Osm100700 (Open End Baler)

HORIZONTAL OPEN END BALEROPERATOR/SERVICE MANUAL HARRIS 340 JEKYLL RD. BAXLEY, GA. U.S.A. 31513 (800) 447-3526 www.harrisequip.com January 2007 Part No. OSM100700 FOREWORD This manual is designed to enhance the utilization of Harris Horizontal Open End Balers. The intention is to provide clear, easy-to-use guidelines for safe operation of the machine. In order for this manual to be effective, the owner and operator must read and understand all of the information. Extra attention must be given to safety precautions before attempting to operate or service the baler. Each Harris baler is pre-assembled and factory-tested to ensure it operates and performs to design standards. If the owner or operator should encounter any problems with the baler, or if any questions arise regarding the baler’s operation or capabilities, please contact HARRIS, Service Department at (800) 447-3526. Using nonstandard parts may adversely affect the operation, performance, and safety of Harris machines, and may void the warranty. To protect investments and ensure safe operation, insist on genuine Harris replacement parts and components for all Harris equipment. The information contained herein refers to U.S. OSHA and ANSI standards. Please use applicable codes, standards, and directives specific to your country. i TABLE OF CONTENTS Forward.......................................................... .......................................................................i Table of Contents........................................... .......................................................................ii 1. SAFETY & EQUIPMENT INFORMATION Owner/Employer Responsibilities ......................................................................... ...........1-1 Introduction ...................................................................................................................... 1-2 Warning Terms .................................................................................................................1-2 Decals and Warning Labels ............................................................................................. 1-3 Warning Decal Location Chart ......................................................................................... 1-4 Warning Decals ................................................................................................................ 1-5 Safety Precautions ........................................................................................................... 1-7 Hydraulic System ............................................................................................................. 1-8 Electrical System .............................................................................................................1-9 Proper Lockout/Tagout (LOTO) ....................................................................................... 1-9 Materials Processed ...................................................................................................... 1-10 Location of Major Components ...................................................................................... 1-11 Description of Major Components ................................................................................. 1-12 2. OPERATION Pre-operation Inspection................................................................................................... 2-1 Items to Inspect and Check ............................................................................................. 2-1 Baler Startup Procedure ................................................................................................... 2-1 Baler Operation................................................................................................................. 2-1 Baler Functions................................................................................................................. 2-2 Loading ............................................................................................................................. 2-2 Compacting....................................................................................................................... 2-2 Loading Wire .................................................................................................................... 2-2 Bale Tying ......................................................................................................................... 2-3 Hand Tying Bales.............................................................................................................. 2-3 Ejecting the Bale............................................................................................................... 2-3 Set Up Procedures ........................................................................................................... 2-4 Touch Screen Panel Views .............................................................................................. 2-5 Unjamming Procedures in the Hopper............................................................................ 2-12 Jam at the Shear Knife and Corrective Measures .......................................................... 2-12 Proper Shutdown Procedures......................................................................................... 2-12 ii ................................ 4-8 LS-2 Platen Forward Stop Limit Switch Adjustment ............................................................................................................................................................. 3-1 Hydraulic Fluid Information ........................................................................................................................................................ 4-4 Balers Without Poppet Block ................................................................................................................................................................................3-5 Single Cylinder Tension Lubrication................... 3-6 Filter Replacement.......................................................................... 4-6 Platen Hold Down Adjustment .................. 3-3 Electric Motor Bearing Lubrication........................ 4-1 Platen Cylinder Rod Relief Pressure Adjustment.............................................. 4-1 Tension Block Adjustment ...............................................................TABLE OF CONTENTS 3.................................................................................................................................................................................................. 4-4 Unloading Valve Pressure Adjustment ............................................................................................................................................................... 3-3 Inserter Lubrication Chart ........................ 3-1 Lubrication ....................................... 4-8 iii ............................................................................................................ 3-7 4.................................................................................................. 4-3 Balers With 150/200 HP Manifold................................ 3-1 Maintenance Records ............................... 4-7 LS-1 Platen Retract Stop Limit Switch Adjustment ..................................................................................................................................................................... 4-3 Platen Cylinder Rod Relief with Poppet ............................................................... 3-6 Suction Strainer Replacement .................3-4 Twister Lubrication Chart ........................ 4-2 Platen Cylinder Rod Relief With Poppet ...................... 4-3 Unloading/Relief Valve Pressure Adjustment.............................................................................................................................................................. 4-2 Balers With 40/50/75/100 HP Poppet Manifold .............................................................................................................................. 4-7 PRX-3/PRX-3A Platen Full Forward Limit Switch Adjustment .............................................. .............................................................................. 4-5 Bale Tension Cylinder Pressure Adjustment ...................................................... 3-7 Service Inspection and Cleaning Requirements.......................................... 4-1 Unloading/Relief Valve Pressure Adjustment............................................... ................................. PREVENTIVE MAINTENANCE General .. 4-6 Limit Switches .................................................. 4-8 LS-4/LS-5 Inserter Retract Stop Limit Switch Adjustment ......... 4-5 Pilot Pressure Adjustment................ 4-2 Unloading/Relief Valve Pressure Adjustment.................................................................................................................................... 4-4 Hydraulic System Pressure Adjustment.......... SERVICE ADJUSTMENTS Balers With 20/30 HP Poppet Manifold .................................. . 4-12 Knife Adjustment............... 4-12 Wire Tension Adjustment .... 4-9 LS-7 Twister Home Limit Switch ........................................................................... TROUBLESHOOTING Electric Solenoid Valve ............................................................................................................................................................................................................................................. ........... 4-11 Hopper Door Safety Interlock Switch Adjustment ........................................................................................... 5-6 Twister Drive Shaft Replacement ................................................................................................................. 6-1 L............................. 4-13 5................. SERVICE AND REPAIR Platen and Cylinder Removal .................................................... 4-11 LS-T Twister Safety Interlock Switch ... 5-6 Twister Knife Replacement ............................................. 6-1 Test for Internal Leakage of Cylinder ................................................................................................................................ 5-4 Cylinder Repair ................................................................................................................. 6-2 Maximum Hydraulic Pressure Not Obtained ...................................................................................E.................................................................................................. 4-12 Twister Motor Brake Adjustment.......................................................................... 6-3 Platen Will Not Retract ................................................................... 6-2 Platen Will Not Move Forward............................................. Indicator Lights ............................................................... 5-9 Torque Chart .............D................................ 5-1 Platen and Cylinder Installation ..................... 6-2 Pump Noise...................................................................................................................................................................................................... 5-3 Platen Guide Bar Replacement ...................................................................................................... 5-5 Twister Hook Replacement ..................................................................................................................................................................................................... 5-8 Procedure for Tightening Screws .......................................................................................... 6-3 iv .......... 5-4 Platen Welded Wearstrip Liner Replacement .........................................................................................................................................TABLE OF CONTENTS LS-6 Inserter Forward Stop Limit Switch Adjustment ......................................................................................................... 5-3 Platen Wearstrip Replacement ................................................................................................................................................................................. 5-10 6.... 4-10 LS-8 Bale Length Star Wheel Proximity Switch Adjustment ................... 5-7 Inserter Needle Replacement ......... 6-1 Main Motor(s) Will Not Start ....... 5-2 Platen Hold Down Liner Replacement .................................................... 5-7 Inserted Needle and Guide Roller Replacement .......................................................................................................................................... 5-8 Wire Die Replacement ............. 5-8 Inserter Roller Replacement ................................................................... .................................. B-1 American National Standard Baling Equipment ................................. 6-5 Twister Will Not Reverse ........................................... and Operation C-1 v ......................................... Maintenance............. 6-4 Machine False Cycles in Auto Mode.............................................................................................................TABLE OF CONTENTS Bale Will Not Eject.......................... 6-4 Wire Will Not Cut............................................................................................................................................................................................................................................................................................................................................................ 6-5 Improper Tie .................................................. 6-6 Inserter Will Not Retract ....... 6-4 Inserter Will Not Go Forward................................................. A-1 Maintenance Checklist and Records ..............Safety Requirements for Installation....................... 6-6 Appendix Typical OSHA Lockout/Tagout (LOTO) Procedures ....................... Guidelines (Advisory) Appendix C.147 . It is very important for the safety of employees that the owner/employer complies with these requirements.Non-mandatory) Lockout/Tagout (LOTO) 1910. These standards include but are not limited to: General Requirements Section 5 (a)(1) of the OSHA act.Mandatory. often referred to as the General Duty Clause. requires employers to “furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees”. and vehicle-mounted work platforms 1910. Personal fall arrest system (Section I . which necessitate the use of personal protective equipment (PPE).147 App A . manlifts. Walking-working surfaces 1910. Owner/employer responsibilities are also contained in 29 CFR 1910 Occupational Safety and Health Standards. 1910. Section 7 and 8.The control of hazardous energy (Lockout/Tagout) (LOTO) 1910. and.SAFETY & EQUIPMENT INFORMATION OWNER/EMPLOYER RESPONSIBLITIES Owner/Employer safety responsibilities are contained in ANSI Z245. which identifies the document as a certification of hazard assessment.Permit-required confined spaces 1-1 .Typical minimal lockout procedures Confined Space Entry 1910. 1910.SECTION 1 . the types of PPE that will protect the affected employee from the hazards identified in the hazard assessment. or are likely to be present. Never use feed conveyors to access the hopper.66. 1910. Working at Elevated Heights The owner/employer is responsible for providing an OSHA compliant working surface for clearing material jams in the hopper. Powered platforms for building maintenance Appendix A. Hazard Assessment 1910. Guarding floor and wall openings and holes 1910 Subpart F. and have each affected employee use. A copy of ANSI Z245. the employer shall: 1910. and. Powered platforms. Note: Non-mandatory Appendix B contains an example of procedures that would comply with the requirement for a hazards assessment.146 . Sections II and III .132(d)(1)(iii) Select PPE that properly fits each affected employee.23. Maintenance and Operation.132(d)(1) The employer shall assess the workplace to determine if hazards are present.5 is appended to this manual for reference.5 Baling Equipment . the date(s) of the hazard assessment. If such hazards are present. Always use an OSHA compliant work surface or platform to access the hopper to clear material jams. the person certifying that the evaluation has been performed. or likely to be present. 1910 Subpart D.132(d)(1)(ii) Communicate selection decisions to each affected employee. Section 5 (a)(2) requires employers to “comply with occupational safety and health standards promulgated under this Act”.132(d)(1)(i) Select.Safety Requirements for Installation.132(d)(2) The employer shall verify that the require workplace hazards assessment has been performed through a written certification that identifies the workplace evaluated. be alert at all times. The Harris baler is capable of compressing a great number of materials into bales and is designed with major emphasis on safety. Harris balers are capable of compressing and baling various materials. if disregarded. WARNING. WARNING TERMS The terms DANGER. to ensure that all precautions are taken before proceeding. service. the baler can cause serious injury or death if used in an unsafe manner. However. If there are any questions regarding operating procedures or safety precautions. and instructions.SECTION 1 . shut the machine down following the prescribed shut-down procedures. If at any time there is a question regarding safety. They denote the following: The word DANGER precedes information dealing with specific immediate hazards which. conscientious attitude and observe safe operating procedures to prevent accidents. high-density materials. referenced as HARRIS throughout this manual. authorized personnel who are thoroughly familiar with the equipment. and watch for conditions that may affect normal machine performance or create an unsafe condition in the work area. or other large. The word WARNING precedes information dealing with hazards or unsafe practices which COULD result in PERSONAL INJURY or DEATH. Service Department at (800) 4473526 to ensure all precautions are taken before proceeding. as well as paper and solid waste. Service Department at (800) 447-3526. 1-2 . Use the emergency stop button in the event of an emergency and notify the proper authorities immediately. It is very important to keep an alert. consult the manual or HARRIS. including scrap aluminum and copper. contact HARRIS. safety features. The Harris baler is not intended for baling ferrous metals. it is the operator’s and owner’s responsibility to have a clear understanding of how the machine functions and to be aware of all the necessary precautions for safe operation. CAUTION.SAFETY & EQUIPMENT INFORMATION INTRODUCTION Before operating the Harris Horizontal Open End Baler. If necessary. or baler repair must be performed only by trained. concrete. The baler operator must know and observe the capacities and limitations of the machine. and NOTE appear throughout this manual and on safety warning signs. WILL result in SEVERE INJURY or DEATH to the user or others. as with any industrial machine capable of applying extreme force through hydraulic pressure. precautions. Corrective measures. O. NOTE The word NOTE precedes information which is vital to proper operation or maintenance of the equipment.SAFETY & EQUIPMENT INFORMATION The word CAUTION precedes information dealing with potential hazards or unsafe practices which. MAY RESULT in PERSONAL INJURY or DAMAGE to the equipment. Box 406 Baxley.SECTION 1 . if disregarded. Ensure all decals are in their proper locations and legible. • • • • Ensure all warnings are obeyed at all times. Please read over and understand all warning decals and locations before attempting to operate the machine. Replacement decals can be ordered free of charge from local Harris distributors or from: Harris Baxley Operations P. Report any damaged or missing decals to the proper authority immediately. GA 31515 (800) 447-3526 1-3 . DECALS AND WARNING LABELS See the list of warning decals and illustrations as well as illustrations of decal locations on the following pages. SAFETY & EQUIPMENT INFORMATION WARNING DECAL LOCATION CHART 1-4 .SECTION 1 . SECTION 1 .SAFETY & EQUIPMENT INFORMATION WARNING DECALS 1-5 . Equipment Starts Automatically. 8. DANGER . 15. Single Phase Electrical (Inside Main Control Panel). 9. 5. contact will cause electric shock. 4. WARNING. WARNING . Harris Logo ANSI Standard Z245. Ensure warning decals are obeyed at all times. DANGER .SECTION 1 . DANGER . 18. 11. 10. Three Phase Electrical (Inside Main Control Panel).Keep all body parts out of machine during operation.Do Not Remove Access Cover. WARNING . 17. Lockout/Tagout (LOTO) prior to removing control power key.Operating and Service Manual Instructions.SAFETY & EQUIPMENT INFORMATION 1. 7. 16. Never use conveyor to access baler hopper.Hazardous Voltage. 2. 460 Volts (Or Applicable Voltage.Avoid serious injury.Confined Space Entry. 340 Jekyll Road. 12. 19. DANGER . 6. GA.Do Not Operate With Guard Removed. 13. keep clear.5 MADE IN AMERICA DANGER .Bale Ejection Area. 115 Volts (Inside Main Control Panel). DANGER . DANGER . Make certain warning decals are in place and legible at all times.High Voltage.Crush Hazard. DANGER . A warning decal location chart is provided on page 5 in this manual to assist in checking for warning decals. WARNING . Inside Main Control Panel). 1-6 . Replacement warning decals can be ordered free of charge from your local distributor or from HARRIS.Hazardous Voltage contact may cause electric shock or burn. 31513 (800) 447-3526. 3. Report any damaged or missing warning decals to the proper authorities immediately. Baxley. 14. Follow employers unjamming procedures should a material jam occur. unless the baler is shut down and Locked out/Tagged out (LOTO) in accordance with OSHA standards. Ensure that the power source is isolated and the machine is Locked out and Tagged out (LOTO) in accordance with OSHA 29 CFR 1910. before operating the machine. authorized personnel familiar with safe operating and maintenance procedures are allowed to inspect. • Make certain all warning signals and interlock devices are working. Severe injury or death can result from ignoring these safety precautions. Never place any part of the body in a potential pinch point. • Be alert and aware of all persons working in the vicinity of the baler. Always access the baler or its hopper in accordance with OSHA requirements. Care must also be taken when maintenance is performed. Always wear proper hand and eye protection when working with the strapper. 1-7 .1-2003 regulations before entering machine or attempting any service or maintenance including clearing material blockages and jams. Never attempt to access the baler for any reason by climbing up the feed conveyor.SAFETY & EQUIPMENT INFORMATION The health and safety of personnel must be considered when operating a baler.147 and ANSI/ASEE Z244. Never enter the baler at any point to perform service work (including clearing major and minor jams). To access material jams. or service the baler. SAFETY PRECAUTIONS • • • • Obey all warning decals. NOTE Only trained. Never perform any operation unless all guards are in place and safety interlock devices are fully functional. always use an OSHA compliant work surface or platform. Never allow anyone to enter or ride on a feed conveyor. Always perform Lockout/Tagout (LOTO) procedures when clearing material jams. Be certain all safety guards and access doors are maintained and secured in place while the machine is in operation. operate.SECTION 1 . SECTION 1 - SAFETY & EQUIPMENT INFORMATION • Be alert and aware of those operating conditions that can adversely affect the operation of the baler. • Know emergency shutdown procedures and where to get help in the event of an emergency. • Never attempt to operate any equipment, or perform service or maintenance without the proper training. • Never operate the baler while under the influence of intoxicants, narcotics, or drugs that impair judgement. Working under the influence of intoxicants or narcotics presents a major hazard to the operator and others in the work area. • Never operate the baler while wearing jewelry or loose clothing which may catch on moving parts or controls. • Always wear proper safety equipment as specified by the employer. Harris strongly recommends head, eye, and foot protection and, in noisy installations, hearing protection. • Do not start or operate equipment which has a malfunction. • Never remove covers on any electrical component, unless the main electrical power supply is off and secured with a padlock. Make sure the machine is Locked out/Tagged out (LOTO) in accordance with OSHA regulations before any service or maintenance is attempted. • Know the location and function of all emergency stop buttons, control switches, instruments, gauges, and protection devices. • Know the location of all fire extinguishers and make sure they are fully charged and maintained, and workers are trained to use them. • Make certain all persons are clear of the baler, conveyors, and other related equipment before starting the equipment. Publications of these safety precautions do not imply or in any way represent an all inclusive list. It is the operator’s responsibility to be familiar with all safety requirements and ensure that the operation of the unit is in accordance with safety requirements and codes, including all applicable Occupational Safety and Health Act (OSHA) and American National Standards Institute (ANSI) regulations, as well as other state and local codes. These regulations and codes change. It is strongly recommended that current applicable OSHA and ANSI standards be available to the operators at all times. HYDRAULIC SYSTEM Any service or maintenance to the hydraulic system must only be performed by trained, authorized personnel and only after the machine is Locked out/Tagged out (LOTO) in accordance with OSHA regulations. Never use hands to check for hydraulic fluid leaks. Hydraulic fluids escaping under high pressure may cause severe injury. In the event of an injury, seek medical treatment immediately. 