of potential problems.

I AWARNING]

Do not get into the baler ci put any part at your body into the baler at any point unless the baler Is shut down and locked out in accordance with OSHA standards. This pre caution must be laken before any service or maintenance Is attempted, including cleanng a Jam or oversize bale.

2-1

SECTION 2- PREVENTIVE MAINTENANCE

HYDRAULIC FLUID RECOMMENDATION FOR HYDRAULIC SYSTEMS

HYDRAULIC OIL

To serve its purpose and give long and satisfactory service, the hydraulic oil must possess desirable physical and chenu cat characteristics. Since stability under agitation and wide ranges of temperatures are very important, the crude from which the finished product has been processed should be of such a nature as to inherently posses these desirable charac tent

VISCOSITY INDEX

Premium hydraulic oil should be used in these hydraulic sys tems, and in addition to the above characteristics, be further fortified by application of selected additives to provide addi tional resistance to wear~ corrosion, oxidation, decomposition, and foaming. All additive treatment should be done by the lubricant supplier with additives that are compatible with each other as well as the base oil into which they are blended.

This factor is very important Oils having low Viscosity Index values tend to be sluggish at lower temperatures and thin out rapidly as operating temperatures increase. This change in viscosity, to a degree, results from the use of oils having Viscosity Indexes below that recommended. The result of using low Viscosity Index oils is unsatisfactory lubrication at

LOW TEMPERATURE

It is recommended that oils to be used in these hydraulic sys teins have a maximum wecosity of 4000 31.15 at 15 Deg F Also, the ambient temperature of the hydraulic oil should be main-tamed at about 90 Deg.F when the system is to be operated.

NEUTRALIZATION NUMBER

operating temperature. When the air temperature around the power unit vanes from 32 to 100 Deg. F a minimum viscosity index of 95 is required.

When the air temperature around the power unit vanes from 10 to 110 Deg. F a minimum viscosity index of 135 is required

This characteristic is used in conjunction with other factors to determine the chemical and physical changes occumng with in the oil as a result of extended use and service. The nets tralizalion number of the oil should be given by the supplier and thss information put on record by the opemtoi~ The change and rate of change occumng in the neutralization value is of utmost importance. It is this rate of change which is most important ratherthan the actual neutralization number on the oil.

Some additives are given a higher neutralization number than others. It is therefore recommended that your compactor ser vice supervisor assume responsibility for periodic sampling of

4 the oil in the system. Then laboratory analysis should be made by the supplier and the results interpreted to the opera-tor, advising as to whether or not the oil in use is safe and sat isfactory for continued service. Most reputable oil companies maintain laboratories and technical staffs which are capable of analyzing hydraulic oil samples and advising the user asto the condition of the oil. Most such oil suppliers render the service on a no-charge basis to the customer.

We recommend the use of a commercial laboratory service for analysis of routine oil samples taken on a regularly scheduled basis. The cost per sample may vary depending on the labo ratory service. The most important analysis are particle count, spectrochemical analysis, water content, and viscosity, HARRIS will provide this service upon request

2-2

CONTAMINATION

It is estimated that as much as 70% of all hydraulic problems may be traced directly to the fluid. It is of utmost importance that all foreign mailer be kept from the hydraulic oil. Invisible quantities of abrasive type contamination may cause serious pump weai~, rnalfunctioning of pumps and valves, and sludge acwmulations within the system in relatively short periods of time. Since the recommended hydraulic oils for these machines are fortified with vanous additives, it is essential that moisture and water be kept from the hydraulic oils and sys tem. Additive treated oils have a definite affinity far more cdt ical than was true in year past when only straight mineral oils were available.

Adequate evidence of the ability of the oil to prevent undue pump wear may be shown by tests conducted as per ASTM 02882 with a total weight loss of 50 mg. maxirnun Other vane pump tests with varying size of pump an&or length of time will be considered on the basis of the evidence subnUtted.

The base oil and its compounding should provide a finish oil that will not shrink or abnormally swell hydraulic sealing eletnenta

A reputable lubricant supplier backed up by a reputable oil com pany is an assurance of obtaining high quality products, and generally speaking, higher quality is worth the higher initial cost

RECOMMENDED HYDRAULIC FLUID

Hydraulic Oil Amoco Arco Chevron Citgo Exxon Gulf Mobil

Phillips Shell Sun Texaco

Companies With Brand Name Rykon 01121 orAW 01121

AWS-215

EP Hydraulic 46 Pacemaker X0-46 or NW Hydraulic 46 Nub H-46 Harmony 46 AW

DTE25

Magnus A” 46 Telhis 46 Sunvis 821 WR or Sunvis 747 RandoHD4G

Hydraulic fluid samples should be taken periodically for labo ratory analysia The actual sampling method is critical It should be done based on ANSI Standard 893.1OM(R1980).

This standard is available From the National Fluid Power Association. 3333 N. Mayfair Road MiLwaukee, WI 53222.

HARRIS will supply you the SAMPLE KITS, or you may obtain your own.

Samples should be placed in a clean, dry, glass bottle with a non-shedding, screw-on cap, and labeled with the date, type of fluid, model arid serial number of the machine.

Two identical samples should be taken, One for laboratory analysis and one for your own preliminary analysis while you are waiting for the lab report.

After your sample has been allowed to stand for 20 toaD min utes to allow all air bubbles to dissipate, visually inspect by holding the bottle up to the light to check for debns in the oil and whether the oil is dear or cloudy.

Any debns is an indication of a severe solid contamination problem, the source of which must be located and corrected immediately. Common sources of this kind of contamination may be component wear, unsealed reservoir covers, or dirty breather filters.

General Specifications For Hydraulic Oil 10 Weight Premium Grade Oil (45) Non-Foaming MU-Wear Additives Viscosity Index, 150 Pour Point 30°F Flash Point 430°F

HYDRAULIC FLUID TESTING

2-3

SECTION 2 - PREVENTIVE MAINTENANCE

OIL SAMPLE COLLECTION PROCEDURE

The oil sample should be collected from the inside of the tank, when the inspection covers are removed to replace the oil strainers located on the intake or suction tube of the hydraulic pum~

Dip the sample bottle into the oil, make sure not to allow con tamination matenal to enter the tank during the process.

The results of the analysis will determine any necessary action, which may need to be taken.

lithe sample is the least bit “CLOUDY” it i~ an indication or water contamination, the source of which must be found and eliminated immediately. Common sources are inadequate outdoor storage, unsealed reservoir covers, or condensntion.

A TMSLOTrER SPOT TEST” may also be performed to test for OXIDATiON. Place a DROP of oil on a piece of white blotter papes Wait 20 to 30 minutes for oil to disperse on paper.

¶Several sheets of blotter paper are in the back of this manu aL)

NOTE:

The blotter test will provide an indication that a more complete test may be necessary.

A. lithe blotter remains colorless or develops only a light yellow nng, oxidation is under control.

8. 11 color develops but is uniform throughout, the oil is stilt serviceable but should be checked for correct additive content.

C. If the sample shows distinct nngs, the fluid should be

0. If a distinct dark spot remains in the middle, but a lighter colored oil migrates outward in the blotter paper, the oil is about to dump (or already has) sludge or other by products into the system. The time for replacement of the fluid has already passed.

Kits are available from your supplier to test for acid content in much the same way you would test the condition of swimming pool watei~ A shift in acid content may indicate a breakdown in the fluid.

NOTE:

Keep accurate, dated records of all pertinent information gained train these tests.

A

,,C~Th..%

B ±~-

‘L~

‘c~:i c/fl

‘~j e~

-~r -~ Jr t~Ae~ — -..-~ •

D

~za~• ~t~z~r

2-4

SECTION 2 - PREVENTIVE MAINTENANCE

LUBRICATION

Scheduled lubrication is essential to keep the baler operating correctly. Insufficient Iubncation will result in rapid wear and shortened service life of baler components.

When lubricating, make sure enough grease is pumped into the bearing to force out any moflae, cfirt, or other abrasive material so the shaft can move freely during operation.

Remove any grease build up to keep the area dean.

When applying oil, be certain tie oil fully lubricates the area, wipe any excess oil from the surfaces of non-moving compo nents so it does not collect dirt or foreign rnatenal.

ELECTRIC MOTOR BEARING

LUBRICATION

The bearings are packed with grease by the motor manufac hirer during assembly of the electric motor. Normally the grease supply is sufficient to last the raeume of the motor.