1-8 SECTION 1 - SAFETY & EQUIPMENT INFORMATION ELECTRICAL SYSTEM Any service or maintenance to the electrical system must only be performed by trained authorized personnel and only after the machine is Locked out/Tagged out (LOTO) in accordance with OSHA regulations. HARRIS balers require a high voltage external power supply. Each unit has three electrical circuits: a main power circuit, a 110 volt circuit for receptacles, and a 24 volt DC control circuit. The high voltage furnishes power to operate the motors, and a transformer converts the high voltage to 24 volts DC to operate the control power circuit, programmable logic controller (PLC), and operator’s control panel. For the main power circuit, high voltage enters the main control panel and goes directly to the drive motors. The control power circuit consists of control buttons on the operator’s control panel, limit switches, proximity switches, pressure switches, relays, timers, and solenoid valves. These switches and valves control the baler. For the electrical system to function properly, electrical components must be kept clean and dry, (i.e., free from dirt and moisture). In order for the baler to operate properly, all limit switches and proximity switches must be properly adjusted and free from foreign materials to prevent the switches from giving false signals to the control circuit. PROPER LOCKOUT/TAGOUT (LOTO) According the OSHA 29 CFR 1910.147, all personnel are to be instructed to perform proper Lockout/ Tagout (LOTO) procedures on the machines they operate. Please thoroughly review Appendix A of this manual for this procedure. 1-9 SECTION 1 - SAFETY & EQUIPMENT INFORMATION MATERIALS PROCESSED Baling materials should consist only of those specifically approved by HARRIS, with written specifications. Other materials may damage the machine by point loading, severe abrasion, extreme impacting, etc. Processing materials which are not covered by the list below will be considered an abuse of the machine. Machine abuse WILL VOID THE WARRANTY. ACCEPTABLE MATERIALS • High grade paper, if segregated and “delumped” • Bulk or Shredded Corrugated paper • Shredded Newsprint UNACCEPTABLE MATERIALS • Masonry, steel, or other such noncompressibles • Pressurized cylinders and cans of any description • Solid Waste Glass, masonry, and other such abrasive noncompressibles can cause excessive wear or damage and can interfere with baler functions, such as shearing or the operation of the door. 1-10 SAFETY & EQUIPMENT INFORMATION LOCATION OF MAJOR COMPONENTS 1-11 .SECTION 1 . HYDRAULIC PUMPS Vane type hydraulic pumps are mounted onto the electric motor. low oil level switch and temperature switch are all available options for the machine. In the event of injury. The reservoir is equipped with a sight gauge/temperature gauge located on the side of the tank. TENSION CYLINDER The tension cylinder and relief valve work in conjunction with the platen. This cylinder is controlled by a pressure reducing valve which applies the proper “squeeze” to the plug bales in order to assist the baling operation of the platen. The valve block assembly is mounted on top of the hydraulic tank. HYDRAULIC OIL RESERVOIR Hydraulic fluid operates under high temperatures. These pumps provide the flow and pressure required to operate the main ram cylinder and other cylinders. The horsepower rating of the electric motor is dependent upon the power unit option chosen. The volume of the reservoir depends upon the power unit. The electric motor is mounted on top of the hydraulic tank. extend fast. hoses or cylinders to prevent the possibility of burns. Oil heater.SECTION 1 . Never use hands to check for hydraulic fluid leaks. and regenerative extend. Fluid escaping under pressure could cause severe injury.  Vane-type pumps are also employed for the circulation of oil through the cooler and filters. These modes are: retract fast. Avoid contact with piping. which places the platen into the appropriate operating mode. CONTROL VALVE BLOCK ASSEMBLY The valve block assembly consists of solenoid-operated pilot-controlled spool valves.SAFETY & EQUIPMENT INFORMATION DESCRIPTION OF MAJOR COMPONENTS MAIN RAM (PLATEN) CYLINDER The main ram (platen) cylinder is controlled by a solenoid-operated directional valve through a microprocessor controller. The hydraulic reservoir is a welded steel tank. ELECTRIC MOTOR The electric motor is supplied with the appropriate voltage to drive the hydraulic pumps. 1-12 . seek medical treatment immediately. extend slow. retract slow. The platen.SAFETY & EQUIPMENT INFORMATION PLATEN The platen is a compression plate structure that is securely fastened to the main ram (platen) cylinder. The electric fan is temperature sensor activated. The plug bales in the retention chamber form one of the walls in the bale forming chamber. MAIN CONTROL PANEL (MCP) The MCP contains electric motor contactors. BALE TYING The bale tying mechanism provides a means for keeping the bale securely bound together as the bale is ejected from the baler. HOPPER The hopper is used as a holding chamber that directs material into the baler. the oil cooler is an air-to-oil heat exchanger through which the hydraulic fluid is pumped. They are also used to start and stop the conveyer during automatic operations. cooler fan. The electric motor contactors control the incoming power to the electric motors for the baler. The MCP is normally located on the side of the hydraulic tank. are covered by hardened steel plates that may be replaced if they wear out. control relays. They are used to control the amount of material fed into the baler for each platen cycle. and the control transformers. FILTER ASSEMBLY The filter assembly receives the oil supplied by the cooler/filter pumps. MATERIAL SHEARING BLADE (KNIFE) The material shearing blade (knife) assembly consists of two hardened steel blade assemblies which pass in close proximity of one another during the platen extend operation. OIL COOLER If applicable. The hydraulic filter is a consumable item that should be changed when the filter gauge indicates. The material shearing blade (knife) assemblies are located as follows: the moving blade (knife) is located on the top leading edge of the platen.SECTION 1 . and the stationary blade (knife) is mounted in the leading edge of the shear beam assembly. PLC. Once the bale is formed. Cooling is achieved by air being forced around the coils by the electric fan. etc. The material shearing blade (knife) assemblies can be adjusted or replaced if they become worn or damaged. the platen indexes the bale into the bale retention chamber. main power circuit breakers. 1-13 . The oil filter removes dirt particles and other foreign objects from the hydraulic fluid. optional conveyors. PHOTO-EYES The photo-eyes are part of the automatic baling control system. as well as the bale compression chamber walls. The platen extends through the hopper chamber into the bale compression chamber where the bale is formed by pressure placed on it by the platen. This will prevent anyone from removing the power key and energizing the baler. OPERATOR CONTROL PANEL (CONSOLE) The touch screen panel is mounted to a swing arm for versatility of operator position. turn off the control power and remove the key. The panel is located over the retention chamber. HIGH VOLTAGE Any service to the electrical system should be performed only by trained.SECTION 1 . 1-14 . Insert the key into the dual-key interlock on the access door and remove the personal key. Maintain possession of the personal key while entering/servicing the baler.SAFETY & EQUIPMENT INFORMATION DUAL KEY INTERLOCK ON ACCESS DOOR If the hopper access door is fitted with a dual-key interlock. authorized personnel only after the machine has been Locked out/Tagged out (LOTO) in accordance with OSHA regulations. 3. 8. Have emergency telephone numbers available. Working area around baler: Keep clean. On auto-tie models. Wear Strips. 2. All warning decals. shut the machine down following prescribed shutdown procedures and notify the proper authorities immediately. Make sure all electrical panels are closed and secure. 14. before operating. Note the position of fire extinguisher and make sure it is fully charged. clean out if necessary. 1. Turn control power switch on operator console to “ON. 9. make sure the tie wires and spools are not damaged or obstructed. Be sure lighting is adequate for safe operation. 10. ejection area. 5. Ensure all guards are in place prior to operation. Corrective measures must be performed only by properly trained personnel or authorized personnel who are thoroughly familiar with the instructions contained in the manual. ensure the baler has been shut down and Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Check wiper. Unlock the “MAIN POWER” switch and rotate the lever to the “ON” position. It should only be completed by trained personnel familiar with safe operating procedures. Look for worn. 13. Welds (broken or cracked). Check behind platen for material build-up. clean out door for material  build-up. Ensure the power key is in the switch on the power panel. While items listed are standard. 7. Make sure feed hopper access door is closed. safety guards and interlock switches must be in place and functional. hoses. 12. 6. 2. overcharged hoppers. 8. All parts of the machine should be visible during pre-operation inspection. Check hydraulic lines. and conveyor before starting the machine. bale chamber. Structural damage. The baler operator must know and observe the capacities and limitations of the machine. 11. there may be other checks required for some baler installations. Set the baler on manual mode by moving the “DRIVE MOTOR” and “BALER” mode selector switches to “MANUAL”.OPERATION PRE-OPERATION INSPECTION A pre-operation inspection is essential for the safe and efficient operation of the Horizontal Open-End baler. Ensure that the main power supply is on. Remove flammable materials. 3. broken and damaged parts such as: Hydraulic hoses.SECTION 2 . ITEMS TO INSPECT AND CHECK 1. Manually cycle the platen and retract it to the home position. add the correct fluid. and fittings for fluid leaks. Be alert at all times and watch for any conditions that might affect normal machine performance such as oversize bales. 7.” 6. or other malfunctions. If such problems arise. 5. BALER OPERATION Never override a safety interlock switch. Start feed conveyors (if applicable). Remove any oil or fluid spills. 9. 4. Broken or missing cap screws and pins. if necessary. Make certain all persons are clear of the charging hopper. Set or check the material selection to be certain the unit is set for the desired bale parameters. 4. 2-1 . Check hydraulic reservoir oil level. Ensure bale discharge area is not obstructed. Press the “push to start” button to start the drive motor. BALER STARTUP PROCEDURE Before performing pre-operation inspections. Set the baler and drive motor selector switch to “AUTOMATIC”. Never attempt to load or handle wire unless the machine is shut down and Locked out/Tagged out (LOTO) in accordance with OSHA standards. 5. each baler function must be controlled individually by the operator using the control panel. COMPACTING The platen compresses material in the baling chamber. Press “PUSH TO START” button. 2. tying. LOADING WIRE Hand and eye protection is required when handling tie wire. 9. LOADING Material is loaded into the baler chamber using a feed conveyor. The photo eye measures the material and determines when the baler is cycled in the automatic mode. 4. Set the “BALER MOTOR SELECTOR SWITCH” in the “MANUAL” or “AUTO” position. Material type and density will determine the number of cycles necessary to form a bale. Remove the bale from the ejection area after it clears the machine. Start feed conveyor system. 10. NOTE If there is wire in the system. BALER FUNCTIONS There are four basic functions in the operation of the Horizontal Open End Baler: loading. On the upper four spools. Remove the spool cover plate and place wire roll on the spool. Place the “BALER MOTOR SELECTOR SWITCH” in the “OFF” position. compacting. run the wires through the wire guide. 7. closest to the baler exit. Set the “BALER MODE SELECTOR SWITCH” in the “AUTO” position.OPERATION 1.SECTION 2 . excess material is cut by the shear blade as the material is compressed. 3. the wire leaves the spool from the top On the bottom spool the wire should leave the spool from the bottom. connect the new wire end to the tail end of the existing wire on the far side of inserter rollers. Set the “BALER MODE SELECTOR SWITCH” in the “OFF” position. Thread the wire through the roller and across the inserter roller. On the inserter side of the baler. and ejecting. Turn 'WIRE TIE SELECTOR SWITCH” to “AUTO”. . 2-2 The machine cycles automatically. A feed hopper is used to assist in the loading process. 6. Set the material selection for the desired bale parameters. After each bale is completed and tied. The baler will start. NOTE To operate the baler in manual mode. 8. it will be pushed out of the baler by the next bale being formed. Run the tie wires down the side of the baler and insert each tie wire in the correct slot on the face of the platen. Leave approximately 12” extending out to the end loop. On auto-tie models. Baler is shut down.OPERATION When there is no existing wire in the auto tie unit. cycling the auto tie unit is not necessary. 6. The wires will be cut and twisted. the bale complete alarm will sound and the baler will shut down. Alarm sounds.SECTION 2 . run the wire through the wire guide. Set the baler and feed system on auto and resume the baling process NOTE If there is existing wire in the system. pull the end of the replacement wire to the front of the baler and secure it. wire ties are applied to the bale. The bale is ejected from the unit as the next bale is being formed. Pull the wires through. cycle the unit by pressing the “PUSH TO TIE” button. 5. Pull the tie wire down the side of the baler. Insert new tie wires in the slots on the platen face. Hand and eye protection are required when handling tie wire. The machine cycles automatically. If there is no existing wire in the auto-tie system. On the twister side of the baler. 7. 8. Shut down and lock out the baler. Start the baler and manually retract the platen. Slots on the face of the Platen. When a bale is complete. the process is completed automatically as part of the baling cycle. Wire is always inserted through the platen face slots at the start of each new bale. 2-3 . BALE TYING After a bale is completed. 4. informing the operator bale ties are needed. Thread the wire through the rollers. 1. 3. and secure the wire end in the same manner as on the inserter side of the baler. The inserter will then return to the retracted position and the secured wire ends can be removed from the side of the baler. HAND TYING BALES EJECTING THE BALE The Open-End baler uses the previous bale held under tension to bale against. Never attempt to load or handle wire unless the machine is shut down and Locked out/Tagged out (LOTO) in accordance with OSHA standards. 2. Run it through the end loop on the tie wire and twist. The inserter should travel behind the platen face. as shown. Switch the baler to the manual mode. Check to make sure the new tie wires stayed in place. . 2-4 PUSH TO START CONTROL POWER When pressed.SECTION 2 .Machine will function. Insert the control power key and turn the switch to the “ON” position. 3. Press the controls “ON” button.OPERATION SET UP PROCEDURES 1. NOTE The panel view should resemble the one shown below. This key switch has three settings: Heat . Perform the Pre-Operation inspection. this pushbutton will start the machine. this pushbutton will shut down all machine functions. Off .starts heaters to bring oil to operating temperature.Machine will not function. The following pages display sample screen shots. On . EMERGENCY STOP When pressed. 2. Panel View 2-5 .SECTION 2 .OPERATION TOUCH SCREEN PANEL VIEWS 1. Cuando se presiona la llave de la pantella del espanol toda lengua cambiara’ al espanol. all screen language will change to Spanish. 5. Material Set-Up Manual Operation Alarm History ?? Help Espanol Function Pad Keys Function Pad Keys are labeled F1 .F10.  ENTER KEY 2-6 Pressing the “Machine Status” button will lead to the screen shown on the following page. 3. Machine Status 2.OPERATION 2. .SECTION 2 . NOTE When “ESPANOL” screen key is pressed. 6. Main Control Screen Touch Screen Options  (shown in turquoise and black) 1. NOTE Press the “Enter” key after any change in the material setup. 4. Pressing the Material Set-Up button will lead to the screen shown on the following page. Machine Status Screen Baler Status Component Locations The baler status is displayed in the top left corner of the screen.Platen Full Forward PRX 4.Platen Short Stroke Switch Current Bale Length The length of the bale being created is displayed along the top of the touchscreen.Twister Home Position LS 9. the baler status is “OFF. 2-7 . 1. PRX8 . In the example shown. LS7 .” The following is a list of components and their locations as they will be viewed on the screen while the machine is in operation.Inserter Back LS Bottom 7. LS1 . PRX3A . Pay close attention to the pressure readings during operation. NOTE Alarm Messages Alarm messages will be displayed along a red bar.SECTION 2 . directly in front of the ESPANOL touchscreen button.Inserter Forward LS 8.Platen Forward Stop LS 3. LS6 .Platen Retracted LS 2. LS4 . PRX3 . the button that was chosen is removed from the screen view. This value will be displayed directly under the Bale Length Heading. LS2 . PRX9 . When a button is pressed and the screen for the chosen button appears.Ram Full Forward Safety Switch 5. All alarm messages should be acknowledged and dealt with in the appropriate manner. Hydraulic Pressure The systems hydraulic pressure will be displayed in the top right corner of the screen.Inserter Back LS Top 6.OPERATION 3.Star Wheel Proximity Switch 10. LS5 . side tension cylinders release. 2-8 Adjustments must be made to the Conveyor Off Delay Timer to prevent hopper overfill. Tension Relief Pressure When this adjustable pressure setting is exceeded by the platen. Conveyor Off Delay Timer Allows the conveyor to continue running after the selected conveyor eye (upper/lower) has been blocked.” Bale Length The bale length is adjustable to obtain the desired length bale. This is another setting used in controlling the bale weight. This is one of a series of settings used in controlling the bale weight. Material Set-Up Screen Baler Status The baler status is displayed in the top left corner of the screen. Display On the right side of the screen are three display buttons describing the machine status: Upper . Material The material being processed will be highlighted in black towards the top of the screen.This location describes the hopper level and will display either Upper or Lower. the baler status is “OFF. The baling process then continues.This location describes the status of the short stroke and will display either Enabled or Disabled.SECTION 2 . Platen Forward Delay Timer Allows time for the product to drop into the baler before ram cycles. In the example shown.OPERATION 3.This location described the status of the conveyor and will display either Photoeye or Reverse. NOTE The enter key must be pressed after any change in material set-up. . Photoeye . allowing the bale to be pushed forward. Enabled . the baler status is “OFF. Alarm messages will be displayed along a red bar. All alarm messages should be acknowledged and dealt with in the appropriate manner.OPERATION Pressing the Manual Operation button will lead to the following screen. 2-9 . F9) control functions on the machine. Press the corresponding function pad key (F1. The hydraulic system pressure is displayed directly below the Bale Length display. Function Options These six options (displayed in green with numbers F1. directly in front of the ESPANOL touchscreen button. F2. Pressing the Help Button will lead to the screen shown on the following page. towards the top. In the example shown. F7. F2. Touchscreen Keys Hydraulic System Pressure These options are located directly below the function options. press the screen in the location of the desired command. Manual Operation Screen Baler Status Alarm Message The baler status is displayed in the top left corner of the screen. Pay close attention to the hydraulic pressure readings during operation. 4. F6. To choose an option. F8. or F9) for desired command. Bale Length The length of the current bale in the machine is displayed on the right side of the screen. F6. F8. F7.SECTION 2 . SECTION 2 - OPERATION 5. ??Help/Troubleshooting Alarms During troubleshooting, alarms are displayed in the red area shown above. The problem is briefly described along with a suggested solution. Do not ignore alarm messages or suggested solutions. 2-10 If any questions arise regarding alarms or suggested solutions, please contact Harris:  1-800-447-3526. SECTION 2 - OPERATION 6. Alarm History Alarm History A typical alarm screen is shown above. 2-11 SECTION 2 - OPERATION UNJAMMING PROCEDURES IN THE HOPPER 1. Determine a material jam exists. 2. Shutdown baler and baler feeding system; then, LOCKOUT/TAGOUT (LOTO). 3. Always use OSHA compliant elevated working surfaces or platforms for clearing material jams in the extension hopper. Use approved fall protection when working from elevated working surfaces or platforms. Serious injury or death WILL occur if anyone falls into the hopper. 4. Dislodge material that is causing the jam in accordance with employers procedure/ instructions. 1. Stop the feed conveyor or material feed process immediately. 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 if the jam clears and the platen enters the bale chamber. 5. If the jam fails to clear: a. Retract the platen approximately halfway. b. Shut the machine down and Lock out/ Tagout (LOTO) in accordance with OSHA and ANSI requirements. c. Remove obstruction. Always perform Lockout/Tagout (LOTO) procedures before clearing material jams. Always access the baler or its hopper in accordance with OSHA requirements. Follow employers unjamming procedures should a material jam occur. DO NOT ENTER HOPPER until familiar with unjamming procedures. Never attempt to access the baler for any reason by climbing up the feed conveyor. Always use an OSHA compliant work surface or platform to access the extension hopper in order to clear material jams. NOTE Only authorized personnel trained in safe operation and maintenance procedures should be allowed to operate, service, or maintain the machine. This includes the clearing of material jams. JAM AT THE SHEAR KNIFE AND CORRECTIVE MEASURES The high pressure alarm will notify the operator when an unusually large amount of material, foreign objects, or combination of both may prevent the shear knife from cutting the material and allow the platen to enter the bale chamber. 2-12 • Serious injury or Death WILL occur if the baler is started and operated while someone is inside the machine. To prevent serious injury or death, follow OSHA requirements regarding Lockout/Tagout (LOTO) procedures. • Never allow anyone to place any part of their body in the machine unless all shutdown and Lockout/Tagout (LOTO) procedures have been followed precisely. • If any questions arise regarding the procedures for machine Lockout/Tagout (LOTO), check with supervisors before entering or allowing anyone else to enter the machine. PROPER SHUTDOWN PROCEDURES 1. 2. 3. 4. 5. Turn off material feed system. Turn baler selector switch to off position. Turn baler motor selector switch to off position. Turn main power supply off and lock out baler. Perform any house cleaning if necessary. VISCOSITY INDEX This factor is very important. a minimum viscosity of 95 is required. Careful attention to proper preventive maintenance will ensure and extend trouble-free operation of the unit. All additive treatment should be completed by the lubricant supplier with additives that are compatible with each other as well as the base oil into which they are blended. 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. the hydraulic oil must possess desirable physical and chemical characteristics. LOW TEMPERATURE It is recommended that oils used in Harris hydraulic systems have a maximum viscosity of 4000 SUS at 15 degrees farenheit. corrosion. decomposition. the ambient temperature of the hydraulic oil should be maintained near 90 degrees farenheit when the system is to be operated. MAINTENANCE RECORDS Prepare and adhere to a regular maintenance schedule. NEUTRALIZATION NUMBER This characteristic is used in conjunction with other factors to determine the chemical and physical changes occurring within the oil as a result of extended use and service. The result of using low Viscosity Index oils is unsatisfactory lubrication at operating temperature.PREVENTIVE MAINTENANCE GENERAL The main objective of a preventive maintenance program is to anticipate and prevent operational malfunctions before they require extended shutdown for major repairs. oxidation. Accurate records of all maintenance performed and a regular review of all maintenance records may provide an indication of potential problems. The change and rate 3-1 . including but not limited to clearing a jam or oversize bale. When the air temperature around the power unit varies from 32 to 100 degrees farenheit. Premium hydraulic oil should be used in Harris hydraulic systems.SECTION 3 . Also. Particular attention and care given to the hydraulic system will extend the service life of the machine. Oil should be further fortified by the application of selected additives to provide additional resistance to wear. the crude from which the finished product has been processed should be of such nature to possess desirable characteristics. When the air temperature around the power unit varies from 10 to 100 degrees farenheit a minimum viscosity index of 135 is required. results from the use of oils having Viscosity Indexes below that recommended. This precaution must be taken before any service or maintenance is attempted. HYDRAULIC FLUID INFORMATION HYDRAULIC OIL To serve its purpose and provide long and satisfactory service. Do not get into the baler or place any portion of the body into the baler at any time unless the baler is shut down and Locked out/Tagged out (LOTO) in accordance with OSHA regulations. Since stability under agitation and wide ranges of temperatures are very important. and foaming. The neutralization number of the oil should be given by the supplier and this information put on record by the operator. and sludge accumulations within the system in relatively short periods of time.PREVENTIVE MAINTENANCE of change occurring in the neutralization value is of utmost importance. RECOMMENDED HYDRAULIC FLUID General Specifications For Hydraulic Oil 10 Weight Premium Grade Oil (46) Non-Foaming Anti-Wear Additives Viscosity Index. Adequate evidence of the ability of the oil to prevent undue pump wear may be shown by test conducted as per ASTM D2882 with a total weight loss of 50 mg. and viscosity. water content. Many oil suppliers render the service on a no-charge basis to the customer. Some additives are given a higher neutralization number than others. and generally speaking. It is this rate of change which is most important. CONTAMINATION It is estimated that as much as 70% of all hydraulic problems may be traced directly to the fluid. It is very important that all foreign matter be kept from the hydraulic oil. rather than the actual neutralization number on the oil. Most reputable oil companies maintain laboratories and technical staff which are capable of analyzing hydraulic oil samples and advising the user as to the condition of the oil. spectrochemical analysis. Since the recommended hydraulic oils for these machines are fortified with various additives. advising as to whether or not the oil in use is safe and satisfactory for continued service. it is essential that moisture and water be kept from the hydraulic oils and system. Other vane pump test with varying size of pump and/or length of time will be considered on the basis of the evidence submitted. Harris recommends the use of a commercial laboratory service for analysis of routine oil samples taken on a regularly scheduled basis. As reputable lubricant supplier backed up by a reputable oil company is an assurance of obtaining high quality products. The cost per sample may vary depending on the laboratory service. Laboratory analysis should be made by the supplier and the results interpreted to the operator. The most important analysis are particle count. 150 Pour Point 30°F Flash Point 43°F Hydraulic Oil Companies With Brand Name Amoco Rykon Oil 21 or AW Oil 21 Arco AWS-215 Chevron EP Hydraulic 46 Citgo Pacemaker XD-46 or A/W Hydraulic 46 Exxon Nuto H-46 Gulf Harmony 46 AW Mobil DTE25 Phillips Magnus “A” 46 Shell Tellus 46 Sun Sunvis 821 WR or Sunvis 747 Texaco Rando HD 46 3-2 . higher quality is worth the higher initial cost. Invisible quantities of abrasive type contamination may cause serious pump wear. HARRIS will provide this service upon request. The base oil and its compounding should provide a finish oil that will not shrink or abnormally swell hydraulic sealing elements. It is therefore recommended that supervisors assume responsibility for periodic sampling of the oil in the system.SECTION 3 . Additive treated oils have a definite affinity far more critical than was true in year past when only straight mineral oils were available. maximum. malfunctioning of pumps and valves. make sure not to allow contamination material to enter the tank during the process. it is an indication of water contamination. It should be completed based on ANSI Standard B93. wipe any excess oil from the surfaces of  non-moving components so it does not collect dirt or foreign material. Any debris is an indication of a severe solid contamination problem. the source of which must be located and corrected immediately. preliminary analysis while waiting for the lab report. Consult the motor manufacturers manual for lubrication requirements. model and serial number of the machine. be certain the oil fully lubricates the area. Remove any grease build up to keep the area clean. unsealed reservoir covers.SECTION 3 . HARRIS will supply SAMPLE KITS. Normally the grease supply is sufficient to last the lifetime of the motor. when the inspection covers are removed to replace the oil strainers located on the intake or suction tube of the hydraulic pump. WI 53222. Common sources are inadequate outdoor storage. After the sample has been allowed to sit for 20 to 30 minutes to allow all air bubbles to dissipate.19M(R1980). OIL SAMPLE COLLECTION The oil sample should be collected from the inside of the tank. glass bottle with a non-shedding. The results of the analysis will determine any necessary action. or other abrasive material so the shaft can move freely during operation. type of fluid. When lubricating. The actual sampling method is critical. the source of which must be found and eliminated immediately. unsealed reservoir covers. When applying oil. screw-on cap. visually inspect by holding the bottle up to the light to check for debris in the oil and whether the oil is clear or cloudy. which may need to be taken. or condensation. This standard is available from the National Fluid Power Association. If the sample is the least bit “CLOUDY”. or feel free to obtain one from suppliers. LUBRICATION Scheduled lubrication is essential to keep the baler operating correctly. Two identical samples should be taken. or dirty breather filters. dry. additional lubrication may be required. Samples should be placed in a clean. Where severe operating conditions exist. ELECTRIC MOTOR BEARING LUBRICATION The bearings are packed with grease by the motor manufacturer during assembly of the electric motor. One for laboratory analysis and one for personal. 3333 N. Mayfair Road Milwaukee.PREVENTIVE MAINTENANCE HYDRAULIC FLUID TESTING Hydraulic fluid samples should be taken periodically for laboratory analysis. and labeled with the date. 3-3 . Common sources of this kind of contamination may be component wear. make sure enough grease is pumped into the bearing to force out any moisture. dirt. Dip the sample bottle into the oil. Insufficient lubrication will result in rapid wear and shortened service life of baler components. 3-4 Inserter frame rollers (Details B and C). 3. Inserter needle rollers (Detail D). . Inserter Chain and Sprocket (Detail A).PREVENTIVE MAINTENANCE INSERTER LUBRICATION CHART Items noted below with a circle should be oiled monthly with SAE#10 or equivalent. 1. 2. Inserter wire guide rollers (Detail D). 4.SECTION 3 . 1. 2. 3-5 .PREVENTIVE MAINTENANCE TWISTER LUBRICATION CHART Items noted below with a circle should be oiled monthly with SAE#10 or equivalent. Two grease Zerks located on all five twister drive shafts. Twister Wire Guide Rollers (Details B and C).SECTION 3 . Twister Drive (Detail A). Items noted below with a square should be greased monthly with Mobilux EPI-Service Grease or equivalent. 2. • Make sure the oil is cool before replacing the filter element. Slide the top filter element into position and push it down on the connector. 4. 5. 3-6 . Place the connector on the top of the bottom filter element and place in the canister. Remove the four bolts and filter cover. 3. Check for leaks.PREVENTIVE MAINTENANCE SINGLE TENSION UNIT LUBRICATION Grease Zerks shown below: FILTER REPLACEMENT • Never attempt to perform maintenance or service unless the baler is shut down and Locked out/Tagged out (LOTO) in accordance with OSHA standards. 6.SECTION 3 . Bolt the filter cover in place. Remove the two filter elements and connector. Make sure there is no contamination inside the canister. Clean the inside of the filter canister thoroughly with a non flammable cleaning solvent and wipe dry. 1. 7. 3.PREVENTIVE MAINTENANCE SUCTION STRAINER REPLACEMENT Make sure the oil is cool before attempting to change the suction strainer. Check behind the platen. 4. 4. clean out if necessary. please contact your supervisor immediately. Reach down in the tank and use a pipe wrench to rotate the suction strainer counterclockwise. DAILY SCHEDULED MAINTENANCE 1. clean out if necessary. SERVICE INSPECTION AND CLEANING REQUIREMENTS Most maintenance procedures requires the machine to be properly Locked out/Tagged out (LOTO) in accordance with OSHA regulations. 3. Remove the access covers. Bolt the access covers in place and reseal with silicone sealant. Do not attempt to perform maintenance on the machine unless it is Locked out/ Tagged out (LOTO) according to OSHA standards. Inserter • • • • Check inserter bars for damage.SECTION 3 . Check inserter needles and rollers. Check cylinder and fittings for fluid leaks. make sure rollers move freely. 3-7 . 2. 2. Check inside inserter frame. If you have any questions regarding Lock out/Tag out (LOTO) procedures. Make sure no contamination gets into the oil through the opening. Clean the access cover and tank surface. 5. Check inserter drive assembly. Remove any foreign material from limit switches or cam bars. Remove the strainer and replace with a new one. 1. etc. Inspect baler floor for gouging or heavy abrasion.030 or 1/32” max . Power Unit • Check pumps. 3. 7. Compressed air used for cleaning and drying purposes must not exceed 30 psi. and hoses for fluid leaks. WEEKLY SCHEDULED MAINTENANCE 1. Use only with effective chip guarding and personal protective equipment (goggles/shield. Check platen cylinder rod for damage. Failure to comply may result in injury to personnel. • Make sure wire guide rollers are moving freely. 8. Check cylinder pins and bolts. Twister • Swing twister out. 4. 5. 4. 8. 3. Replace oil strainer. Twister gear box fluid level. 6. Check platen guide bar clearance. 2. Clean out fins on oil cooler using forced air. and abrasions.SECTION 3 . • Knife clearance . • Replace wear strips if knife clearance exceeds 3/16”. Clean off power unit using a broom and forced air. 7. • Check for material buildup. Take oil sample. 2. Baler work area • Sweep floor and clean area around baler. 3-8 . Bale Counter • Make sure counter wheel and switch are free to operate correctly. nicks. Check platen hold down adjustment. SEMI-ANNUAL SCHEDULED MAINTENANCE 1.shim as necessary.PREVENTIVE MAINTENANCE 5. Replace breather cap. inspect twister hooks for damage. 2. 3.015 to . fittings. 6.). Replace oil filter. Check platen wear strips by measuring. MONTHLY SCHEDULED MAINTENANCE 1. Clean off power unit using a broom and forced air. gloves. • Make sure the bale eject area is clean. valves. Inspect gear box fluid level. 4-1 . 1. Recheck the pressure setting. 5.SECTION 4 . 5. 2. Release the control and secure the lock nut.SERVICE ADJUSTMENTS BALERS WITH 20/30 HP POPPET MANIFOLD: UNLOADING/RELIEF VALVE PRESSURE ADJUSTMENT NOTE All pressure adjustments must be made by “RAISING” the pressure. MAIN RAM CYLINDER ROD RELEIF PRESSURE ADJUSTMENT NOTE All pressure adjustments must be made by “RAISING” the pressure. Locate the RVGA main ram cylinder rod relief valve. 7. push button and hold. Turn the adjusting screw DPBB clockwise until the pressure gauge (G-2) reaches the correct PSI as specified on the hydraulic schematic. Press the platen forward. It takes two people: one will operate the controls while the pressure is being adjusted. Retract the main ram and hold in the retract position. Turn the adjusting screw on DPBB counterclockwise until the pressure gauge (G-2) drops below 500 PSI. Release the platen forward push button and secure the locknut on DPBB adjusting screw. To adjust the pressure. 4. 3. 3. Rotate the adjusting screw on RVGA relief valve clockwise until the pressure gauge GB reaches the correct PSI as specified on the hydraulic schematic. Release the platen forward push button and secure the lock nut on the RVEA adjusting screw. Turn the adjusting screw RVEA clockwise until the pressure gauge (G-1) reaches the correct PSI as specified on the hydraulic schematic. Press the platen forward push button and hold. Start the pump motor using the correct start up procedure. 4. 1. Extreme caution must be used at all times. Set the baler in manual mode with pump motor running. Release the ram forward push button. Press the platen forward push button and hold. Release the platen forward push button. There needs to be direct communication between the two parties with a two way radio to reduce the risk of accidental injury. This procedure must be completed by trained service personnel only. 2. Recheck both pressure settings. Turn the adjusting screw on DPBB counter-clockwise until the pressure gauge (G-1) drops below 500 PSI. 6. and adjust if necessary. Loosen the lock nut on RBEA and DPBB. the motor must be running. Adjust if necessary. Loosen the locknut and rotate the adjusting screw counter-clockwise a few turns. Press the platen forward push button and hold. 2. 3. There needs to be direct communication between the two parties with a two way radio to reduce the risk of accidental injury. To adjust the tension pressure. 1. 4-2 . Remove the cover and loosen the lock nut on ZW-4 and RV-3. Extreme caution must be used at all times. Loosen the locking nut. locate the adjusting screw marked PBDB on the tension block. the machine must be running and there must be material in the baler.SECTION 4 . To adjust the pressure. The pressure gauge is located in the hydraulic line going into the port labeled T. rotate the adjusting screw counterclockwise. The platen bales against the material held in the bale exit by the tension cylinders.C. Press the platen forward push button and hold. (All locations are marked with a steel plate or etching) 3. the motor must be running. Set the baler in manual mode with pump motor running. Run the platen to the full forward position. BALERS WITH 40/50/75/100 HP POPPET MANIFOLD: UNLOADING/RELIEF VALVE PRESSURE ADJUSTMENT NOTE All pressure adjustments must be made by “RAISING” the pressure. 1. The procedure must be completed by trained service personnel only. It takes two people: one will operate the controls while the pressure is being adjusted. rotate the adjusting screw clockwise. NOTE To adjust the tension pressure. To decrease pressure. 2. Release the ram forward push buttons. The tension pressure will vary depending on the material being baled and the desired bale density. on the tension block. Turn the adjusting screw (RV-3) counterclockwise until the pressure gauge  (G-1) drops below 500 PSI.SERVICE ADJUSTMENTS TENSION BLOCK ADJUSTMENT The tension block controls the amount of pressure the tension cylinders apply to the bale. 4. To increase the pressure. Rotate the adjusting screw on the unloading valve counter-clockwise until pressure gauges GP-3 and GP-4 drop below 800 PSI. 6. then raise it back up to the pressure specified on the hydraulic schematic. Manually energize solenoid #3 to make sure the setting is correct. NOTE All pressure adjustments must be made by “RAISING” the pressure. 5. It takes two people: one will operate the controls while the pressure is being adjusted. Turn adjusting screw on 2W-4 clockwise until the pressure gauge (G-2) drops below 500 PSI. BALERS WITH 150/200 HP POPPET MANIFOLD: UNLOADING/RELIEF VALVE PRESSURE ADJUSTMENT NOTE All pressure adjustments must be made by “RAISING” the pressure. 1. the baler must be operational. 1. 2. Loosen the lock nut on Motor #1 System Relief.SERVICE ADJUSTMENTS 4. Press the platen forward push button and hold. Rotate the adjusting screw. Release solenoid #3 and wait for the pressure to drop. Release solenoid. Replace the adjusting screw cover. To make adjustments to the relief valve. 7. 4. The procedure must be completed by trained personnel only. Rotate the adjusting screw on LRV relief valve clockwise until pressure gauge OR1 on operator’s console reaches the correct PSI as specified on the hydraulic schematic. PLATEN CYLINDER ROD RELIEF WITH POPPET To adjust the pressure. Release the platen forward push button and secure the lock nut on RV-3 adjusting screw. Rotate the adjusting screw counter clockwise until pressure gauge TP-2 drops below 2400 PSI. Manually energize solenoid #2 to make sure the setting is correct. 4. Press the platen forward push button and hold. Manually energize solenoid #1. Start pump motor #1 using the correct start-up procedure. Turn the adjusting screw RV-3 clockwise until the pressure gauge (G-1) reaches the correct PSI as specified on the hydraulic schematic. Pressure gauges GP-3 and GP-4 should both read the pressure specified on the hydraulic schematic. The procedure must be completed by trained service personnel only.SECTION 4 . Secure the lock nut. Secure the lock nut. Release the ram forward push button and secure the locknut on the 2W-4 adjustment screw. Replace the adjusting screw cover. set the baler in manual mode. Manually energize solenoid #2. Extreme caution must be used at all times. Remove the cover on the adjusting screw on the unloading valve. LRV platen cylinder rod relief valve: remove cover and loosen lock nut. Release the platen forward push button. Loosen the lock nut manually. With both pump motors running. Remove the covers on the adjusting screws for motors #1 and #2 system relief valves. Energize solenoid #3. Loosen the lock nut on Motor #2 System Relief. 5. There needs to be direct communication between the two parties with a two way radio to reduce the risk of accidental injury. Retract the platen and hold in the retract position. Wait for pressure to drop. 3. 3. Extreme caution must be used at all time. Turn the adjusting screw on 2W-4 clockwise until the pressure gauge (G-2) reaches the correct PSI as specified on the hydraulic schematic. Release the control and secure the lock nut. Raise the pressure back up to the pressure specified on the hydraulic schematic. Raise the pressure back up to the pressure 4-3 . the motor must be running. 5. 2. Press the platen forward push button and hold. 6. rotate the adjusting screw counter clockwise until pressure gauge GP-2 drops below 2400 PSI. Replace the adjusting screw cover. Rotate the adjustment knob counter clockwise. 2. 3. Manually energize solenoid #1 to make sure the setting is correct. Secure the lock nut. Depress and hold the “PLATEN FORWARD” button. BALERS WITHOUT POPPET BLOCK: HYDRAULIC SYSTEM PRESSURE ADJUSTMENT NOTE On balers with two main pumps. 3. 4-4 . Rotate the adjustment knob clockwise. Motor #1 System Relief should be the pressure specified on the hydraulic schematic. Replace the adjusting screw cover. It will take two people to make the adjustment. Start pump motor #1 using the correct start-up procedure. 2. Secure the adjustment knob by tightening the lock nut. Replace the adjusting screw cover. 4. 7. Rotate the adjusting screw on 6 relief valve clockwise until pressure gauge GX-2 on operator’s console reaches the correct PSI as specified on the hydraulic schematic. 1. Release solenoid. PLATEN CYLINDER ROD RELIEF WITH POPPET 1. Rotate the adjusting screw. 8. 5. increasing the pressure to the pressure specified on the hydraulic schematic. 6. Retract the platen and hold the control lever in the retract position. All pressure adjustments must be made by “RAISING” the pressure as described in the hydraulic schematic. One to operate the controls and one to set the pressure. Wait for the pressure to drop. 4. reducing the pressure. 9. Place the baler in manual mode and move the platen to the full forward position. Loosen the lock nut under the adjustment knob.SECTION 4 .SERVICE ADJUSTMENTS specified on the hydraulic schematic. Observe relief valve pressure gauge. Replace all of the adjusting screw covers. the adjustment procedure must be completed on both pump relief valves. 10. Recheck the pressure setting by manually energizing the solenoid and reading the pressure gauge. #6 platen cylinder rod relief valve: remove cover and loosen the lock nut. Release the control and secure the lock nut. Install a pressure gauge in the test port as shown. Press and hold the “PLATEN FORWARD” button. 5. raising the bale tension cylinder pressure to the desired level between 250 and 800 PSI to achieve the proper bale weight. 4. NOTE All pressure adjustments must be made by “RAISING” the pressure. 2. 5. TENSION CYLINDER PRESSURE ADJUSTMENT NOTE The bale tension cylinder pressure is required to form the desired bale density and weight. 10. Rotate the adjusting knob clockwise. 6. reducing pressure to approximately 250 PSI. Place the baler in manual mode and move the platen to the full forward position. 4. Allow the baler to cycle and bale material. Observe the pressure gauge on the relief valve. Loosen the lock nut under the adjustment knob on the unloading valve. system pressure to the pressure specified on the hydraulic schematic as described in the HYDRAULIC SYSTEM PRESSURE ADJUSTMENT procedure. Return the hydraulic. Secure the adjustment knob by tightening the locking knob. 4-5 .SERVICE ADJUSTMENTS UNLOADING VALVE PRESSURE ADJUSTMENT 1. Rotate the adjustment knob on the unloading valve clockwise. 8. 7. 9. Place the baler in automatic mode. 2.SECTION 4 . To adjust the bale tension cylinder pressure: 1. 3. Set the hydraulic system pressure relief valve at 500 PSI as described in the HYDRAULIC SYSTEM PRESSURE ADJUSTMENT Procedure. increasing the pressure to the pressure specified on the hydraulic schematic. Rotate the adjustment knob counter clockwise reducing the unloading pressure. 3. Loosen the locking knob. 6. Rotate the adjustment knob counter clockwise. It will require a certain amount of experimentation to determine the proper pressure setting. Secure the adjustment knob by tightening the lock nut. As normal wear occurs during operation. Loosen the lock nut under the adjustment screw. NOTE All pressure adjustments must be made by “RAISING” the pressure. NOTE Make sure both bolts are adjusted equally. 4. PLATEN HOLD DOWN ADJUSTMENT The platen hold down is located on the back side of the feed hopper. Tighten lock nuts.SERVICE ADJUSTMENTS PILOT PRESSURE ADJUSTMENT 1. Secure the adjustment screw by tightening the lock nut. 5. 3. Maintaining correct adjustment of the hold down is necessary. Adjust the hold down so it makes contact with the top of the platen. Start up the baler using the proper procedure and observe the platen as it moves forward compacting material. damage will occur to the baler floor. Rotate the adjustment screw clockwise increasing the pressure to 100 PSI. If this happens. 