Where severe operating conditions e~ast additional hibrication may be required. Consult the motor manufact.ureres manual for lubrication requirements.

LIFTING INSTRUCTIONS

Because the s~e arid weight of many HARRIS Horizontal baler components, it is necessary to use a suitable lilting device for removal. Make sure that the lIftIng device, sllngs, chains and related hardware have the rated capacity to safe ly make the required lift.

IACAU11ON I

Stand clear of any component being lifted, use a guide line if necessary for control dunng the lifting.

IACIkU110N I Due to the variations In the size of Horlzntal balers man ufactured, the weight ranges listed are intended to serve ONLY AS A GUIDELINE. If them Is a question of lifting device capacity and exact weights are required contact the service dept at HARRIS.

HARRIS Products Box 406, Jekyll Road Baxley,GA 31513 600~447-3526

WEIGHT (LBS)

MIN MAX

Platen Cylinder 1,000 15,000 Directional Valve 25 500 Electncal Molorsw4,urnps. 200 1,600

Main 50 250 Pilot 11 200

Hydraulic Pumps. 100 300 Complete Power Unit 1,500 1,500 Platen — —

Shear KnIfe. 40 400

2-5

FILTER REPLACEMENT

JAWARNING I

Never attempt to perform maintenance or service unless the baler is shut down and locked out in accordant with OSHA standards.

Make sure the oil is cool before rcplactng element

1. Remove the four bolts and filter covet

2. Remove the two filter elements and connector.

3. Clean the inside of the fitter canister thoroughly with a non flammable cleaning solvent and wipe dry. Make sure there is no contamination inside the canister.

4. Place the connector on the bottom filter element and place in the canister.

5. Slide the top filter element into position and push it down on the connector.

6. Bolt the filter cover in place.

7 Check for leaks.

SUCTION STRAINER

REPLACEMENT

IAWARNING I

Never attempt to perform maintenance or service unless the baler is shut down and locked out in accordance wIthOSHA standards.

Make sure oil is cool.

I. Remove the access cover.

2. Reach down in the tank and use a pipe wrench to rotate the suction strainer counter clockwise.

3. Remove the strainer and replace with a new one.

4. Bolt the access covers in place and reseal with silicone sealant.

BOLT

COVER

TOP ELEMENT

CONNECTOR

BOTTOM ELEMENT

CANISTER BOLTED INSIDE

ThE OIL RESERVOIR

2-6

SERVICE INSPECTION AND CLEANING REQUIREMENTS

DAILY PLATEN

A. Check behind the piatea

Baler floor dean If necessary.

Limit switches. cam bait, remove any foreign matenat Check cylinder and Irtlings for fluid leaks.

B. Inserter check inserter bars for damage.

Check inserter needles and rollers, make sure rollers move freely.

Check inside inserter frame, clean out if necessary.

Check inserter dnve assembly, clean out it necesssary.

C. Baler WorkArea Sweep floor end dean area around baler.

Make sure the bale qect area is clean.

D. Power Unit Check pumps, valves, ritlings, and hoses for fluid leaks.

E. Twister Swing twister out inspect twister hooks for damage.

Check for material buildup.

Make sure wire guide rollers are moving freely~

F Bale Counter Make sure4 counter wheel and switch are free to opec SEMI-ANNUAL ate corTectly. A. Replace oil lifter.

B. Replace oil strainer.

WEEKLY

A. Clean off pwer unit using broom and forced air.

B. Clean out fins on oil cooler using forced air.

C. Check cylinder pins & boils.

I). Check platen cylinder rod for damage nicks and abra sions.

E. Check platen hold down Øustment.

F Inspect baler floor for gouging or heavy abrasion.

S. Inserter gear box fluid level.

H. Twister gear box fluid leveL

POWER UNIT

MONTHLY

A. Clean off pwer unit using broom and forced air.

B. Check platen guide bar clearance.

C. Check platen wear stnps by ineasunng.

Knife clearance 1164” to 3/16” Replace wear strips if knife clearance exceeds 3/16”

C

PLATEN OPERATED

CHECK VALVE

C. Replace breather cap.

P. Take oil sample.

PLATEN HOW DOWN

HOLD DOWN PLATEN

2-7

SECTION 2- PREVENTIVE MAINTENACE

2-8

PLATEN HOLD DOWN ADJUSTMENT

SECTION 3 - ADJUSTMENTS C

The platen hold-down is located on the back side of the feed hoppet The hold down keeps the rear of the platen from rais ing up chinng compaction, preventing the front of the platen from pushingdown. damaging the baler floor.

Maintainmg correct adjustment of the hold-down is necessary for proper baler operation.

PLAtEN HOLD DOWN

As normal wear occurs during operation, wear strips on the platen and platen hold-down gradually wear away, when this happens adjustment of the hold down is required.

To Make the adjustment extend the platen to the full forward position and shut the baler down.

ACAUTION I

2. Turn the adjustment bolts clockwise to tighten the hold down.

IAWARNING I

Never attempt to make an adjustment unless the baler Is shut down and locked out In accordance with OSHA standars.

NOTE:

Make sure bothe bolts are adjusted equally.

3. Adjust the hold-down so It makes contact with the top of the platen, rotate the bolt an additional one halt turn.

4. Tighten lock nuts.

5. Start up the baler using the proper procedure and observe the platen as It moves forward compacting matenal.

NOTE:

If the rear cite platen raises up the hold-down needs to be tightened morn.

6. II the bolts are fully lightened down and the platen continues to push up it will be neces nary to replace the platen hold-down wear strip and possibly the platen wear ships to pre vent machine damage.

Over tightening the hold down will cause excessive wear to the wearstrlp and shorten Its service life.

FEED HOPPER

1. Loosen lock nuts on the platen hold-down adjustment boils.

PLATEN HOLD DOWN

ADJUSTMENT DOLT

WY

C 3-1

SECTION 3- ADJUSTMENTS

HYDRAULIC SYSTEM PRESSURE PRESSURE GAGE

ADJUSTMENT

1. Loosen the lock nut under the adjustment knob.

2. Rotate the adjustment knob counter clockwise, reducing the pressure.

NOTE:

Any pressure adjustment must be made by ‘RAISING” the pressure.

3. Set the baler in the manual mode arid move the platen to the full forward position.

NOTE:

It will take two people to make the adjustment One to operate the controls and one to set the pressure.

4. Depress and hold the PLATEN FORWARD” button.

5. Observe relief valve pressure gage.

6. Rotate the adjustment knob clockwise Increasing the pressure to the correct PSI setting as called for on the hydraulic schematlc~

7 Secure the adjustment knob by tightening the locking nut.

UNLOADING VALVE PRESSURE NOTE:

ADJUSTMENT Any pressure adjustment must be made by ‘RAISING” (For Machines without poppet block) the pressure.

1. Set the hydraulic system pressure relief valve atthe cor red PSI setting as called for on the hydraulic schematic, as described in the HYDRAULIC SYSTEM PRESSURE ADJUSTMENT Procedure.

2. Loosen the lock nut under the adjustment knob on the unloading valve.

3. Rotate the adjustment knob counter clockwise reducing the unloading pressure.

4. Set the baler in the manual mode and move the platen to the full forward position.

NOTE:

It will take two people to make the adjustment One to operate the controls and one to set the pressure.

5. Install a pressure gage in the test port as shown.

6. Depress and hold the PLATEN FORWARD” button.

7 Observe the pressure gage on the relief valve.

S. Rotate the adjustment knob on the unloading valve clock wise increasing the pressure to the correct PSI setting as called for on the hydraulic schematic.

REUEF VALVE

PUMP

LOCK NUT

ADJUSTMENT KNOB

9. Secure the adjustment knob by tightening the locking nut.

10. Return the hydraulic system pressure to the correct PSI setting as called for on the hydraulic schematic as described in the HYDRAULIC SYSTEM PRESSURE ADJUSTMENT procedure.

REUEF VALVE PUMP

PRESSURE

GAGE

3-2

PILOT PRESSURE ADJUSTMENT GAGE

1. Loosen the lock nut under the a4ustment screw.

2. Rotate the adjustment screw counter clockwise to reduce the pressure.

NOTE:)

Any pressure adjustment must be made by RAIS1NG” the pressure.

3. Obseive the pilot pressure gage.

4. Rotate the adjustment screw clockwise mcreaing the pressure to the coned PSI setting as called for on the hydraulic schematic.