2. Over tightening the hold down will cause excessive wear to the wearstrip and shorten its life. When this happens. 3. The hold down keeps the rear of the platen from pushing up during compaction. Loosen lock nut on the platen hold down adjustment bolts. Rotate the adjustment screw counter clockwise to reduce the pressure. and rotate the bolt an additional one half turn. 2. 1. adjustment of the hold down is required. 4. Turn the adjustment bolts clockwise to tighten the hold-down. preventing the front of the platen from pushing down.SECTION 4 . wear strips on the platen hold down gradually wear away. 4-6 . Observe the pilot pressure gauge. Cycle the baler in the automatic mode making certain the limit switch stops the platen at the correct position. LS-1 PLATEN RETRACT STOP LIMIT SWITCH ADJUSTMENT Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 5. Adjusting timing. Never attempt to make any adjustment unless the baler is Locked out/Tagged out (LOTO) in accordance with OSHA standards. it will be necessary to replace the platen hold down wear strip and possibly the platen wear strips to prevent machine damage. Rotate the shaft and retighten screw. This indicates the switch is activated. Retract the platen so the front of the platen is flush with the rear edge of the feed hopper. Length of the actuator arm Loosen the socket head capscrew that holds the arm shaft clamp. so that only the wheel at the end of the arm comes in contact with the trip mechanism. 3. 1. 4-7 . Hold the arm shaft in the activated position and tighten the arm shaft setscrew. Determine which direction the switch should be adjusted. 1. Loosen the setscrew on the actuator arm and position the actuator on the cam as shown. Shut the baler down. Tighten the arm length setscrew. Insert a screwdriver in the slot on the arm shaft. If the bolts are fully tightened down and the platen continues to push up. Rotate the shaft until the switch clicks. (see illustration). 2. Retighten setscrews.SECTION 4 . Loosen the shaft clamp screw. 4. This minimizes any unnecessary wear to the actuator arm. Lengthen or shorten as necessary. 6. LIMIT SWITCHES NOTE Adjustments need to be made to the Limit Switch after installation is complete.SERVICE ADJUSTMENTS NOTE If the rear of the platen pushes up. the hold down needs to be tightened more. Place the baler in the manual mode. 2. Extend the platen to the full forward position which is the full length of the cylinder rod. 4-8 . Place the baler in manual mode. Tighten the arm length setscrew. Insert a screwdriver in the slot on the arm shaft. 4. Shut the baler down. LS-2 is used to stop the platen and reverse its direction in the automatic baling mode. 2. Loosen the actuator arm setscrews on the cam as shown.SERVICE ADJUSTMENTS LS-2 PLATEN FORWARD STOP LIMIT SWITCH ADJUSTMENT NOTE The platen full forward limit must be set prior to setting the platen forward stop limit. Retract the inserter until the rear of the inserter is approximately 1/8” from the stop block on the inserter frame as shown. LS-4/LS-5 INSERTER RETRACT STOP LIMIT SWITCH ADJUSTMENT 1. Observe the platen to make sure the LS-2 is functioning correctly. Hold the arm shaft in the activated position and tighten the arm shaft setscrew. 3. Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. NOTE This adjustment is the same for both PRX-3 /PRX-3A limit switches. 1. Rotate the shaft until the switch clicks. 2.SECTION 4 . This indicates the switch is activated. PRX3/PRX-3A PLATEN FULL FORWARD LIMIT SWITCH ADJUSTMENT 1. Place the “wire tie selector switch” in the manual position. Place the baler in automatic mode and cycle. Measure 4” between the full forward cam and the platen forward stop cam. Shut the baler down. Loosen the setscrew on the adjustable cam. Tighten the setscrew. SERVICE ADJUSTMENTS NOTE This adjustment is the same for both LS-4 and LS-5 Limit Switches. Place the “wire tie Selector Switch” in the manual position. 2. Manually cycle the Auto-Tie. 4.SECTION 4 . Insert a screwdriver in the slot on the arm shaft and rotate the shaft until the switch clicks. ensuring all wires are cut and twisted correctly. The back of the slot on the inserter needle should be 1/8” from the wire cutter bar as shown. Tighten the arm length setscrew. Loosen the setscrew on the actuator arm and position the actuator on the cam as shown. 3. Position the inserter into the twister mechanism. This indicates the switch is activated. 5. This indicates the switch is activated. Insert a screwdriver in the slot on the arm shaft rotate the shaft until the switch clicks. 4-9 . Tighten arm length setscrew. LS-6 INSERTER FORWARD STOP LIMIT SWITCH ADJUSTMENT 1. Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 2. 6. Hold the arm shaft in the activated position and tighten the arm shaft setscrew. 5. Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Retract the inserter and load wire into the autotie unit. Manually cycle the inserter make certain the rear of the inserter does not come in contact with the stop block. Loosen the setscrew on the actuator arm and position the actuator on the cam as shown. Hold the arm shaft in the activated position and tighten the arm shaft setscrew. 4. 3. 2. release the twister forward button. 4. press the Emergency Stop Button.SECTION 4 . 4-10 . Position the twister hooks in a vertical position. additional adjustment of the cam is needed.SERVICE ADJUSTMENTS NOTE In order to position the twister hook before releasing the twister forward button. 3. Loosen the setscrews on the limit switch and position the arm as shown. LS-7 TWISTER HOME LIMIT SWITCH 1. NOTE If the twister hooks are not in a vertical position with twister home light on. Loosen the setscrew on the cam and position the cam as shown. When the twister home light goes off. Check the twister hooks to make certain they are in the vertical position. Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Tighten the setscrews. 5. Place the wire tie selector switch on manual using the twister forward button. Pull out emergency stop button and start the baler. Press the twister forward button. The twister should return to the home position and the twister home light should come on. and observe the twister home light. Tighten the setscrew. SERVICE ADJUSTMENTS HOPPER DOOR SAFETY INTERLOCK SWITCH ADJUSTMENT There should be a small space (between 3/16” and 1/4”) between the switch components. the baler will not run. the twister hooks can be manually moved to the desired position before making the cam and limit switch adjustment. Loosen the set screws and adjust as necessary. NOTE If the interlock switch components are not properly spaced.SECTION 4 . The proximity switch should be adjusted to 1/8” from the teeth on the sprocket. LS-8 BALE LENGTH STAR WHEEL PROXIMITY SWITCH ADJUSTMENT Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. NOTE There is a brake release on the twister drive motor. 4-11 . By releasing the brake. either too close or too far apart. Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. To increase tension. Start the baler and swing the twister unit away from the baler. By releasing the brake. there needs to be light tension on the spool.SERVICE ADJUSTMENTS LS-T TWISTER SAFETY INTERLOCK SWITCH There should be a small space (between 3/16” and 1/4”) between the switch components. . Different wire types require different amounts of tension to feed correctly. NOTE If the interlock switch components are not properly spaced.SECTION 4 . the baler will not run. For the wire to feed correctly. the twister hooks can be manually moved to the desired position before making the cam and limit switch adjustment. TWISTER MOTOR BRAKE ADJUSTMENT NOTE There is a brake release on the twister drive motor. 4-12 In the center of each wire spool is a spring loaded adjustment. Loosen the set screws and adjust as necessary. WIRE TENSION ADJUSTMENT Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. either too close or too far apart. The machine should shutdown. turn the adjustment nut clockwise. 2.030 to1/32” maximum.SECTION 4 . Rotate the bolts counter clockwise several turns. Determine the space needed to make the correct clearance. Shim NOTE 3. NOTE It may be necessary to apply heat to the bolts to break them loose. position the knife on the main ram directly under the knife on the frame. To check the knife clearance.SERVICE ADJUSTMENTS NOTE The correct knife clearance is . Never attempt to make an adjustment unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Use the correct wrench and.030 or 1/32” maximum. adjustment is necessary. 1.1.015 to . you may need to weld a nut to the bolt head for ease of removal. Measure the space between the knife edge on both ends and in the center. Loosen the bolts which hold the knife to the frame. when necessary. Insert the correct shims between the knife and baler frame. an extended leverage bar to break the seat on the bolt. Check Clearance 4-13 . The bolts should be replaced with grade 8 bolts to prevent fatigue failure after being heated. Tighten all knife bolts and check the knife clearance. Loosen the bolts which hold the knife to the frame. On bolts with damaged heads. If the space exceeds . Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 4. Fully retract the platen and shut the baler down. Remove the four bolts which hold the platen hold down assembly to the frame. Place the block between the face of the platen and the bale and slowly push the bales out of the baler. Connect a chain or cable to the platen and slowly pull it out of the baler. Make sure there is proper blocking at the bale exit so the platen does not drop when it clears the baler. 12. On newer models. unplug the OIT and disconnect the ram position transducer by unscrewing the connector on the end of the tube. With the baler in the manual mode. 3. Support the cylinder by blocking with a forklift or suitable lifting device. 14. b. 5. Remove the pilot operated check valve on the rear of the cylinder.SERVICE AND REPAIR PLATEN AND CYLINDER REMOVAL 1. 6. NOTE It may be necessary to place a hydraulic jack between the baler sides to allow removal. Disconnect the hydraulic lines and plug the parts and cap hoses to prevent fluid loss and contamination. Plug the parts on both valve and cylinder to prevent contamination. 11. 10. Remove the locking bolt and cylinder pin connecting the rear of the cylinder to the baler frame. Remove the safety guards from the top and sides of the baler. Use a jack or a come-along to force the bale eject side tension tubes out. Remove the platen limit switch cams by unbolting them from the platen. 5-1 . a. 2. Remove the locking bolt and cylinder pin which connects the cylinder rod to the platen to remove the cylinder.SECTION 5 . Weld an eye on the front of the platen. 16. 7. The rear mounting bracket must also be unbolted. 15. Secure them to the baler frame with a clamp or chain. Use a hydraulic jack to support the rear of the cylinder. Clean out the inside of the baler and bale eject area. use a suitable blocking material such as large wood beams. 8. Make sure there is no pressure on the fluid going into either end of the platen cylinder. Make sure there are no flammable materials inside the baler. 13. Release all of the pressure on the side tension cylinders. Rotate the adjustment knob counterclockwise reducing the pressure to 0 PSI. Loosen the locking knob on the control valve. 9. Fully extend the platen and shut the baler down. NOTE Not all models are equipped with a pilot operated check valve. Using the procedures outlined in the adjustment section. Install the pilot operated check valve and reconnect the hydraulic lines. 5. 12. 7. Use a hydraulic jack to support the rear of the cylinder. LS-2/LS-3 platen full forward limit switches (2). Turn the adjustment bolts clockwise to tighten the hold down.SERVICE AND REPAIR 17. NOTE It will be necessary to use an extension on the forks or blocking material to push the platen back into position. Platen retract stop limit switch. adjust the following components: a. c. On newer models. Install the ram position transducer rear mounting bracket. Bolt the platen limit switch cams to the platen. Line up the holes and install the cylinder pin and locking bolt which connect the rear of the cylinder to the baler frame. reconnect the OIT and ram position transducer. e. 10. Carefully line up the platen. Make sure they are correctly replaced in their original position. NOTE It may be necessary to place a hydraulic jack between the sides to allow installation. Start up the baler. Install the hold down assembly in the baler. Line up the holes and install the cylinder pin and locking bolt which connect the cylinder rod to the platen. 6. d. Ensure all hoses are connected to their original locations. 3. and bolt it to the baler frame. LS-2 platen forward stop limit switch. Platen hold down. 8. Loosen the lock nuts and turn the adjustment bolts counter clockwise. 9. Replace the safety guards on the top and sides of the baler. NOTE It is recommended that new o-rings be installed where applicable. 2. Use a forklift or suitable device to lower the cylinder into position.SECTION 5 . Make sure the bale eject side tension tubes are forced out against the side of the baler. Ensure all of the adjustment is taken out of the hold down. Set the platen in a vertical position on the face. Carefully lower the platen back down to a horizontal position. 13. b. NOTE Make sure both bolts are adjusted equally. Slowly push the platen back into the baler. Remove the clamps or chains holding the bale eject side tension tubes against the baler frame. Remove the lifting eye from the front of the platen. Bale tension cylinder pressure. 4. 11. 5-2 . PLATEN AND CYLINDER INSTALLATION 1. Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 5-3 . 6. Using the old liner as a guide. Install the new liner. Remove the four bolts which hold the platen hold down assembly to the frame. PLATEN GUIDE BAR REPLACEMENT 1. 11. 9. compacting material. Start up the baler using the correct procedure. NOTE It may be necessary to place a hydraulic jack between the sides to allow installation. 3. 4. Remove the safety guards from the top and both sides of the baler. Rotate each bolt an additional one half turn. Fully extend the platen and shut the baler down. 10. Tighten the adjustment bolt lock nuts. Adjust the hold down so it makes contact with the top of the platen. 12. Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. NOTE Make sure both bolts are adjusted equally. Loosen the lock nuts and turn the adjustment bolts counterclockwise. 7. 5. the hold down needs to be tightened more. Make sure all of the adjustment is taken out of the hold down. 13. Replace the safety guards on the top of the baler. NOTE It may be necessary to place a hydraulic jack between the sides to allow removal. NOTE If the rear of the platen pushes up. It is recommended that new bolts be used. Fully extend the platen and shut the baler down. Remove the old liner. drill and counter-sink the replacement liner. Remove the top safety guards. 3. 2.SECTION 5 . Install the hold down assembly in the baler and bolt it to the baler frame. Unbolt the platen hold down assembly and remove it from the baler.SERVICE AND REPAIR PLATEN HOLD DOWN LINER REPLACEMENT 1. Cycle the platen and observe the platen as it moves forward. 8. 2. Remove the countersunk bolts which hold the wear liner in place. Turn the adjustment bolts clockwise to tighten the hold down. Refer to platen and cylinder installation section. 7. 8. Replace any worn or damaged bolts. Remove the platen from the baler. Install the new guide bars. Install all of the wear strips using new bolts. 2.SECTION 5 .SERVICE AND REPAIR NOTE It may be necessary to place a hydraulic jack between the baler sides to allow removal of the platen hold down assembly. NOTE There are two wear strips on the top of the platen. Remove the platen as outlined in Platen and Cylinder Removal. Thoroughly clean the platen and inspect it for structural damage. Refer to platen hold down adjustment. 3. and an upper and lower wear strip on each side. PLATEN WELDED WEARSTRIP LINER REPLACEMENT 1. PLATEN WEARSTRIP REPLACEMENT 1. guide bars. Use a cutting torch or air arc to remove all welds. Adjust if necessary. 5. 8. Manually extend and retract the platen. Use care not to damage during removal. Remove the bolts which hold the guide bars to the side of the baler frame. Inspect the inside of the baler. 7. Check for proper adjustment and operation. 6. Using a grinder. 3. Replace worn parts and repair as necessary. and baler floor for structural damage. 2. 5. NOTE It may be necessary to place a hydraulic jack between the baler sides to allow replacement of the platen hold down. Replace the platen hold down assembly. 6. Start at one end of the liner. Install the platen. drill and countersink the replacement parts. If the cylinder is not removed. Refer to the platen and cylinder removal section. polish the liner surface to locate plug welds. Set the platen upright on the face to gain access to all wear strips. 4. support the assembly so it cannot fall over. hold down liner. 4. The bottom may be in three parts or one solid strip. Remove the old wear strips. platen. Using the old wear strips as a guide. Use care when cutting so the platen structure is not damaged. NOTE The guide bars extend into the bale chamber. 5-4 . Replace the shear knife if necessary. causing major problems for the liner replacement process. Replace the safety guards on the top and both sides of the baler. It will be necessary to strike the hot weld area with a heavy hammer to properly seat the wear strip at the welded point. 8. The smaller size cylinder does not have a seal retainer to remove. o-rings and rod wiper. Remove any surface scars that could cause damage to the head gland during removal. cutting scars. replace the o-ring with a new one before replacing the piston. remove it from the rod by rotating it counter clockwise. 2. unbolt the rod seal retainer to remove the rod seal. On the larger size cylinders. 9. 6. Replace the seal retainer and tighten all bolts (when applicable). 5-5 . 10. Check the cylinder rod for nicks. NOTE All welding should be completed by a certified welder in accordance with AWS standards. Place a bar through the cylinder rod pin hole and use a spanner wrench to unscrew it. 14. Block the piston rod so it cannot drop causing damage when head gland is removed. Unbolt the rod seal retainer (when applicable). Carefully slide the piston and rod assembly back into the cylinder tube. Start at the center plug hole. If the piston is removed from the rod. 15. and remaining welds. Remove the piston seals and wearband from the piston. Tack weld one edge of the wear strip liner in place after it is correctly positioned on the platen. 5. Use a spanner wrench and unscrew the head gland from the cylinder tube. Slide the head gland off of the cylinder rod. Apply a light coat of hydraulic fluid to the components. Remove any surface scars which could cause damage. and scratches. Inspect the cylinder tube and piston for scoring or damage.SECTION 5 . It is important to make certain the liner mates the surface of the machine correctly. scratches. 5. Block the cylinder rod so the rod and piston doesn’t drop causing damage when it clears the tube. It may be necessary to build up an area where damage has occurred. Slide the head gland onto the cylinder rod and tighten with the spanner wrench. 13. and burrs. burrs. 6. Inspect the piston rod for scoring. Make sure all surfaces are smooth and square. and inspect the head gland for damage. 7. ensuring they are correctly installed so they will properly seal. 11. Remove all seals. Refer to platen and cylinder removal. 7. Remove the cylinder from the baler. If the piston needs to be replaced. 12. 4. NOTE There are two cylinder styles depending on bore size. Install the new wear band. CYLINDER REPAIR 1. 3.SERVICE AND REPAIR 4. o-rings. Check all platen structure surfaces for damage. Make sure each wear strip is flat and square after it is welded. nicks. Use a suitable lifting device to secure the tube end of the cylinder and pull the piston rod and piston out of the cylinder tube. Install a new wear band and piston seals. wear band. Apply a light coat of hydraulic fluid to the components. Work to the edges. 4. Remove the upper and lower locking pins and swing the twister unit out away from the baler. Make sure the inserter is fully retracted. 6. each located on a separate drive shaft in two rows. Replace the upper and lower locking pins. Make sure they are replaced in their original position. 7. Tighten and check all allen head setscrews. 5-6 Unbolt and remove the top twister guard. Bolt the replacement cutting knife blade in place. 9. Loosen the allen head setscrews. Bolt the top twister safety guard in place. 4. There are ten twister hooks. 5.SERVICE AND REPAIR TWISTER HOOK REPLACEMENT 1. 8. 5.SECTION 5 . 3. Make sure the inserter is fully retracted and shut the baler down. 6. Loosen the allen head set screws and remove all ten twister hooks. Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. TWISTER KNIFE REPLACEMENT 1. 2. Tighten and recheck all allen head setscrews. Bolt the inside cover plates to the twister frame. 11. Install the twister hooks. 2. Swing the twister unit into position against the baler and replace the upper and lower locking pins. Remove the upper and lower locking pins and swing the twister unit out away from the baler. Swing the twister unit into position against the baler. 13. Shut down the baler. Bolt the top twister safety guard in place. NOTE Five hooks on one row point up and five hooks on the other side point down. Unbolt and remove the inside cover plates to expose the twister knife mechanism. 12. Remove the two bolts which hold the cutting knife blade in position. Bolt the replacement stationary knife to the twister frame. . Install the new twister hooks so they point in the same direction as the ones which were removed. 7. Remove the nut and counter-sunk bolt which holds the stationary knife to the twister frame. This provides access to all five twister knives. Unbolt and remove the top twister safety guard. 3. 8. Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 10. 9. Loosen the allen head setscrews and remove the sprocket and key. 5. Remove the grease zerks. Install and tighten the countersunk bolt. Remove and replace the roller. 3. INSERTER NEEDLE AND GUIDE ROLLER REPLACEMENT Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 7. 3. Unbolt and remove the inside cover plates. Replace the twister hooks so they point in the same direction as when they were removed. This provides access to the drive shaft assemblies. If the bolt extends below the needle. Close the twister drive cover and replace the retaining bolt. 17. Remove the connecting link and drive chains from the twister drive shaft assembly. Remove the safety guards on the inserter frame. 14. 1. Install the grease zerks on the replacement bearing assembly. NOTE When new bolts are installed. Loosen the allen head set screw and remove the ten twister hooks. 16. Replace the upper and lower locking pins. cut or grind off the excess bolt. 4. Replace the safety guard on the inserter frame. 2. Bolt the top twister guard in place. 4. and tighten the setscrews. Swing the twister unit into position against the baler. make sure the bolt does not extend below the needle. Bolt the replacement bearing and drive shaft assembly to the twister frame. 6. Replace the inside covers in place on the twister frame. Remove the upper and lower locking pins and swing the twister unit out away from the baler. 12. Loosen the setscrews and remove the two set collars. Use an allen wrench to remove the countersunk bolt. 10. Unbolt and remove the top twister guard. 1. 5-7 . Remove the retaining bolt on the twister drive cover. 2. Install the two set collars on the replacement bearing assembly. 18. Replace the drive chains and connector links.SERVICE AND REPAIR TWISTER DRIVE SHAFT REPLACEMENT Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 13. Remove the four bolts which hold the drive shaft assembly to the twister frame. 8. 20. Install the drive sprocket and key on the drive shaft. Line up all of the sprockets. 19. Tighten and check all allen head setscrews. 15.SECTION 5 . 11. 3. 4. 5. WIRE DIE REPLACEMENT Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Install new die. Remove the safety guards from the inserter frame. Bolt the new needle in place. Remove the four bolts which hold the inserter needle in place on the needle carrier. 2. 1. 2. Remove the nut and bolt which hold the roller in place. INSERTER ROLLER REPLACEMENT Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. Remove the lock collar and die. If the bolt is worn. Install the new roller and bolt.SERVICE AND REPAIR INSERTER NEEDLE REPLACEMENT Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. replace it with a new one. 5. Replace the safety guards on inserter frame. Loosen the setscrews which hold the lock collar in place. 