5. Secure the adjustment screw by tightening the lock nut.

(C

LIMIT SWITCHES

TIMING ADJUSTMENT

LOOSEN TO ROTATE

NOTE: ACTUATOR ARM

There are 2 adjustments to be made on a Umit Switch after Instaflation Is complete.

A. Length of the actuator ann.

1. Loosen the socket head capserew that holds the ann shaft clamp, lengthen or shorten as necessary~ so that only the wheel at the end of the aim comes in contact with the Up mechanism. That minimizes any unneces saw wear to actuator arm. Retighten setscrews.

B. Adjusting timing.

1. Determine which direction the switch should be adjusted, then loosen the shaft clamp screw, (SEE ILLUSTF1A11ON) rotate the shaft and retigliten screw.

LOCK NUT

ACTUAtOR ARM LENGTh ADJUSTMENT

3-3

SECTION 3 - ADJUSTMENTS

PLATEN RETRACT STOP LIMIT

SWITCH ADJUSTMENT

1. Set the baler rn the manual mode. Retract the platen so the front of the platen is flush with the rear ec~e of the feed hopper. Shut the baler down.

2. Loosen the setscrew on the actuator am) and position the actuator on the cam as shown.

3. Insert a screwdriver in the slot on the arm shaft. Rotate the shaft until you hear the switch clidc. this indicatoc the switch is activated.

4. Hold the aim shaft in the activated po~fion

5. Cycle the baler an the automatic mode making certain the limit switch stops the platen at the cor rect position.

I AWAANING1

Never attempt to make an adjustment unless the baler is shut down locked out in accordance with OSHA standards.

S

3-4

LS-2 PLATEN FORWARD STOP

LIMIT SWITCH ADJUSTMENT

5. Insextascrewdnverintheslotonthearmshaft. Rotate the shaft until you hear the switch dick. This indicates the switch is activated.

NOTE:

LS-2 is used to stop the Platen Forward and Reverse Its direction m the automatic baling mode.

I Set the baler in the MMANUAL~ mode. Slowly extend the main ram to the full forward position with the cylinder fully extended.

2. Shut the baler down. Remove the top osver exposing the limit swftches. Make a mark an the main ram and guide bar.

3. Start the baler and refract the platen 3W Shut the baler down.

4. Loosen the set screws on the actuator arm and position the actuator on the cam, as shown.

IAWARNING I

Never attempt to make an adjustment unless the baler is shut down and locked out in accordance with OHSA stan dart.

6. Hold the arm shaft in the activated position and lighten th earni shaft set screw. Tighten the arm length sat screw.

7 Cycle the baler in the automatic mode, making certain the limit switch stops the ram at the correct position. Make sure the cyhnder does not bottom out.

1$ 2

3-5

SECTION 3 - ADJUSTMENTS

PRESSURE SWITCH ADJUSTMENT

1. Remove the cover plate, loosen the lack screw and rotate the adjustment nut clockwise to the full down or above PRESSURE SWITCH the desired pressure setting.

NOTE:

The further down the adjustment nut is turned, the higher the pressure required to activate the switch.

2. Set the pump relief *Iydraulic System Pressure at the desired pressure for the pressure switch to be activated.

The hydraulic system pressure should be set between 1800 and 2000 PSI (or the piessure switch adjustment

NOTE:

Refer to the “Hydraulic System Pressure Adjustmenr section in tins manual for the cowed procedure.

3. Depress and hold the ‘Platen Forward’ pushbutton.

NOTE:

There are two types of control systems. If the baler is equipped with a SLC-150 control system, the procedure is different than machines with a relay system.

4. Relay system Rotate the pressure switch counter clockwise until the TR-2 timer is activated. The solenoid anti timer are locaL ed inside the main electncai panel. The solenoid will make a distinct click sound when it activates. Stop rotat ing the pressure switch adjustment nut when the click is heard

SLC-150 System Rotate the pressure switch adjustment nut counter clockwise until the Input Ught Number 103 comes on. The light will come on when the pressure switch is at the desired pressure.

NOTE:

The light is on the 51.0-150 module inside the main elec tncal panel and can be seen by baking through the win dow. It is not necessary to open the panel

5. Re-adjust the hydraulic system pressure to the correct pressure setting as described in the 1-lydrauric System Pressure Adjustment section.