1. Make sure the platen is correctly positioned and manually move the inserter mechanism forward. . Replace lock collar and tighten setscrews. 3. Check to be sure the new needle is properly aligned and operates correctly. 1. 5-8 Remove the wire from the die.SECTION 5 . 2. Rethread wire through the die. 4. Start up the baler. SECTION 5 . ROUND PATTERN SEQUENCE 5-9 .SERVICE AND REPAIR PROCEDURE FOR TIGHTENING SCREWS The following method should be used for tightening screws in order to obtain maximum clamping force. minimum added stress from external loading. and an infinite number of cyclic loadings. maximum torque value. maximum fatigue resistance. SERVICE AND REPAIR TORQUE CHART 5-10 .SECTION 5 . there is power to the function described. make sure all safety precautions are taken. such as solenoid valves. to the controller. The method used in blocking the rod will be different. If the pressure reading was low and the cylinder has internal leakage. indicator lights. 5. Input lights indicate electrical power from sensing devices on the machine.D. 3. In the event that all checks are made and the problem cannot be corrected.SECTION 6 .) Never attempt to perform service or repairs unless the baler is Locked out/ Tagged out (LOTO) in accordance with OSHA standards. 6-1 . Place the baler in manual mode. If the light is not on. Do not attempt to enter the baler or make any adjustments unless the baler is Locked out/Tagged out (LOTO) in accordance with OSHA standards. If the pressure gauge reading is considerably less than the specified operating pressure of the baler. ELECTRIC SOLENOID VALVE To manually energize the solenoid valve. L. but they all have a pin located in the end of the solenoid. Each light is identified by a slot position and row number (example: slot 2. When a light is illuminated. 2.TROUBLESHOOTING This section contains an outline for assisting service personnel in isolating the cause when a baler develops a problem. A brief corrective action is given to assist in correcting the situation. Before attempting to take any corrective action. internal leakage is possible.E. NOTE Solenoid valves have different shapes. Block the piston rod to prevent it from moving forward. 4. etc. 1. TEST FOR INTERNAL LEAKAGE OF CYLINDER NOTE This test applies to all cylinders. there is no power flow. Extend the piston rod to approximately 1/2 of the rod travel distance and shut the baler down. INDICATOR LIGHTS These lights are used to trouble shoot the Electrical Control System. etc. This can be done by blocking between the ram head and the baler wall. The problem is listed along with a list of possible causes. there will be a rushing or spraying sound (like a water fall) caused by oil escaping past the packing ring (or piston seals on smaller cylinders. number 2-4). such as limit switches. use a welding rod or small screwdriver and depress the pin located on the end of the solenoid. Press the Platen Forward Push Button and hold. pressure switches. contact the Harris Service Department at 1-800-447-3526. Output lights indicate electrical power from the controller to activating or indicating devices. Pressure relief set to low or defective. Cylinder bypass. Check twister unit. Check main power switch. 2. 1. Pull button out. E. 6-2 . Repair or replace pump. 1. No incoming power. 1. Safety interlock switch. Oil level low in reservoir. Maximum Hydraulic Pressure Not Obtained Possible Cause Corrective Action A. Reset pressure if necessary. Reset overload on motor starter. 2. B. Worn pump. Motor overload tripped. 3. Air leakage in oil intake. Solenoid valve leaking. Check hopper door. Check valve on unloading valve. Check for internal cylinder leakage. 1. Perform electrical system continuity check. 2. 1. 1. (Requires qualified electrician). Repair or replace pump. 1. 1. Check suction tube for broken seal. Check oil fluid level. Electrical circuit malfunction. 2. 1. D. 1. 1. Repair or replace.SECTION 6 . 1. D. Emergency stop button depressed. Check baler manual input in “Panel View Screens”. Replace if necessary. 3. Pump shaft seal. 3. Repair or replace. E.TROUBLESHOOTING Main Motor(s) Will Not Start Possible Cause Corrective Action A. add if necessary. Worn pump. 2. C. C. Pump Noise Possible Cause Corrective Action A. Check vacuum indicator located on oil filter. B. C. Check current load (AMPS). 1. Check relief valve for correct pressure setting (2200 PSI). B. Check drive motor manual input in “Panel View Screens”. D. the problems should be in solenoid or the electrical circuit. Check for internal cylinder leakage. 1. (Manually shift solenoid as a starting point to locate malfunction. Make sure inserter is fully retracted. Refer to I:0/1 photo eye manual. G. 2. B. Cylinder bypass. 3. Check electrical and hydraulic schematics. Perform electrical circuit continuity check. See if cylinder rod is retracting. 1. Make sure inserter is fully retracted. Platen Will Not Retract Possible Cause Corrective Action A. Pilot operated check valve malfunction. 2. C. Move selector switch to auto. H. 1. B. F. 1. Cylinder bypass. Valve spool not moving. I. Wire tie selector switch on manual. Electrical circuit malfunction. Check for internal cylinder leakage. Photo cell malfunction (Auto Mode). Check pilot pressure to valve. 1. Photo cell malfunction (Auto Mode). 1. 2. 1. 1. LS-2 limit switch malfunction. LS-1 Limit switch malfunction. Replace cylinder pin. 3. Check input I:0/4. Perform continuity check on limit switch. Cylinder rod pin missing. 1. 1. Insufficient pilot pressure. NOTE Set baler on manual mode. Insufficient pilot pressure.SECTION 6 . D. the problems should be in solenoid or the electrical circuit. 1. See if material is causing a false signal. NOTE Set baler on manual mode. 1. (Requires qualified electrician) E.TROUBLESHOOTING Platen Will Not Move Forward Possible Cause Corrective Action A. Check input I:0/3. Electrical circuit malfunction. C. (Requires qualified electrician) E. 6-3 .) If the manually shifted solenoid activates the function. 2. 2.) If the manually shifted solenoid activates the function. (Manually shift solenoid as a starting point to locate malfunction. Refer to I:0/1 photo eye manual. Outputs vary by machine. 1. 1. Perform electrical circuit continuity check. Inserter out of position. Solenoid valve malfunction. F. Perform continuity check on limit switch. Solenoid valve malfunction. Valve spool not moving. Inserter out of position. See if material is causing a false signal. 3. adjust if necessary. Refer to sensor unit manual for troubleshooting procedure. Check limit switch for proper adjustments. Perform continuity check on limit switch. 3. Check pressure gauge on relief valve. Inserter motor malfunction. 2. Excessive dirt build up on sensor unit.SECTION 6 . Inspect and clean sensor unit inside feed hopper. Look inside hopper. Sensor unit malfunction. 5. Check for material causing false signal. Modular control valve malfunction. 1. 1. 2. (Requires qualified electrician) . B. Check input I:1. Inserter Will Not Go Forward Possible Cause Corrective Action A. Machine False Cycles In Auto Mode Possible Cause Corrective Action A. Jam at shear knife. Check pressure gauge on relief valve. PRX-3-PRX-3A Limit switch malfunction. 1. D. Perform continuity check on limit switch. Check for proper adjustments. 1. Check coupler between motor and gear reducer. 6-4 Motor fuse blown. C. B.0/5 & I:2/11. Motor starter malfunction. 2. 4. Check input I:0/1. B. Gear reducer coupler loose. Material blocking sensor unit. Perform continuity check on limit switch. 3. Motor overload tripped (reset if necessary) Motor burned out. 1. 1. 1. Check output O:0/5. C. Bale tension pressure too high. E. Refer to unjamming procedure in this manual if there is a jam. 1. 2. Check input I:0/8. Check input I:0/9. LS-7 Limit switch malfunction. 1. 1. 3. 1. C.TROUBLESHOOTING Bale Will Not Eject Possible Cause Corrective Action A. 2. Low system pressure. LS-6 Limit switch malfunction. adjust if necessary. Continued Possible Cause Corrective Action F. Check oil level. Check cutting edges. 2. 1. 3. Electrical circuit malfunction. Improper wire tension. 2. 1. Improper inserter adjustment. Check for proper adjustment. B. 1. C. Check output O:4/0. Check drive sprockets and chain. Twister hooks out of position. Check knife operating mechanism. 3. 2. Perform continuity check on limit switch. Drive chain loose. Make sure wire spools are not tight. 3. Wire cut valve malfunction. Check valve solenoid. D.SECTION 6 . Drive mechanism malfunction. Improper Tie Possible Cause Corrective Action A. 1. C. Check cylinder for bypass. 2. Wire Will Not Cut Possible Cause Corrective Action A. G. Cylinder does not operate. I. (Requires qualified electrician). 1. 2. Adjust cam on LS-7 limit switch. 1. Check cylinder pins. Bent or damaged needle. Too many twist on wire. B. 4. 1. Gear reducer malfunction. Check input I:0/8. 2. Needles improperly aligned. 1. 1. 1. 2. 1. LS-6 Limit switch malfunction. Make sure wire is threaded correctly. E. 6-5 . Make sure gear reducer output shaft will rotate.TROUBLESHOOTING Inserter Will Not Go Forward . Knives do not operate correctly. 5. Perform continuity check on electrical circuit. H. Needles not going forward far enough. Check limit switch adjustment. Check drive sprockets and chain. 1. 3. Check drive sprocket on gear reducer. Check idler sprocket. Make sure spool moves. Check pressure to cylinder. Perform continuity check on electrical circuit. D. C. LS-4/LS-5 Limit switch malfunction. Defective motor starter. Check limit switch for proper adjustment. Defective motor starter. 1. Reset if necessary. Inserter Will Not Retract Possible Cause Corrective Action A. PRX-3/PRX. E. Perform continuity check on limit switch. Wire not cut. I. 3.TROUBLESHOOTING NOTE If the auto-tie does not operate in the automatic mode. Motor starter malfunction. LS-6 Limit switch malfunction. 1. Check inputs I:0/5 & I:2/11. 1. Check inputs I:0/9. 3. B. if necessary. H. check the LS-8 star wheel bale counter. Repair or replace. 2. 1. Check for material causing false signal. Check and replace. 1. 1. Reset overload switch. Motor overload tripped. Drive reducer malfunction. 2. 1. 1. Check limit switch for proper adjustment. 3. C.SECTION 6 . Motor burned out. 4. LS-7 Limit switch malfunction. . Check inputs I:0/6 & I:0/7. Perform continuity check on limit switch.3A Limit switch malfunction. Electrical circuit malfunction. Check for proper adjustment. Check coupler between motor and gear reducer. 2. 1. Perform continuity check on limit switch. Adjust cam on LS-7 switch. B. Check wire cutting mechanism. Check output O:0/8. (Requires qualified electrician) F. Check motor starter. Twister Will Not Reverse Possible Cause Corrective Action A. Check drive sprocket on gear reducer. 1. Perform continuity check on limit switch. D. 3. 2. Inserter motor malfunction. 2. Twister hook out of position. Check and repair. if necessary. 1. Defective motor. 2. (Requires qualified electrician) E. Check idler sprocket. F. 1. 1. 1. Damaged twister hook. 6-6 Motor fuse blown. 1. G. Gear reducer coupler loose. 2. Motor overload tripped. Make sure it is adjusted and operating correctly. Make sure gear reducer output shaft will rotate. 1.0/06. 2. Perform continuity check on electrical circuit.8. 6-7 . Electrical circuit malfunction. Gear reducer malfunction. Check output O.TROUBLESHOOTING G. 1. Check oil level. 2.SECTION 6 . H. COMPLIANCE WITH THIS PROGRAM All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout.147 App A Regulations (Standards . All employees.1910. shall understand the hazards of the energy. and Locked out/ Tagged out (LOTO) before employees perform any servicing or maintenance where the unexpected energization or start-up of the machine or equipment or release of stored energy could cause injury. upon observing a machine or piece of equipment which is Locked out/Tagged out (LOTO) to perform servicing or maintenance shall not attempt to start. A-1 . Table 1: Name(s)/Job Title(s) of affected employees and how to notify Name Job Title How to Notify 1. It shall be used to ensure that the machine or equipment is stopped.Appendix A TYPICAL OSHA LOCKOUT/TAGOUT (LOTO) PROCEDURES OSHA . SEQUENCE OF LOCKOUT Notify all affected employees that servicing or maintenance is required on a machine or equipment and that the machine or equipment must be shut down and Locked out/Tagged out (LOTO) to perform the servicing or maintenance. energize. The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the machine or equipment utilizes. or use that machine or equipment. The authorized employees are required to perform the lockout in accordance with this procedure. and shall know the methods to control the energy. isolated from all potentially hazardous energy sources.29 CFR) PURPOSE This procedure establishes minimum requirements for the lockout of energy isolating devices before maintenance or servicing is performed on machines or equipment. Type of Controls Push button and switches Location of Controls Operator control panel 3. Table 4: Type(s) and location(s) of energy isolating devices Types of Energy Isolating Devices Locations of Energy Isolating Devices Control power key switches Operator control panel and main control panel.). Lockout the energy isolating device(s) with assigned individual lock(s). close valve. A-2 . etc. Type and Magnitude Hazards Methods to Control Electricity. shut it down using the normal stopping procedure (depress the stop button. 480V Power Circuit Electric shock Disconnect main power source Electricity. its hazards and the methods to control the energy.Table 2: Type(s) and magnitude(s) of energy. open switch. Deactivate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s). 110V Control Circuit Electric shock Disconnect main power source 2. Main power disconnect switch Main power panel 4. If the machine or equipment is operating. Table 3: Type(s) and location(s) of machine or equipment operating controls. etc. hydraulic systems. Return operating control(s) to neutral or "off" position after verifying the isolation of the equipment. blocking. or water pressure. repositioning. springs. 7. elevated machine members. The machine or equipment is now locked out. rotating flywheels. If baler fails to start up.methods to dissipate or restrain. bleeding down. then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. the baler has been successfully isolated.5. and air. A-3 . gas. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed. Table 6: Method of verifying the isolation of the equipment. Type of Stored Energy Residual hydraulic system pressure Method to dissipate or restrain Vent hydraulic fluid to tank (only required when servicing hydraulic system) 6.) must be dissipated or restrained by methods such as grounding. Method of verifying the isolation of the equipment Attempt to start baler by following start up procedure. steam. Table 5: Type(s) of stored energy . etc. Stored or residual energy (such as that in capacitors. 13. Note: The removal of some forms of blocking may require reenergization of the machine before safe removal. 5. Check the work area to ensure that all employees have been safely positioned or removed from the area. Verify that the controls are in neutral. 17. 20. Feb. Sept. 3. [54 FR 36687. 61 FR 5507. 1. Remove the lockout devices and reenergize the machine or equipment. Oct. 1990. 1. 1989 as amended at 54 FR 42498. Check the machine or equipment and the immediate area around the machine to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact. the following steps shall be taken. 55 FR 38685. 1996] A-4 . 2. Sept. Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for used. 1989. 4.RESTORING EQUIPMENT TO SERVICE When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition. Completely clean inside of reservoir with non-flammable compatible cleaning solvent. Make certain all surfaces are clean and dry  Inspect the inside of the tank for cleaning materials left behind  Install new O-ring seals on each cover and bolt covers in their original position  Check pump pressure    Check pump mount bolts    Check clean limit switch/proximity switch/lasers    Check air breather filter(s)    Remove and clean filters    Remove and clean tank magnets    Check all bolts    Check limit switch/proximity switch/lasers    Check oil level     Inspect solenoid hose or connection     Check safety interlocks and safety warning signs     Pipe flange gather cylinder     Hose pump(s)     Hose connections     Pipe flanges in pipe runs     Ensure oil temperature OK     Ensure filter condition OK     Visually inspect gather cylinder mount bolts     Visually inspect pipe clamp bolts     B-1 .Appendix B Maintenance Checklist and Records Model: ____________ Serial: ____________ A M W D Drain hydraulic oil from tank with all cylinders retracted. Analyze a sample of hydraulic fluid and log results  Replace all oil and air filters  Remove both inspection plates and access cover. DAILY MAINTENANCE RECORD Model: ______________ Serial: ______________ DAILY Oil level (1” from top of sight gauge) Inspect structure Safety interlocks functioning properly Gather cylinder pipe flange Hose pump(s) Hose connections Pipe flanges in pipe runs All cylinder rod seals Oil temperature OK Filter condition OK Gather cylinder mount bolts Pipe clamps bolts Check safety covers and guards Inspect seals Inspect O-rings Inspect valves Inspect cylinders Inspect pumps Inspect solenoid valve hoses Inspect cylinder hoses Inspect pressure gauge hoses Inspect pressure switch hoses Inspect gather ram cylinder Month: ______________ Year: ______________ S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S . DAILY MAINTENANCE RECORD Model: ______________ Serial: ______________ DAILY Replace worn or cracked hoses Check tank manholes for leaks Check flange plugs for leakage Inspect pressure relief valves Clean photo-eye and laser lenses Check for broken bolts Debris not hindering cylinders Limit and prox switch E-stops working Month: ______________ Year: ______________ S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S . JANUARY DAILY Check pump pressure Check limit switch/proximity switch Check air breather filter Check all pipe flange bolts Cylinder packing retainer bolts Cylinder head bolts Check cylinder piston rods for burrs Check all cylinder mounting bolts Check pipe clamps Check hose connections for damage Condition of knives Clean oil cooler fins using compressed air 1 2 3 4 FEBRUARY 5 1 2 3 4 MARCH 5 1 2 3 4 APRIL 5 1 2 3 4 MAY 5 1 2 3 JUNE 4 5 1 2 3 4 5 .WEEKLY MAINTENANCE RECORD Model: ______________ Serial: ______________ Year: ______________ In addition to the Daily Maintenance Record tasks. perform the tasks below on a weekly basis. MONTHLY MAINTENANCE RECORD Model: ______________ Serial: ______________ Month: ______________ Year: ______________ In addition to the Daily and Weekly Maintenance Record tasks. perform the tasks below on a monthly basis. DAILY Check and clean lasers Remove and clean filters Remove and clean tank magnets Check all bolts Inspect liners and guide bars for wear Clean electric motor air vents Check knife clearance JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC . perform the tasks below every year. Weekly. and Monthly Maintenance Record tasks. Inspect the inside of the tank for cleaning materials left behind. Install new O-ring seals on each cover and bolt covers in their original position YEAR DAILY Drain hydraulic oil from tank with all cylinders retracted. Remove both inspection plates and access cover. Completely clean inside of reservoir with non-flammable compatible cleaning solvent. Completely clean inside of reservoir with non-flammable compatible cleaning solvent. Install new O-ring seals on each cover and bolt covers in their original position 21 22 23 24 25 26 27 28 29 30 31 . Inspect the inside of the tank for cleaning materials left behind. Analyze a sample of hydraulic fluid and log results. Remove both inspection plates and access cover. Replace all oil and air filters. Analyze a sample of hydraulic fluid and log results. Make certain all surfaces are clean and dry. Make certain all surfaces are clean and dry. YEAR DAILY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 32 33 34 35 36 37 38 39 40 Drain hydraulic oil from tank with all cylinders retracted. Replace all oil and air filters.ANNUAL MAINTENANCE RECORD Model: ______________ Serial: ______________ In addition to all Daily. . 5-2008 ENVIRONMENTAL INDUSTRY A S S O C I A T I O N S for Equipment Technology and Operations for Wastes and Recyclable Materials – Baling Equipment – Safety Requirements WASTE EQUIPMENT TECHNOLOGY ASSOCIATION A PART OF THE ENVIRONMENTAL INDUSTRY ASSOCIATIONS 4301 CONNECTICUT AVENUE.5 . NW • SUITE 300 •WASHINGTON. DC 20008 TELEPHONE: 202-244-4700 • FAX: 202-966-4824 .2008 ANSI Z245.American National Standard ANSI Z245. . Inc. Maintenance and Operation Secretariat Environmental Industry Associations Approved February 27.5 – 2008 American National Standard for Equipment Technology and Operations for Wastes and Recyclable Materials Baling Equipment — Safety Requirements for Installation. 2008 American National Standards Institute.ANSI Z245. N. Moreover. Washington. New York. 42nd Street. The procedures of the American National Standards Institute require that action be taken periodically to reaffirm. Phone: 212-642-4900. The use of American National Standards is completely voluntary. Requests for interpretations should be addressed to the secretariat or sponsor whose name appears on the title page of this standard. D. and that a concerted effort be made toward their resolution. Published by Waste Equipment Technology Association (Part of Environmental Industry Associations) 4301 Connecticut Ave. marketing. no person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute.. substantial agreement has been reached by directly and materially affected interests.. or withdraw this standard. but not necessarily unanimity. 11 W. whether he has approved the standards or not. from manufacturing. Fax: 212-398-0023. purchasing.American National Standard Approval of an American National Standard requires verification by ANSI that the requirements for due process. CAUTION NOTICE: This American National Standard may be revised or withdrawn at any time. and other criteria for approval have been met by the standards developer. or procedures not conforming to the standards. Purchasers of American National Standards may receive current information on all standards by calling or writing the American National Standards Institute. 10036. 