6. lighten the lock screw and replace the cover on the pres sure switch.

ADJUSTMENT NUT

COVER PLATE

STATUS INDICATOR LIGHT

3-6

PROCESSOR UNIT - SLC 150

TERMS YOU NEED TO KNOW

1. a) Incoming line winng tenmnais. b) Wiring terminals for 20 inputs. Self-lifting pressure plates allow for easy wire insertion and secure connections. Terminals accept two #14 AWS wirea The lunged cover (shown in the open position) has write- on areas for identification of external circuits. The tenninal block is removable for easy processor unit replacement Terminal block removal:

2. Winng termials for 12 outputs. The removable terminal block has the same construction as the lIne-input termi nal block. Ilirigled cover (shown in the open posticm) has write-on areas.

3. Color patch. Red. black, blue, green, purple or yellow.

identifies the 6 processor unit versions.

4. Five red LED diagnostic indicatois:

SECTION 3- ADJUSTMENTS

DC POWER - Indicates that the processor unit is ener gized and DC power is being supplied.

PC RUN - Indicates that the processor unit is in the Run mode.

CPU FAULT - Indicates the processor has detect ed an error in either the CPU or memory.

Operation is automatically stopped.

BAmRY LOW - an optional battery provides back-up power for the CMOS RAM memory. This LED alert you when the battery voltage level has falFen below a threshold level.

FORCED l!O - Indicates that one or more input or output addresses have been forced to an ON or OFF state.

5. Input power fuse compartment if the terminal volt age is present but the DC POWER LED is not lit, the fuse may be blown. Refer to Page 17 for fuse replace ruent procedure.

6. Input status indicators. Twenty red tEDs, indentified with address numbers 1 thru 10 and 101 thru 110, cor responding to numbers below the input winng terminals.

When an input circuit is energized, the corresponding status indicator will be lit.

7 Output status indicators. Twelve red tEDs, identified with address numbers 11 thru 16 and 111 thru 116, cor responding to numbers above the output winng termi nals. When a programmed output instruction is TRUE, the corresponding output circuit will be energized.

Auto-on power-up, the processor runs thru Its normal diag nostic tesis and then automatically enters the Run mode (If it was in the Run mode at the last power-down).

Manual-On power-up, the processor runs thru its diagnostic tests but witinot enter the Run mode. To enter the Run mode, you must move the switch to the auto position or use The pocket programmer (or personal computer).

T T.

H

HU(~1~

S. AutolManual switch. This switch controls restarting of the processor unit after a power loss or brown-out

3-7

9. EEPROM memory module compartment The optional memory module can be plugged into the processor. (Cat.

No. is 1745-M1.SLC 150 processot requires a Senes B module or a Senes A module having a 28-pm chip4 The pocket programmer or personal computer software allows you to store your processor RAM programm the EEPROM. You can also load a program from the EEP ROM into the processor RAM. In addition, the processor unit has an Auto-Load feature.

Further details on using the EEPROM module are found in the

51.0 programmable Controller User’s Manual and in Pubricatlon 1745-a4.

10. Communication port The pocket programmes interface converter, or TCAT cable is plugged into this socket

11. Socket for connecting an expansion unit or high speed input module. We’ve included a 20-pm to 10-pm ribbon cable with the processor unit. Save this cable. You will need it if you want to connet an 110 expansion unit to the processor unIt or if you want to connect both a high speed input module and an expansion unit.

12. Battery compartment An optional battery assembly can be installed in this compartment This win provide a typi cal 24 year back-up power for the CMOS RAM memor~

_i 4 “1 I~ fl ‘~ I

LP~I’ — •4-, r ~ ~ IwI..

• EtUrl, . ----t-- ‘ . -

TERMS YOU NEED TO KNOW

.a) Incoming line wiring temunals b) Winng tenmnals for 20 inputs. Self-lifting pressure plates allow for easy wire insertion and secure connections. Terminals accept two 414 AWS wires. The hinged cover (shown in the open position) has write-on areas for identification of external circuits. The tem’imal block is removable for easy expan sion unit replacement Terminal Block Removal:

a Wiring temvnals for 12 outputs. The removable terminal block has the same construction as…