20008 Copyright © 2008 by the Environmental Industry Associations All rights reserved No part of this publication may be reproduced in any form. without prior permission of the publisher.C. New York. Substantial agreement means much more than a simple majority. processes. Printed in the United States of America . Consensus requires that all views and objections be considered. in an electronic retrieval system or otherwise. revise. Consensus is established when. consensus. or using products. The American National Standards Institute does not develop standards and will in no circumstances give an interpretation of any American National Standard. their existence does not in any respect preclude anyone. W. in the judgment of the ANSI Board of Standards Review. ........................................................................................................15 Emergency controls .............................................................................................................................................3 8.......................1 8.................................................................................20 Vertical upstroke balers – additional safety features .......................................4 5....9 5..................15 Service openings............................2 2 Normative references ...................14 Safeguards and features Access Covers ................................................15 Operating switches and sensors........................5 – 2008 Table of Contents Page Foreword (informative).............. warning and danger markings .......2 7......2 4....................28 Safety program.............................25 Procedures for the control of hazardous energy sources (lockout/tagout) ........................1 7.........................................................................................................................................................................................................................................................7 5..................................................................................................................................1 1 Scope ......................................16 Container/cart lifting systems......................................2 3 Definitions...........8 5.23 7 7................5 5.......................................................................................................................................................................................................................3 7.........15 Security switch ................15 Power disconnect..........................10 5...........................2 5..........................................................................................31 ..29 Training requirements ..................................................1 5..........4 Safety and training program General ......................................................................................................21 6 Reconstruction and modification................................AMERICAN NATIONAL STANDARD ANSI Z245..............................................................................................................................15 5 5.........................................................................................21 Caution........................................................................................................................................................................................28 General Training .........................................................................................................4 Operational requirements Owner/Employer responsibilities for stationary compactors .......................20 Horizontal balers – additional safety features...................................................23 Operator/employee responsibilities for stationary compactors .....................................................................28 8 8............................................................................16 Emergency controls ...........................................................................................................................................................................................................................................................3 Installation requirements General requirements .............6 5........................... iii 0 Introduction (informative) .......2 8................................................................................................................................................18 Vertical downstroke balers – additional safety features..............................................11 5........13 5.....................16 Interlocks...12 5...........................................................17 Startup alarms..............................................3 5..........16 Guarding ....................................................................................................................1 4..................................15 Controls....................26 Procedures for work in confined spaces ..............29 Annexes A i Bibliography (informative) ..........2 4 4......................................................................................................................................................................................................................................................................................... .......................................................................................................................................................................................................9 Vertical upstroke baler (chain driven) ..................................13 Two-ram horizontal baler with single-compression cylinder ...............................11 Horizontal closed-chamber baler ................................................................................................................5 – 2008 Figures 1 2 3 4 5 6 7 8 Vertical downstroke baler..................AMERICAN NATIONAL STANDARD ANSI Z245.............................................11 Two-stage vertical/horizontal (continuous) extrusion baler........................12 Two-stage horizontal baler (two compression strokes) ........................17 ii .................................................14 Guard or loading hopper – minimum loading height for baler...........................................10 Horizontal extrusion baler .................................................................................... maintenance and operation of commercial baling equipment. SACOM Safety Communications City of Corpus Christi Allied Waste Industries. Inc.51 – 2008 establishes safety requirements for the design and construction of commercial baling equipment commonly used in recycling. ANSI Z245. Zanzig Denny Gill Thomas Stevens Denny Pool Steven M. Washington. Zantec. NW.C. Inc. c/o Environmental Industry Associations. For all baling equipment manufactured prior to 12 months after the approval date of this standard. Solid Waste Association of North America NIOSH Waste Industries Schaefer Systems International. Inc.5 standard. Inc. 20008. Committee approval of this standard does not necessarily imply that all members of the committee voted for its approval. Both these standards taken together revise and replace ANSI Z245. the Z245 Committee had the following members: Gary Satterfield.5 – 2008 FOREWORD (This foreword is not part of American National Standard Z245. Inquiries. Inc. D. Waste Management. Technology and Operations for Wastes and Recyclable Materials. please refer to the previous editions of the ANSI Z245.A. Inc. SP Industries. solid waste disposal and raw materials handling.. Allied Waste Industries. requests for interpretation and suggestions for the improvement of this standard should be directed to the Secretary.AMERICAN NATIONAL STANDARD ANSI Z245. Ameri-Kan Wolverine Recycling Services. Inc. Inc. Suite 300. Wienkes David E. Inc. This standard was processed and approved for submittal to ANSI by the Accredited Standards Committee Z245 on Equipment. Knaub Jerald G. The effective date of this standard shall be 12 months after the approval date of this standard by the American National Standards Institute. EST Solutions.5 – 1997. Chairman Lou Guilmette Karon Simoni (Alternate) Carl Hursh Gary Satterfield John Gilstrap Brent Dieleman Paul Moore Ralph A. Martin Susan Eppes Gerald Van Beek Jeffrey D. Rehrig Pacific Company City of Tacoma . Malter W. Inc.5 -2008) This American National Standard is applicable to the safety requirements for the installation. A companion standard. CSP Mike Schwalbach Dave Carlisle iii City of Rochester City of Rochester Commonwealth of Pennsylvania (DEP) Waste Equipment Technology Association Institute of Scrap Recycling Industries. At the time it approved this standard. Environmental Equipment Solutions Malter Associates. Inc. 4301 Connecticut Ave. Ford Michael L. Kaplan Mark Johnson (Alternate) Garry Mosier. Accredited Standards Committee Z245. A. Chairman Michelle Andersen Arthur Barham Don Barnes Steve Chytry Bruce Clark Ted Claunch Ed Correale Steve David Dan Dominguez Susan Eppes John Etherton Gary Fleming Ralph Ford Bill Geise Shannon Harrop Henry Jobe Mark Johnson Kim Kawasaki Gene Kesler Gus Koufonikos William T.AMERICAN NATIONAL STANDARD ANSI Z245. which provided the draft of this standard to Z245 Committee. Martin Will Moss Gerald Peters Harvey Podolsky Denny Pool Robert Riethmiller Jim Roseberry Gary Satterfield Michael Savage Joe Szany Jerry Van Beek Sidney Wildes iv . Lowther W. had the following members: Kent Spiers.5 – 2008 Accredited Standards Committee Z245 Subcommittee 5 on Baler Safety. The units of distance measurement used in this standard are in the inch-pound system. maintenance. Refer to the approved edition of ANSI Z245.51-2008. Notes are informative and provide guidance for the evaluation of a normative requirement. 1 . Maintenance and Operation 0 Introduction This standard was developed by American National Standards Institute Accredited Standards Committee Z245 Subcommittee 5 on Balers and approved by Accredited Standards Committee Z245. The requirements contained in this standard are not intended to apply to other components of end-use applications where a baler is part of a designed system. New requirements and revisions are not intended to be retroactive for balers manufactured to comply with earlier revisions of this standard. which details the safety requirements for design and construction of balers. This standard revises the baling equipment safety requirements found in ANSI Z245.AMERICAN NATIONAL STANDARD ANSI Z245. repair and operation necessary to ensure the safe operation of the baler. Exceptions pertain to normative requirements. The first value is the requirement. This standard complements ANSI Z245. When a value for measurement is followed by a value in other units in parentheses. Exceptions and notes contained in the standard apply to the clause or sub-clause in which they are contained or to which they reference. the second value is only approximate. The requirements contained in this standard pertain to new balers as produced by the manufacturer.5 – 2008 American National Standard for Equipment Technology and Operations for Wastes and Recyclable Materials — Balers — Safety Requirements for Installation.5-1997 by providing specific requirements for installation.5 in effect at the time of manufacture for those requirements. service.html.gov/nara/cfr/index.5 .2 The requirements of this standard apply to balers rated at 600 volts or less.51-2008. 3. and are employed in accordance with the manufacturer's installation. constitute provisions of this American National Standard. ANSI Z245. operation. unless the context clearly indicates otherwise.gpo. and reconstruction (where applicable) of baling equipment covered by ANSI Z245. through reference in this text. modification. 3. Permit Required Confined Spaces OSHA 29 CFR Part 1910. 2 . 3. on the basis of their specific experience and training. OSHA 29 CFR Part 1910. and parties to agreements based on this American National Standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below.1 access cover or door: A panel covering an opening that is designed to permit access to the interior of the baler.1997. operation.147. Safety Requirements for Workplace Floor and Wall Openings. All standards are subject to revision. the definitions below apply to terms used throughout this standard. and Railing Systems.html.5 – 2008 Scope This standard revises safety requirements with respect to the installation. 1 2 Available online at http://www.1-1995 (R2002).5 automatic bale tying device: A device which installs wires or bands around a bale to maintain the bale's compressed state.2 access gate: A moveable barrier/guard that swings on hinges or moves in/on a track and is distinguished from a door by having openwork.gpo. 3. Lockout/Tagout of Energy Sources 3 1 2 Definitions For the purposes of this American National Standard. Baling Equipment — Safety Requirements The following regulations contain provisions which.4 authorized employee: A person who. maintenance. through reference in this text. Stairs.146. 1.AMERICAN NATIONAL STANDARD 1 ANSI Z245. is permitted to perform certain designated duties. for outdoor or indoor use. constitute provisions of this American National Standard. At the time of publication. repair.3 affected employee: An employee whose job functions place them in proximity to potential hazards related to work being performed by authorized employees. the editions indicated were valid. 2 Normative references The following standards contain provisions which. ANSI A1264. and maintenance instructions and procedures. Baling Equipment – Safety Requirements. Available online at http://www.gov/nara/cfr/index. 3. 15 baler types: Balers are generally either single-stage balers or multiple-stage balers. to a dense form that will support handling and transportation as a material unit. i) two-stage horizontal/vertical (continuous) extrusion baler: A multiple-stage baler in which the first-stage ram operates with a vertical downstroke compression stroke perpendicular to the line of action of the second-stage ram. 3.7 bale: A mass of material compressed.8 bale chamber: The area of the baler where compression takes place and the bale is formed.13 baler: A machine used to compress solid waste. They are classified as follows: a) single-stage baler: A baler with one ram mechanism. Several types of balers are covered by this standard.10 bale ejector system: The mechanism used to assist in the removal of a finished bale from the baling chamber. (see Figures 1 through 7 for illustrations of types of baling equipment. 3 . b) multiple-stage balers: Balers with two or more separate ram mechanisms. This specifically excludes stationary compaction equipment that may be used to compact materials into a container. 3. i) vertical downstroke baler: A single-stage baler in which the ram travels in a vertical direction. 3. to a density or form that supports handling and transportation as a material unit.9 bale chamber door(s): The portion of the baling chamber that is opened to permit ejection of the bale.6 automatic start/cycling control: A control that uses an automatic actuator or sensor to initiate the operation of the baler on demand. with or without binding.11 bale restraint device: A device that exerts pressure on the bale to increase the density during formation in horizontal extrusion type balers. when refuse is loaded into the loading chamber. 3.14 baler loading hopper: An extension of the loading chamber on balers that provides for accumulation of material during the ram full cycle. then returns to its rest position (retract stroke). 3. with or without binding.) 3. iv) horizontal extrusion baler: A single-stage baler in which the ram movement is horizontal. initially downward (compression stroke).5 – 2008 3. 3. primary materials.12 bale tie slot: A space or area provided for insertion of bale ties to tie or secure the finished bale. 3.AMERICAN NATIONAL STANDARD ANSI Z245. and a bale restraint device is provided. iii) horizontal closed-chamber baler: A single-stage baler in which the ram movement is horizontal and the end of the bale chamber is fixed by a bale chamber door. the end of the bale chamber is open. initially upward (compression stroke). 3. ii) vertical upstroke baler: A single-stage baler in which the ram travels in a vertical direction. iii) three (or more)-stage baler: A multiple-stage baler in which each compression stroke operates perpendicular to the line of action of the preceding stroke. ii) two-stage horizontal baler: A multiple-stage baler in which the first-stage ram operates with a horizontal compression stroke perpendicular to the line of action of the second-stage ram. then returns to its rest position (retract stroke). or recoverable materials. Containers typically range in size from one (1) cubic yard to seventy (70) cubic yards in capacity.20 confined space: An area within the baler that has adequate size or configuration for personnel entry. 3.18 commercial waste: Waste produced by stores. 3. has limited means of access or egress. 3. forks. or release of stored energy in order to prevent injury to persons in or near the machines. winches and reeving cylinders mounted to a foundation or stationary equipment that are used to complete a lift and dump cycle of containers and/or carts into the loading chamber of the baler. roll-off. and hydraulic cylinders. It is typically used for the collection of commercial and industrial waste that utilizes manual lifting or mechanized lift systems for unloading. A contract laborer may be used to supplement the employer's regular workforce and usually performs the same or similar duties as regular full-time employees. commercial and industrial waste that utilizes mechanical lift systems for unloading. warehouses. 3. b) commercial/industrial: A three. or can start automatically while unattended. It is typically used in collection of residential.16 cart: A wheeled container that receives. 3. holds and stores loose refuse.5 – 2008 3. and are designed to be picked up. 3. hook-lift and hoist-type equipment will incorporate features that differ between types of compatible lifting mechanisms utilized. holds and stores loose refuse. cables.26 control of hazardous energy sources (lockout/tagout): A program which utilizes procedures for affixing appropriate lockout or tagout devices to energy isolating devices.AMERICAN NATIONAL STANDARD ANSI Z245.19 component: A part or assembly which complies with specified requirements and is used in the construction of the baler.23 continuously operating balers: Balers where the main motor remains in continuous operation. start-up. such as (but not limited to) lifting arms. offices.or four-wheeled container that receives.24 contract laborer: An employee of a person or company that provides labor (work) for a specified fee to another employer. 3. holds and stores loose or compacted refuse for lifting. 3. and set off by that equipment. holds and stores loose refuse. transported. in the following manner: a) residential: A two-wheeled container that receives. 4 . The work or service provided may be outside the scope of materials supplied or services provided by the employer or operator’s workforce.17 chute: An enclosure connected to the baler and to an adjacent structure that funnels material into the loading chamber.21 container: A receptacle (also referred to as a bin) that receives.25 contractor: A person (or company) who contracts to supply certain materials or provide a specific service (work) for a stipulated fee and/or a specified period such as baler equipment maintenance services. 3. Containers are specially designed for use with certain types of equipment.22 container/cart-lifting systems: Component mechanisms. Residential carts typically range in size from 45 to 100-gallon capacity. 3. Commercial/industrial carts typically range in size from one-half (1/2) cubic yard to four (4) cubic yards in capacity. Carts are generally classified by their size and application as either residential or commercial/industrial. Containers used in conjunction with tilt-frame. unloading and/or transportation by mechanical means. and other nonmanufacturing operations. restaurants. and is not designed for continuous employee occupancy. and to otherwise disable machines or equipment to prevent unexpected energizing. unloaded. Containers used with rear-loading baling equipment will incorporate features that differ from containers used with front-loading baling equipment. pneumatic. but who is not authorized to operate the baler. 16 years old or older. kinetic. illustration and general information.41 integrated power unit: Power unit that is contained within the body/framework of the baler. activating it. 3. 3. 3. and not as part of normal operation. and performing initial checks. 3. The device that can be actuated in an emergency situation to stop a machine’s process or cycle.35 energy sources: Sources of energy that include. 3. who is trained and authorized by the employer to place materials into the loading chamber of a baler. 3. company. hydraulic. but are not limited to.31 electrical power disconnect: A device that breaks the circuit supplying all electrical power to the baler.39 informative: Refers to the portions of this standard provided only for purposes of clarification. and can be locked in the off position.g.30 electrical enclosure: That portion of a product that renders inaccessible any part that presents a risk of electrical shock. etc. 3. The portions of this standard considered informative do not contain mandatory requirements. another. companies or entities to work for compensation. Notes and Annexes are considered informative. 3.28 cycle: The operation of a mechanism to perform one complete operation having a definite beginning and end. or entity who hires one or more individuals. and having fixed or selective points of loading and discharge. industrial processes. gravity.38 industrial waste: Waste produced as a result of manufacturing.32 emergency stop (E-stop): A stop arising from a sudden and unexpected need. mechanical. or vertical device for moving or transporting material in a path predetermined by the design of the device. 3.33 employee: An individual hired by an employer to work for compensation.).43 loader: An individual.AMERICAN NATIONAL STANDARD ANSI Z245.36 guarding: The use of a device or mechanism designed and constructed to prevent the operator of baler and others from coming into physical contact with the point of operation or a hazard. 5 . The Foreword.40 installer: A company or person responsible for putting a baler in place. 3.34 employer: A person.44 loading chamber: The opening within the structural configuration of the baler in which the material is loaded prior to compression by the ram. 3. 3.27 conveyor: A horizontal.5 – 2008 3.42 interlock: A device or mechanism used to connect individual components together so that the action of one part of the baler is constrained by.37 hazard: A condition of such a nature that it may precipitate an accident or injury. 3. or dependent upon. chemical. thermal and potential energy sources (e. 3. 3. electrical. 3. 3. incline.29 dock ramp: A structural platform for walking on or driving a vehicle on that provides access from an adjacent structure or area to the baler. or demolition operations. 53 maximum system pressure: The maximum operating pressure in the hydraulic system corresponding to the pressure relief valve setting for the system. repair. addition to or removal from the original equipment or component. will prevent opening or removal of the access door or cover it is protecting.55 modification: Any change.58 operator: An individual. 3. partnership. title. 3.45 loading height: The vertical distance between loading sill and working surface. alteration. They can be mounted on the main control panel. 3. or use. Device can also be used to prevent unauthorized operation of the baler. or maintain balers. clean. 3.62 pinch point: A point at which it is possible for a person to be caught between moving parts. or between moving and stationary parts. made in such a manner that the changed or altered portions or function of the equipment or component are different than the manufacturer's original design.46 loading hopper: An enclosure mounted on the baler that serves to direct the flow of material into the loading chamber. partnership.56 normative: Refers to the portions of this standard containing the mandatory requirements (shall).48 lockable device: A device that. on or to. converging walls or other configurations which could trap a worker.57 operating controls: The controls for operating the baler. unit.AMERICAN NATIONAL STANDARD ANSI Z245.54 mechanical enclosure: A portion of the product that prevents unintentional contact with internal mechanical parts that involve risk of injury.51 maintenance testing: Functional and operational checks that may be performed on balers and systems by authorized employees before. 3. employer. 3. The body of this standard is considered normative. once locked.61 person: An individual. corporation. 3. 6 . 18 years old or older.50 maintenance personnel: Employees who are trained and authorized by the employer to service. or lien. or after maintenance and before placing the baler back in regular service.47 loading sill: The ledge over which material is deposited into the baler. or system. inspect.59 owner: An individual. or business that holds legal ownership papers. specification. corporation. 3. and requires a key-like device to unlock. the baler frame or located remotely at a control station. material which may engulf a worker. of the baler. during. legal entity. legal entity. 3. 3. who is trained and authorized by the employer to operate a baler. 3. 3. the baler equipment. 3. 3. 3.60 permit required confined space: A confined space within the baler that contains or has the potential to contain a hazardous atmosphere.52 manufacturer: The term manufacturer includes any intermediate or final-stage manufacturer prior to the baler being offered for sale. 3. 3.5 – 2008 3. or has any serious safety or health hazards.49 main control panel: The panel that contains the motor starting controls and relays. or business. 73 residential waste: Waste produced by single and multi-family residences. generally for the purpose of placing the equipment back into full operation and substantially extending the service life contemplated at the time of original manufacture.72 repair: Any replacement. This signal word is limited to the most extreme situations. 3. 3.69 recyclable materials: Materials that because of their physical properties.75 service opening: A protected opening into the interior of the baler that is designed to permit access to the interior for the purpose of service. characteristics or other intrinsic value can be reused. or maintenance.77 should: Use of this word in this standard denotes a recommendation that is a sound safety practice. 3. commercial.63 pit: A cavity in the ground. and residential. and industrial solid wastes. or a sunken or depressed area that is adjacent to a floor area.66 ram (also known as platen): The powered component of a baler that moves the refuse from the loading chamber to where it is compacted. 3. 3. which if not avoided. b) "WARNING" — indicates a potentially hazardous situation. beyond normal repair and servicing. and which have been diverted. including garbage. which if not avoided. 3. but not of a size to permit a person to pass through. 3. It may also be used to alert against unsafe practices. may result in minor to moderate injury. including recyclable materials. will result in death or serious injury.67 rated component pressure: The rated working pressure as provided by the component manufacturer. industrial. floor. ashes. 3. rubbish. or residential wastes. reprocessed. repair. A pit may be used to store materials to be fed into the baler.74 safety signs: Signs meeting the Occupational Safety & Health Administration (OSHA) requirements used to depict three levels of hazards: a) "DANGER" — indicates an imminently hazardous situation.65 point of operation: The area of the equipment where work is performed upon the material. substitution.5 – 2008 3.68 reconstruction: The disassembly and re-assembly of equipment. and c) "CAUTION" — indicates a potentially hazardous situation. it does not denote a mandatory requirement. 3. which if not avoided. removed or recovered from commercial. 3. separated. processed and returned to use as other products. 3. 3. or converted for other uses or products after their original design use has been completed.6. could result in death or serious injury. incinerator residues.64 platen: see ram. (See figures 1 . plant trimmings. 3.) 3.71 refuse: Any type of solid waste (except human wastes). or overhaul of the original baler or components made in such a manner that the baler and functions of the repaired portions retain minimum design specifications established by the original manufacturer (not a modification).70 recycling: A series of operations or processes by which wastes or other materials are collected. street cleanings. 7 .AMERICAN NATIONAL STANDARD ANSI Z245.76 shall: Use of this word in this standard denotes a mandatory requirement. 3. trommels. industrial. solids.5 – 2008 3. This definition does include material diverted from the waste stream for the purpose of recycling. incineration residue. 8 . normally stand-alone. ashes. street cleanings. plant trimmings. trash. and residential activities.83 waste: Any type of solid wastes (except human wastes) such as garbage. Excluded are solid or dissolved materials such as domestic sewage and solid or dissolved materials in irrigation return flows or industrial discharges.82 unattended baler with automatic startup: Baling equipment where the main motor will start and the baler will cycle automatically while unattended when activated by a signal from a sensor or a sequencing program or device. conveyors.81 system pressure: The range of operating pressures ranging between normal and maximum operating pressure in the hydraulic system as stated by the manufacturer. in an integrated fashion for the simultaneous or sequential processing of materials (such as. 3. 3. 3.80 system: The combined use of several technologies. 3. etc ). shredders. liquids or gases. or the like which are generated and discarded by commercial.79 sustained manual pressure control: A control that requires continuous pressure by the operator to allow the baler to operate. 3. semi-solids. rubbish.AMERICAN NATIONAL STANDARD ANSI Z245.84 working surface: Any surface on which employees perform job duties or upon which employees are required to work while performing assigned tasks.78 start-up alarm: An audible and visible alarm distinctive and recognizable as a signal to provide warning that the baler will begin to operate. AMERICAN NATIONAL STANDARD Figure 1 – Vertical Downstroke Baler 9 ANSI Z245.5 – 2008 . 5 – 2008 Figure 2 – Vertical Upstroke Baler (Chain Driven) 10 .AMERICAN NATIONAL STANDARD ANSI Z245. AMERICAN NATIONAL STANDARD Figure 3 – Horizontal Extrusion Baler Figure 4 – Horizontal Closed-Chamber Baler 11 ANSI Z245.5 – 2008 . AMERICAN NATIONAL STANDARD FIRST−STAGE RAM ANSI Z245.5 – 2008 LOADING CHAMBER FEED BALE RESTRAINT DEVICE RAM TOP COVER BALE CHAMBER AUTOMATIC BALE TYING DEVICE (NOT ON MANUAL TIE EXTRUSION BALERS) SECOND−STAGE RAM Figure 5 – Two-Stage Vertical-Horizontal (Continuous) Extrusion Baler 12 . AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 Figure 6 – Two-Stage Horizontal Baler (Two Compression Strokes) 13 . AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 Figure 7 – Two-Stage Horizontal Baler With Single-Compression Cylinder 14 . or the 5. and shall affix to such equipment the date of installation. local ordinances and the manufacturer’s recommendations. including emergency stop buttons. 5 Safeguards and features 5.2.4. the actuator of the switch shall be located or guarded so that unintended operation is unlikely.4.2 An electrical power disconnect shall be located within sight of.3 Emergency controls 4. 15 . 4.1. shall be designed and located to prevent unintentional activation.5 – 2008 4. it shall be by recessing. the material feed area. 5. and no more than 50 ft (15 m) away from the main control panel.3.1 Each control shall be clearly and conspicuously labeled as to its function.1 Emergency stop controls shall be readily accessible to the operator or shall be located within 3 ft (91. distinguishable from all other controls by size and color.2 Service openings 5.2. within 3 ft (91.2 Operating controls. 5.3. such as start buttons. 4.3.51.3.4 cm) of the access door.3.2 Power disconnect 4.3 Controls 5. 4. secured by a lockable device or removed by the use of hand tools only. secured by a lockable device. 5.2 like.1 Removable covers shall protect service openings that expose pinch points.4 cm) of the point of operation.3 The actuator of an interlock switch shall be located so that unintentional operation is unlikely. The covers shall be interlocked. or be removable by the use of hand tools only. installer's name and a statement attesting to compliance with this standard. applicable codes.1 Access covers 5. shall be red. ribs.4 Operating switches and sensors 5.3 Stop buttons.1 General requirements ANSI Z245.1.1 Access covers shall be interlocked. 5.1 Installation shall include a power disconnecting means that can be locked in the “off” position. or if chute fed.1 When the unintentional operation of a switch results in a risk of injury to persons. 5.1 The installer of balers shall do so in accordance with the appropriate sections of this American National Standard and ANSI Z245.4.AMERICAN NATIONAL STANDARD 4 Installation requirements 4. and shall not be recessed. barriers. When guarding is utilized for the actuator of the switch. 5. 5. or b) The installation of an access gate or door that is interlocked in such a manner as to prevent the movement of parts at the point of operation when the gate or door is open.8 Guarding 5.4. such as a timer. 5. 5.1 Protection of personnel from contacting moving parts at the point of operation shall be provided by one of the following methods or by other means as effective as the following means: a) The installation of a guard or loading hopper with a minimum loading height above the working surface of 42 inches (106.4 cm) or greater (see figure 8).4 A device that starts a baler automatically. or 16 . NOTE: An electrical power disconnect is to be located within sight of. that shall prevent any person from contacting moving parts at the point of operation. an automatically reset overload-protective device.7 Interlocks 5.6 Emergency controls 5. and no more than 50 ft (15 m) away from. 5. the main control panel.7 cm) (dimension “Y”).7. b) Making wiring connections or alterations.4 cm) of the access door. NOTE: Emergency stop controls are to be readily accessible to the operator or are to be located within 3 ft (91.1 For emergencies. the emergency stop controls are to be within 3 ft (91. 5.7. or similarly functioning security switch.7.3 An interlock shall not be capable of being defeated by materials such as wood.4 cm) of the point of operation or the material feed area. metal chips or debris that could accumulate in normal use.4 When movement of a guard actuates an interlock.1 A key-lock on-off switch. such as by: a) Damaging of the interlock. shall be provided by the manufacturer as a means to disconnect power to the operating controls and lock these controls in the "off" position. a safety retract feature shall be provided such that whenever the unit is shut off and started again.1 Access door(s) of loading chambers shall have an interlock system that prevents cycling motion while the access door(s) is open. the ram will always retract to its rear position.8. or c) The use of tools or other materials (such as magnets and wedging devices) 5.7. 5.AMERICAN NATIONAL STANDARD ANSI Z245. shall not be employed unless it utilizes a startup alarm. or a means of stopping and controlling the movement of the ram at any point shall be provided.2 An interlock shall not be readily defeated without intentional purpose.5 Security switch 5. and the sum of dimensions “X“ and” Y” equaling 84 inches (213.6. If chute fed. or the like.5 – 2008 5. the arrangement shall be such that the guard is in place when the interlock is in the position that permits operation of the parts being guarded.5. except for those stated in 5. such that the operator can not activate the controls while standing under a raised container. 5.2 Controls for container/cart lifting systems. this may result in an unsafe condition or damage to the cart. Figure 8 – Guard or loading hopper .AMERICAN NATIONAL STANDARD ANSI Z245.9.9 Container/cart lifting systems 5.9.minimum loading height for balers 5.3. and located outside the area of operation of the lifting system and container.9.9. 5.1 Lifters for containers/ carts provided with balers. shall be of the sustainedmanual-pressure type.1.5 – 2008 c) Sustained-manual-pressure controls located in such a way that the operator cannot reach the point of operation and within an area fully visible to the operator of the complete point-ofoperation area when a guard is not used. 5.1. 17 . and in direct line of sight of the lifting operation.3 Safety check valves in the hydraulic system or mechanical lock systems shall be provided to hold the lift in its position should a failure occur with a lifting system hydraulic hose.9. or marketed separately and recommended by the manufacturer for use with the baler.9.1 General 5.2 Container/cart lifters 5. NOTE: If an operator attempts to use a lifter to cycle containers/carts for which it was not designed.9.1 Container/cart lifting systems for balers shall be installed in accordance with the manufacturer's instructions.1.2. shall conform to the following requirements: a) The lifter must be compatible with the type(s) of containers/carts it is to cycle. and 3) the cycle is initiated by a manual control by the operator do not require an initial start start-up alarm 5. or other similar devices with interlocked access that prevent entry or operation when not in place.AMERICAN NATIONAL STANDARD ANSI Z245.10. and i) The lifter shall be equipped with a device to secure the container/cart to the lifter during the lifting cycle.2 Initial start-up cycle alarms 5.1 Audible and visual alarms 5. d) The control shall be capable of reversing the direction of motion of the lifter at any point in the cycle. 5.3.3 Continuous/automatic start-up alarm for automatic balers 18 .9. 5. 5. Exception: Vertical balers that are fully enclosed such that 1) no body part can come in contact with any moving part.10. 2) the ram/rams only cycle one time. and pushed to lower and shall be marked to indicate function.1 Balers shall have a minimum 20-second audible and visual start-up alarm sequence before the main motor/motors can start. An automatically adjustable audible signal shall be capable of producing at least 10 dBA above the ambient noise level. a cage.1 Automatic container/cart lifting systems shall have the point of operation and area through which the container moves completely enclosed by guards.2 Any visible alarm shall be a flashing or pulsating type.5 – 2008 b) A minimum cycle time for the lifter shall be specified and the lifter cycle time shall be capable of being adjusted only by the use of a tool.2.10. f) The normal position for an operator using the controls shall not place the operator underneath a raised container or cart. c) Upon release of pressure on the operating device by the operator. The start-up alarm sequence shall include a minimum of 5 seconds of audible and visual alarms followed by a minimum of 15 seconds of the visual alarm.1. g) Control levers shall be designed such that they are pulled to raise.3 Automatic container/cart lifting systems 5.1 Any audible alarm shall be a pulsing or intermittent signal and shall be adjustable to at least 10 dBA above the ambient noise level. h) Push button controls shall be arranged with the “raise” button higher than the “lower” button and shall be marked to indicate function.10 Start-up alarms 5. 5.10.2 Automatic container/cart lifting systems shall have an emergency stop control.9.6) 5. e) Controls shall be located so as to prevent inadvertent operation of the lifter.1. the lifter shall stop and hold at its current position in the cycle.3.9. (see Note in 5. NOTE: There may be more than one set of controls.10.10. 10.10. The baler shall not restart until the automatic starting control circuit has been manually reset (energized) to initiate a normal startup sequence with startup alarm and startup time delay.10. interlock interrupts and automatic starting control circuits 5.1 The switch shall be maintained in the actuating position for the entire 20-second delay in order to energize the automatic starting control circuit.4.2 The start-up sequence shall be completed before the ram(s) move. the baler shall not automatically restart when the access door or gate is closed (interlock re-engaged).6 Emergency stop controls.1 When actuated.3.10.10.3 The automatic control circuit shall be de-energized when power is removed from the baler.2 For balers with automatic starting control circuits. the baler shall not restart automatically when electrical power is supplied until the automatic starting control circuit has been manually reset (energized).5 – 2008 5.4 For balers with automatic bale tying devices.7.1 Continuously operating balers and unattended balers with automatic startup shall have a minimum time delay of 20 seconds from the time the switch controlling the automatic starting control is initiated until the automatic starting control circuit is energized.6. the baler shall not automatically restart when the emergency stop control is reset.1 Continuously operating balers and unattended balers with automatic startup shall have a visible warning alarm that is activated as long as the automatic starting control system is energized.4 For balers with automatic starting control circuits.10.4 Start-up time delay 5.10. NOTE: The warning alarm may be the same alarm used for the start-up alarm in 5. 5.6.3.7. The baler shall not restart until the automatic starting control circuit has been manually reset (energized) to initiate a normal startup sequence with startup alarm and startup time delay.10.3 For balers with automatic starting control circuits. 5.4. 5. 5.AMERICAN NATIONAL STANDARD ANSI Z245.6. 5. an emergency stop button shall be provided at the tying device. the automatic starting control shall not be energized.10. 5.4.3 If the automatic starting control circuit becomes interrupted. 5.10. emergency stop controls shall stop the baler motor and disable any automatic starting control circuit. 5.3. in either the automatic or manual mode.10.10. 5. 5.5 Warning alarm 5. 19 .10.1.2 If the switch controlling the automatic starting control circuit is released before the end of the 20second delay period. 5.10. the circuit shall not reactivate until a new start-up sequence has been completed.10.10.10.1.6.1 A horizontal baler with an automatic starting control circuit shall have a start-up alarm that is activated when the baler is started or when the automatic starting control circuit is activated.10.1.7 Automatic starting control circuit 5. 5.5. 12.12. or will open with the raising of the ram.2.2 The loading chamber closure shall completely cover the loading chamber before the ram can be activated into its compression stroke.5 – 2008 5.3 If the loading chamber closure does not have an automatic opening feature.3 Baler chamber door locking mechanisms 5.) 5.1 Ram compression stroke interlock 5.11.12.2.11. 5. (See figure 2.2.1 The ram shall not move unless the bale chamber door(s) is fully closed and latched. 5.1. Unless otherwise designed to eliminate the pinch point. balers shall be equipped with a mechanical or electrical interlock to prevent the closure from being opened faster than the baler ram. 5. then the ram shall stop or return to its rest position if the loading chamber closure is opened more than ½ inch (13 mm) at any time during the compression stroke.3.2 Loading chamber closure 5.12.11.4 If the loading chamber closure does have an automatic opening feature at the completion of the compression stroke.1 A loading chamber closure shall be provided.1 An interlock shall be provided to keep all doors closed during the ram compression stroke. except when operated with a sustained-manual-pressure control. so as to prevent operator access to the top of the ram during its upward motion. or equipped with a sustainedmanual-pressure control. 5. 20 .11.11.11. but not as to allow any pinch points or hazards to be exposed.1 A guard for the ram shall be provided between the ram and the floor line of the baler pit in an upstroke baler.1 Locking mechanisms for bale chamber door(s) shall be designed to allow for controlled relief of pressure as the door(s) is opened.12.1 Bale chamber door(s) ANSI Z245.11.1 Locking mechanisms for bale chamber door(s) shall be designed to allow for controlled relief of pressure as the door(s) is opened.2 Ram guard 5.AMERICAN NATIONAL STANDARD 5. 5. The loading chamber closure must remain in place until the completion of the compression stroke.12 Vertical upstroke balers – additional safety features 5.3. or be otherwise designed to eliminate the pinch point.3 Bale chamber door locking mechanism 5.11.11.11 Vertical downstroke balers – additional safety features 5. then the baler shall have a mechanical or electrical interlock to prevent the closure from being raised faster than the baler ram motion to prevent operator access to the top of the baler ram during its upward motion. 5.1. 5.12.2.2. 14.672 inches (17.4. If during the compression stroke the closure is moved from its fully closed position.3 A caution. warning and danger markings 5.14 Caution.5 A marking intended to inform the user of a risk of injury to persons shall be prefixed by a signal word "CAUTION. 5. which must reset the baler start-up cycle. with lettering or symbols in a contrasting color. the loading chamber closure shall completely cover the loading chamber before the ram can be activated in its compression stroke.14.13.AMERICAN NATIONAL STANDARD 5.1 Baling equipment or a separately packaged attachment having a hidden or unexpected risk of injury to persons shall be marked to inform the user of the risk.2 All cautionary.1.1 Baler loading hopper access door(s) shall be equipped with a control circuit interrupt.4 Ram top cover 5.1 Baler loading hopper access doors ANSI Z245." or "DANGER. 5.13. 5.07 mm) high. When the ram is fully extended. 5. The closure shall remain in place until completion of the compression stroke.1 The top of the ram on all horizontal balers shall be covered to prevent access to the backside of the ram face as it extends into the loading chamber.4 A cautionary marking intended to instruct the operator shall be legible and visible from the position normally assumed by the operator when starting the baler or from the position normally assumed for the specific operation involved. with lettering or symbols in a contrasting color.13." The marking shall be in letters not less than 0.2 Bale chamber door closure 5.Red.13. or predominantly red.13.13. or predominantly orange.14. 5.Orange. 5.6 Markings shall be color coded as follows: "DANGER" . 5.14.13.1 An interlock shall be provided on all closed-chamber horizontal balers to ensure return of the baling ram face into the loading chamber area before the manually operated bale chamber door opening mechanism is activated. 21 .2. Other such markings for servicing or making settings and adjustments shall be legible and visible to the individual when such work is being accomplished.1 On horizontal balers not equipped with a loading hopper.13 Horizontal balers – additional safety features 5. 5." "WARNING. warning. 5. the ram cover shall cover the full length and width of the loading chamber opening. "WARNING" . warning. and operator markings shall be located on or immediately adjacent to each automatic sensing device and at the point of operation. or the door opening mechanism shall be designed to allow for controlled relief of the pressure against the door as it is manually opened. the ram shall stop.5 – 2008 5. danger.14.3. or danger marking shall be permanent and legible and shall be located on a permanent part of the baler.13.14. The signal word shall be more prominent than any other required marking on the baling equipment. to prevent baler operation with the door open.3 Baler loading chamber closure 5. and shall be readily visible after installation of the baler. or for other reasons) shall be marked to indicate that such servicing is to be done with the equipment disconnected from the supply circuit.12 A sign shall be located on each access cover. with lettering or symbols in a contrasting color. 5. To reduce the risk of electrical shock.14.5 – 2008 "CAUTION" .14.Yellow. such as: "WARNING — DO NOT REMOVE ACCESS COVER EXCEPT FOR SERVICING. 22 .14. such as: "DANGER — DO NOT ENTER" 5. burrs. which is visible from a loading position. 5. 5. and at the point of operation. disconnect all such connections before servicing.13 A sign shall be located on each access gate that prohibits access to the loading chamber from a walkon ramp. such as: "WARNING — GATE MUST BE CLOSED BEFORE OPERATING BALER" 5. such as: "DANGER – DO NOT ENTER" 5.14. The ends or heads of bolts or other fastening devices shall be located in such a way that they do not constitute a hazard.8 A baler having provisions for two or more separate connections to a branch circuit or other powersupply source shall be permanently marked with the word "CAUTION" and the following or the equivalent: "This baler has more than one connection to the source of supply.16 On commercial/industrial balers without a loading hopper. a sign shall be located at the loading sill(s) such as: "DANGER — DO NOT ENTER" This sign shall be visible from both sides of the baler.15 A sign shall be located on each outside face of the loading hopper. splinters.14.AMERICAN NATIONAL STANDARD ANSI Z245. or predominantly yellow. FOLLOW LOCKOUT/TAGOUT PROCEDURES" 5. to make an operating adjustment.14.14. such as: "DANGER — HIGH VOLTAGE" (or appropriate voltage) 5.14. such as: "WARNING — THIS BALER STARTS AUTOMATICALLY" 5.7 A baler having a part of an enclosure that is removable without the use of a tool (to attach.14. or other sharp projections.4-2002.14.9 All signs shall be furnished with rounded or blunt corners and shall be free from sharp edges. a sign shall be located on each control panel and power unit." The marking shall be located at each point of connection.10 A sign shall be located on or immediately next to each automatic sensing device. 5. NOTE: Additional guidance for markings can be found in ANSI Z535.14 A sign shall be located on any inside face in the loading hopper.11 Where voltage exceeds 120 volts. or repair the baler. such as: "WARNING — BEFORE OPERATING LIFTER.17.3 Reconstructed or modified balers evaluated and determined to conform to the requirements of ANSI Z245. and manufacturer’s recommendations. maintain.51 shall be identified on the baler by a statement attesting to compliance with the ANSI Z245. . b) Providing to employees instruction and training in safe work methods before assigning them to operate. service.g.5 – 2008 5. CLEAR AREA OF ALL INDIVIDUALS" A sign shall be located in clear view of the dumper system and container. Such instruction and training shall include procedures provided by the manufacturer.1 Reconstruction or modification of any baler (including power units and controls) shall be in accordance with requirements of ANSI Z245.1 A sign shall be located in the vicinity of the lifting system controls.18. bridging of the loading chamber or feeding chute.2 A sign shall be located at or near the entrances to those confined spaces for which hazardous energy control procedures are provided. ordinances. If installing into a system.AMERICAN NATIONAL STANDARD ANSI Z245. 7 Operational requirements 7. examine prevailing safety standards of associated equipment. The employer will maintain records as to the names of employees and the dates of training. and shall be responsible for all of the following: 23 a) Ensuring that the installation of the baler conforms to local codes.51.14.51 standard or shall have an approved listing mark. such as: "DANGER — STAY CLEAR OF LIFTER AND LIFTING AREA" 5.2 Reconstructed or modified balers shall be permanently identified with the name of the manufacturer or person conducting the reconstruction or modification and the date of reconstruction or modification.14.14. clean. 6.. The owner/employer shall provide properly maintained balers that meet all applicable regulatory safety requirements and the requirements of this standard. jam of materials).1 Owner/employer responsibilities for balers. 6. modify.14.18 Balers containing one or more confined spaces meeting the criteria of " confined space" 5.14. such as: “WARNING – FOLLOW LOCKOUT/TAGOUT PROCEDURES BEFORE ENTERING” 5. such as: "DANGER — CONFINED SPACE" 6 Reconstruction and modification 6. c) Providing instructions for addressing abnormal situations (e.1 A sign shall be located at or near the entrances to those confined spaces for which hazardous energy control procedures are provided.18.17 Container/cart lifting systems 5. reciprocating floor. j) Utilizing the manufacturer's recommended procedures for access control for permit-required confined spaces as part of the employer's program (see 7. or are replaced if damaged. servicing. or by other means as effective as those means of protection. maintaining. 24 . in accordance with the manufacturer’s recommended procedures.8. h) Implementing a program for the maintenance of the baler which will incorporate the following elements: 1) Requirements for trained.147 of Title 29 of the Code of Federal Regulations (OSHA) (see 7. including adherence to safe practice. k) Protecting any person by one of the methods in 5. or repairing) the baler. including adherence to safe practices and the employee requirements of this standard and monitoring the employee’s operation of balers and taking appropriate action to ensure proper use of equipment. competent maintenance employees or contractors to perform inspection and repair work.3). warning and danger markings required by 5. component equipment. prior to placing the baler into service. providing: 1) Protection for employees by means of: i) Limiting access within 6 feet (183 cm) of the edge of the pit to authorized employees. 3) Ensuring that all required safety features are operational and functioning. or push pit that is flush with or below the facility floor.1. e) Monitoring the employee’s operation of the baler and taking appropriate action to ensure proper use. ii) Training authorized employees to recognize and avoid the hazards associated with the pit area. any mechanical malfunctions or breakdowns that affect the safe operations of the baler. prior to placing into service. l) For balers fed by means of a loading pit conveyor.5 – 2008 d) Assigning only trained employees to work on (which includes operating. This shall include keeping all malfunction reports and records of inspections and maintenance work performed. f) Repairing. and 4) Ensuring that all caution. i) Utilizing the manufacturer's recommended procedures for the control of hazardous energy sources (lockout/tagout) in a program complying with Part 1910.14 are installed and legible. 2) Providing for the cleaning. including periodic maintenance. loading. cleaning. and repairing.AMERICAN NATIONAL STANDARD ANSI Z245. g) Establishing and following a program of periodic and regular inspections of all balers to ensure that all parts. and safeguards are in safe operating condition. and adjusted. defaced or missing. any reported malfunction or defect that affects the safe operation of the baler.4). inspection and repair of the baler in accordance with the manufacturer's recommendations. Guard railings and toe boards shall be provided on the sides of docks and ramps. Occupational Safety and Health Administration requirements. such as: "RESTRICTED AREA — AUTHORIZED EMPLOYEES ONLY" 2) Providing a device to the extent practicable. and other protective devices to ensure that these devices are not disabled or bypassed. o) Providing for an adequate work area around the baler for safe maintenance. b) Using the baler only after receiving instruction. oil. These shall be located around the loading chamber opening if walk-on ramps are used to deposit refuse into the loading chamber. allowing their use only in locations where a startup alarm is utilized or it is demonstrated that automatic starting does not result in a risk of injury to persons.S. p) Keeping all surrounding walking areas and floors free from obstructions. 7. These inspections shall be in accordance with (g). which prevents trucks or other motor vehicles that unload directly into the loading pit from rolling into the pit. NOTE: Achieving acceptably low risk of injury would include demonstrating that lockout procedures are strictly adhered to when bridging in feed chutes occurs or jammed material must be cleared from the loading chamber n) Providing guard railings for dock ramps that meet U. u) Ensuring that only authorized employees (18 years old or older) operate. but do not operate balers. grease. or maintain balers. and iv) Limiting access by unauthorized persons by installing signs. and w) Incorporating balers into the employer's safety program (see Section 8). .5 – 2008 iii) Requiring that others whose employees use the pit area provide assurance of such training. s) Ensuring that containers supplied are capable of withstanding the maximum forces generated by the baling system. inspect. switches. servicing.AMERICAN NATIONAL STANDARD ANSI Z245.2 Operator and employee responsibilities. and cleaning procedures. m) When balers equipped with automatic start/cycling controls are provided. and not to permit the baler to be operated unless these devices are fully functional. and accumulations of waste matter. v) Ensuring that only authorized employees (16 years old or older) load. t) Ensuring that loaders are aware of hazards and safety requirements. Operators who work on and around the baler shall be responsible for the items listed below: 25 a) Using all applicable safety features provided on the baler. q) Maintaining records or employee reports of malfunctions. r) Specifically inspecting safety interlocks. and water (slipping and tripping hazards). g) Ensuring that all persons are clear of the tailgate (on baler-container combinations so equipped) before the tailgate is opened or shut. etc. d) Ensuring that access doors and service opening covers are in place. and maintaining the baler only if 18 years old or older and after being properly instructed and trained.3. hydraulic. or other potential energy sources (e. or malfunction of. secure. mechanical. thermal. etc. and know the methods to control the energy (see 7. f) Ensuring that all persons are clear of the baler point of operation before actuating any compaction cycle controls or container/cart lifting system controls and being prepared to stop the compaction cycle or container dumping operation if necessary.1 The owner/employer shall have a hazardous energy control (lockout/tagout) procedure to follow when performing servicing and maintenance on balers where the unexpected energization or start up of equipment. 7.3. 26 . kinetic. or other protective devices and that the baler is not operated unless these devices are fully functional. The lockout/tagout procedure shall isolate and render safe all energy sources. guards. gravity. chemical. i) Ensuring that no one disables or bypasses safety interlocks. inspecting. shall understand the hazards. j) Locking out the unit when inspecting malfunctions.3). l) Operating. including ensuring the proper position of all locks. k) Coupling and securing a compatible container to a baler frame as specified by the baler and container manufacturer(s). 7.. 7.5 – 2008 c) Reporting any damage to. or performing maintenance (except maintenance testing).2 The owner/employer shall utilize the instructions provided by the manufacturer for the control of hazardous energy sources. including electrical. pneumatic. and m) Loading.).3 Procedures for the control of hazardous energy sources (lockout/tagout) 7. and/or locked before operations begin.AMERICAN NATIONAL STANDARD ANSI Z245. the baler only if 16 years old or older.3 The lockout/tagout procedure shall include but is not limited to the following: a) Shutting down all power sources. h) Using the baler in accordance the manufacturer’s instructions. or other problems arising from daily operations. The affected employee shall identify the type and magnitude of the energy that the baler uses. e) Ensuring that the area of operation around container/cart lifting systems and the container will be clear of persons during all phases of the lifting operation prior to energizing the dumping system. the baler by submitting a report to the employer or responsible authority when the damage or malfunction occurs.3. doors.. servicing. It shall be used to ensure that the baler is stopped.g. switches. or release of stored energy could cause injury to employees. isolated from all potentially hazardous energy sources and locked out before employees perform any servicing or maintenance where the unexpected energization or start-up of the baler or release of stored energy could cause injury. The operator shall warn all persons not to cross behind or under an open tailgate. but not operating. jams. AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 b) Removing keys or other devices that enable the baler; c) Using a lock to secure the power supply or, if that is not feasible, installing a tag on an appropriate location, using a non-reusable fastener, or installing a similar warning device; d) Placing operating components in such a position so as not to be subject to possible free fall and/or installation of additional blocking devices to prevent such free fall of any raised or elevated component; and e) Relieving stored hydraulic or pneumatic pressure, after blocking devices are installed, if maintenance is to be done to the hydraulic or pneumatic system. 7.3.4 The procedure shall address the following: a) Sequence of lockout for the baler: 1) Notify all affected employees that servicing or maintenance is required on a baler and that the baler must be shut down and locked out to perform the servicing or maintenance. 2) The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the baler utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. 3) If the baler is operating, it must be shut down by the normal stopping procedure (depress stop button, open switch, close valve, etc.). 4) De-activate the energy isolating device(s) so that baler is isolated from the energy source(s). 5) Lock out the energy isolating device(s) with assigned individual lock(s). 6) Stored or residual energy must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc. 7) Ensure that the baler is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. Caution: Return operating control(s) to neutral or “off” position only after verifying the isolation of the equipment. NOTE: The machine or equipment is now locked out. b) Restoring the baler to service. When the servicing or maintenance is completed and the baler is ready to return to normal operating condition, the following steps shall be taken: 1) Check the machine or equipment and the immediate area around the machine or equipment to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact. 2) Check the work area to ensure that all employees have been safely positioned or removed from the area. 3) Verify that the controls are in neutral. 27 AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 4) Remove the lockout devices and reenergize the machine or equipment. NOTE: The removal of some forms of blocking may require re-energizing of the machine before safe removal. 5) Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use. 7.4 Procedures for work in confined spaces 7.4.1 The owner/employer shall have a written procedure for work in confined spaces meeting the criteria of “permit required confined spaces," such as integrated power units. The procedure shall utilize the manufacturer’s instructions for the hazardous energy control (lockout / tagout) procedure which shall isolate and render safe all energy sources, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other potential energy sources (e.g., gravity, kinetic, etc.). which may create a hazard during entry into each of those confined spaces. a) These instructions shall include the requirement to affix a sign to the baler, at or near the entrances to those confined spaces for which hazardous energy control procedures are provided, such as, “Warning — Follow lockout/tagout procedures before entering.” b) These instructions shall include the requirement to affix a sign to the baler, at or near the entrances to those confined spaces for which hazardous energy control procedures are provided, such as, “Danger — Confined Space.” 8 Safety and training program 8.1 General 8.1.1 Employers shall evaluate and manage safety issues related to the operation of baling equipment as part of their safety program. 8.2 Safety program 8.2.1 The employer’s program shall include at a minimum the following elements: a) A hazard assessment in which the employer conducts a review of the various types of baling equipment that the employer utilizes and the hazards associated with them and, review and assess the capabilities, qualifications and training of any person who may potentially encounter these hazards. b) An evaluation of the means and methods of controlling the hazards identified in the hazard assessment, including information such as industry and regulatory requirements; instructions for the operation, inspection, and maintenance of balers, and other information appropriate to the hazards that are identified c) A written program, based upon the hazard assessment and evaluation, to include procedures for the operation, inspection, and maintenance of balers, prohibited practices, record keeping, training requirements, and normative references to documents, such as operating manuals, that are relied upon and may be required as part of that program; d) A program, conforming to 8.3, for the implementation of the written program; and 28 AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 e) Periodic review and program revisions as necessary to ensure the effectiveness of the safety program. 8.3 General training 8.3.1 Employers shall ensure all employees, including supervisors, contract laborers, and all other persons engaged in the operation, cleaning, maintenance, service or repair of baling equipment are properly trained appropriate for their assigned jobs and tasks. Contractors who may be engaged to operate or maintain the employer’s balers shall be advised of the unique hazards related to the equipment that may affect the activities in which the contractor’s employees will engage. 8.3.2 Training frequency 8.3.2.1 Training shall be provided upon initial assignment to a job or task, with periodic refresher training to maintain the required level of competence. Retraining shall be provided for employees whenever their job assignments change, or an equipment change occurs that presents a new hazard. Additional retraining shall be provided whenever the employer has reason to believe, or periodic inspections reveal, that employee deviations from procedures have occurred, or inadequacies in the employee's knowledge of procedures become evident. 8.3.3 Instructional information 8.3.3.1 Employers are required to refer employees to, and have readily available, the manufacturer's instructions to ensure correct operating and maintenance procedures and work practices are understood and followed. Employers are required to ensure employees possess knowledge and skills to safely operate the baler. 8.3.4 Contract labor 8.3.4.1 Employers shall ensure for each job or task performed that training is provided either by the contract laborer's parent employer or by the employer. 8.3.5 Training records 8.3.5.1 Employers are required to maintain training records to include the date(s) of the training and the type of training received. Records are required to be maintained as required by applicable regulations. Contractors and contract laborers are required to provide the employer with appropriate training records upon demand. 8.3.6 Equipment-specific training 8.3.6.1 Training shall be tailored for individual operations and the type of equipment utilized including detailed, equipment-specific training for machine operators, as well as maintenance personnel and supervisors who must operate equipment as part of their job duties. Training shall include practical demonstration of equipment operation knowledge and skills by the employee, as appropriate to the requirements of the employee’s job duties. 8.4 Training requirements 8.4.1 Training is required to include at a minimum: a) The necessary training as identified in the hazard assessment [see 8.2.1 a)]; 29 including the instructions provided with the equipment. and c) Operational instruction on each specific type of equipment used by the employee. the Departments of Transportation.AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 b) The training required by laws and regulations. and other applicable regulatory agencies. 30 . such as those of federal and state Occupational Safety and Health Administrations. and Railing Systems.132.3-2002.23. Lockout/Tagout of Energy Sources OSHA 29 CFR Part 1910. Baling Equipment — Safety Requirements 1 ANSI Z535. Stairs.3 OSHA 29 CFR Part 1910. Electrical Standard for Industrial Machinery ANSI/NFPA 82-1998.S. Washington.51-2008. Environmental and Facility Safety Signs ANSI Z535.1-1995 (R2002). DC 3 Available over the Internet from www.gov 4 Available from American Society of Mechanical Engineers 31 4 .S.3 Industry Standards ASME B15.4-2002. Conveyors and Related Equipment 1 Available from Environmental Industry Associations 2 Available from U. Government Printing Office. Machine Guarding A.146.147.AMERICAN NATIONAL STANDARD ANSI Z245.5 – 2008 Annex A (informative) Bibliography A. Safety Requirements for Workplace Floor and Wall Openings.1-1996. Guarding of Floor and Wall Openings and Holes OSHA 29 CFR Part 1910. Accident Prevention Tags A.1-2002. Mechanical Power Transmission Equipment ASME B20. Safety Color Code ANSI Z535. General Requirements for Personal Protection Equipment OSHA 29 CFR Part 1910.5-2002. Government Health & Safety Regulations 2.1-2000. Incinerators and Waste and Linen Handling Systems and Equipment ANSI Z245.2-2002. Product Safety Signs and Labels ANSI Z535. Permit-Required Confined Spaces OSHA 29 CFR Part 1910.1 American National Standards ANSI A1264.212. ANSI/NFPA 79-2002.2 U.osha. Criteria for Safety Symbols ANSI Z535. refund of the purchase price of any part or component. The COMPANY reserves the right to make improvements and changes in the design and/or specification for its EQUIPMENT without notification and without incorporating the changes in the EQUIPMENT on order or delivered. OR ANY IMPLIED WARRANTIES ARISING FROM COURSE OF PERFORMANCE. or alternatively.O. of the warranty period to the original PURCHASER. loss of product. Corporate Headquarters 200 Clover Reach Drive Peachtree City. Labor during the remainder of the warranty period described above will be provided at the standard rates charged by the COMPANY for service work. competent personnel. hereafter. or failure to read. or two thousand (2. decals and/or instructions attached to the EQUIPMENT. safety and maintenance instructions. filters. for a period commencing the date the EQUIPMENT is placed in service or thirty (30) days after shipment of the EQUIPMENT whichever occurs first. Ave Cordele. or (c) marked with all warnings. (4) the PURCHASER fails to notify the COMPANY promptly in writing of any alleged defects within the aforementioned warranty period.Harris Waste Management Group. (b) maintained in good operating condition using approved components and service techniques and instructions applied by competent maintenance personnel. or (5) in the event the EQUIPMENT is not: (a) operated by fully-trained. PURCHASER’S site) if so requested by the COMPANY. indirect. o-rings and routine adjustments). whichever occurs first. for its brand labeled as Selco. In the event of any deviation from this specific written warranty. It is expressly agreed by the parties signing this agreement that: (1) The COMPANY makes no guarantees or warranties of any nature except as stated in this agreement. Any such refunded or replaced parts shall be promptly returned by the PURCHASER to the COMPANY. GA 31513 1-800-447-3526 1-912-367-4661 1-912-367-5227 fax HWMG. view or follow prescribed or reasonable operation. 2005 . OR 97015 1-800-233-5010 1-503-650-7919 1-503-650-8064 fax Harris UK Operations Unit 11 Malmesbury Business Park Malmesbury Wiltshire SN16 9JU. profits or income in connection with the purchases. and extending for a period of one (1) year.B. has been subjected to accident. loss of production. or failure to replace worn parts in a timely manner. or to damage caused by unauthorized or improper repairs. abuse or misuse. to perform the warranty work by the COMPANY to the PURCHASER. (F.E. One (1) Year Limited Warranty This Limited Warranty only applies to VERTICAL and HORIZONTAL balers hereafter. and (4) that the COMPANY shall never be liable for incidental. COURSE OF DEALING OR USAGE OF TRADE. contingent upon prior written authorization. The foregoing notwithstanding. UK 44 (0) 1666-829494 44 (0) 1666-826663 fax Effective October 1. The COMPANY and the PURCHASER expressly agree that the COMPANY’S obligations are limited solely to the COMPANY’S choice of repair or replacement (F.B. Inc. the following conditions shall void the warranty: (1) The EQUIPMENT. negligence. Subject to the terms and conditions herein. It is expressly agreed that the remedies provided in this Limited Warranty are the exclusive remedies for the PURCHASER or third parties without the advance written authorization by the COMPANY. the COMPANY warrants to the original PURCHASER that the EQUIPMENT listed hereto will be free from manufacturing defects in materials and workmanship performed by the COMPANY. Inc. operation or use of the EQUIPMENT. The COMPANY will provide labor for repairs or replacement of defective part or component for a period of the first ninety (90) days or the first five hundred (500) hours. such deviation shall not alter any other terms of the warranty. or thirty (30) days after the date it could have been shipped in case shipping is delayed by factors or conditions which are not the responsibility of the COMPANY. point of manufacture) of any defective part. alteration. improper operation or maintenance. limitations and exclusions as set forth by the third party manufacturer of said EQUIPMENT or component. Jannsen Road Clackamus. conditions. the EQUIPMENT. or any part thereof. (3) that the COMPANY’S liability is expressly limited to and the PURCHASER’S sole exclusive remedies are those stated in this agreement.O. manufactured by Harris Waste Management Group. loss of operating supplies. Form 990331 VH-Std Revision 1 Cordele Operations 315 West 12th. ARE HEREBY EXCLUDED AND NEGATED. component or workmanship. Inc. wear strips. modification. Subject to the terms and conditions herein. or loss of revenues. including without limitation.000) hours use of the EQUIPMENT whichever occurs first. or consequential damages of any nature. (2) the EQUIPMENT has been subjected to operating conditions beyond that for which it was designed. (3) the EQUIPMENT has processed materials for which it was not specifically designed to process. fuses. GA 31015 1-800-468-5657 1-229-273-2500 1-229-273-8877 fax West Coast Operations 9049 S. GA 30269 1-800-373-9131 1-770-631-7290 1-770-631-7299 fax Baxley Operations 100 Jekyll Road Baxley. (2) THAT ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any labor to replace a defective part or component is not included under the terms of this limited warranty. the COMPANY. Specifically EXCLUDED from this warranty are normal wear and maintenance items (including but not limited to: liners. for EQUIPMENT and/or components that are manufactured for and/or by a third party that the COMPANY’S warranty to the original PURCHASER shall be limited to the terms. The following information is important to ensure correct information is received regarding a particular baler installation. Model Number: ______________________________________ Serial Number:_______________________________________ These drawings should be readily accessible. thus.:__________________________________ Electric Circuit No.:_________________________________________ Hydraulic Circuit No.IMPORTANT SERVICE INFORMATION Balers are tailored to meet specific requirements. each installation is unique.: ___________________________________ . they will be used for reference information throughout this manual: Foundation No.: ______________________________________ Conduit No. HARRIS Baxley Operations 340 Jekyll Road Baxley.com .harrisequip. GA 31513 (800) 447-3526 www.