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Excel EX62 Owner's Manual

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HORIZONTAL BALER
EXCEL MODEL EX62
Owners Manual
:
FOR
CUSTOMER _________________
SN: EX2_____
CUSTOMER SUPPORT
1-800-475-8812
th
 January 15
, 2012
1

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  • Page 1 HORIZONTAL BALER EXCEL MODEL EX62 Owners Manual CUSTOMER _________________ SN: EX2_____ CUSTOMER SUPPORT 1-800-475-8812  January 15 , 2012...

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION FEATURES TROUBLESHOOTING AND SERVICE SPECIFICATIONS ADJUSTMENTS SAFETY PRECAUTIONS ROTATING CUTTING EDGE EMPLOYER REQUIREMENTS PLATEN TO CUTTING EDGE LOCK OUT/TAG OUT PROCEDURE LIMIT SWITCH ADJUSTMENT GENERAL HYDRAULIC EMPLOYER RESPONSIBILITIES PRESSURE SWITCH PUMP COMPENSATOR AND PROCEDURE RELIEF VALVE BASIC PART IDENTIFICATION PUMP TORQUE LIMITER INSTALLATION INSTRUCTIONS PUMP...

  • Page 4: Introduction

    INTRODUCTION THANK YOU FOR CHOOSING AN EXCEL BALER. You have selected a precision-engineered product designed with advanced features for modern recycling center baling. The power of intelligent engineering and use of the highest quality components available guarantee many years of maximum performance and reliable service from your baler.

  • Page 5: Features

    BALER DOOR SAFETY INTERLOCK SYSTEM EXCEL’s patented bale door interlock system provides total safety in closed door baling. If an operator attempts to open the latch while the baler is in operation, the motor stops then the platen decompresses and backs off the bale. The door also must be...
  • Page 6 SHORT STROKE CYCLE This feature enables the ram to cycle with shorter (8”)chamber penetration. The short stroke cycle produces approximately 17 seconds cycle time, allowing material such as corrugated cardboard to be baled at higher production rates. INTEGRATED CONVEYOR CONTROLS W/CONVEYOR MOTOR STARTER (optional) All conveyor controls are conveniently located on the control panel with the baler controls.

  • Page 7: Specifications

    SPECIFICATIONS HEIGHT - 62” LOADING 52 1/2” FRAME LENGTH - 179” WIDTH - 77” CHAMBER - 47”L x 60”W x 30”H FEED OPENING - 54”W x 35”L SHIPPING WEIGHT - 14,000 LBS. 10’ x 20’ AREA REQUIRED TO OPERATE - PUMP - 34 GAL.
  • Page 8 Diagram A. EXCEL Model EX62 Structural Specifications Diagram.

  • Page 9: Safety Precautions

    EMERGENCY STOP BUTTON Every unit manufactured by EXCEL has a RED extended head emergency stop button. All personnel should be aware that depressing this button at any time stops the machine from operating. Emergency Stop button(s) must not be over ridden or defeated in any way.
  • Page 10 SAFETY DECALS Replace all Safety Decals as they become unreadable or are missing. For proper decal replacement see the Decal list under the DETAILED PART IDENTIFICATION section of this manual. Obtain new Safety Decals at no charge, by contacting Excel Manufacturing.

  • Page 11: Employer Requirements

    EMPLOYER REQUIREMENTS The employer will establish a procedure for the locking and tagging out of energy sources as required by OSHA. The employer will provide training to all personnel involved in the operation, service and maintenance of the equipment. The employer will monitor the employees operation of the equipment, ensuring that safe practices are being followed. The employer will establish a program of regular inspections as outlined in the section CARE AND MAINTENANCE.

  • Page 12: Lock Out/Tag Out Procedure

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

  • Page 13: Basic Part Identification

    BASIC PART IDENTIFICATION The parts diagram on the following page shows the location of key parts and baler controls. Some of the parts require installation. These parts have been shipped packed inside the baler. As you read the description of each part and control, find that part on your baler to familiarize yourself with its location.
  • Page 14 Diagram B. EXCEL Model EX62 Basic Parts Identification Diagram.

  • Page 15: Installation Instructions

    After the baler arrives, inspect the overall condition of the baler for damage during shipping. Remove all the loose parts and information papers. Make sure that all parts required for assembly have been received. If any items are missing or appear damaged, contact your EXCEL Manufacturing representative immediately.

  • Page 16: Hydraulics

    HYDRAULICS Diagram E. Temperature/Sight Gauge The hydraulic system has been completely operated and tested at the factory. Check all hydraulic connections to insure that no leaks have developed during transit. Check the oil level within the reservoir. The oil in the temperature/sight gauge on the side of the reservoir should be even with the oil level arrow when the platen is fully retracted.
  • Page 17 Drill or punch a hole in the electrical enclosure to allow the electrical power line to enter the box. Protect parts from metal chips. After drilling or punching holes in the electrical box, extract all metal filings or chips from the box. Do not blow them out or premature contactor failure will result! Run electrical power lines from the customers MAIN disconnect switch to the electrical box.

  • Page 18: Remove Attatched Parts

    Diagram G. Connecting Electrical Power to Disconnect Inside Box. Close the electrical box. Do not close the MAIN power supply switch or turn the handle to ON until instructed to do so in the START UP AND TESTING section of this manual. REMOVE ATTATCHED PARTS Open baler door and remove clean out tool from inside tube at top front of chamber.

  • Page 19: Final Inspection

    INSTALLATION STEPS Block up front end of baler one foot off from floor. From underneath the baler, place a wire guide into a slot, sliding the front of the wire guide to the front of the baler. Push the guide into the slot completely, so that the front of the guide rests on the tube at the front of the baler, and so that the holes in the guide are aligned with those on the baler.

  • Page 20: Start Up And Testing

    START UP AND TESTING Do not test this baler until all involved persons have completely read and understood this manual. Make sure that all access covers are in position and that the baler chamber door is closed and secured with the latch.
  • Page 21 Depress the green FORWARD button once again. The motor will start and the platen will move forward and then reverse automatically after reaching full extension into the bale chamber. It will return to its retracted position and the motor will shut off.

  • Page 22: Operating Instructions

    The employer must provide instruction and training in safe methods of work to employees before assigning them to operate, clean, service, maintain, or repair the equipment. Such instruction and training shall include procedures provided by EXCEL Manufacturing. Employers are responsible for repairing, prior to placing baler equipment into service, any mechanical malfunctions or breakdowns that affect the safe operation of the equipment.
  • Page 23 Diagram K. Operating Controls. START UP ALARM - When the baler disconnect switch is turned on, the emergency stop switch is released and the key switch is turned to hand or auto, the buzzer will sound and the red light will flash for 20 seconds before the baler and conveyor controls are unlocked.

  • Page 24: Semi Automatic Baler Cycle

    FORWARD - Green Push Button When the SYSTEM is set to AUTO, depressing the FORWARD button activates auto cycle and starts the motor and the platen moves forward. When the platen reaches full extension into the bale chamber, it reverses automatically and returns to its original starting position.

  • Page 25: Bale Tieing

    BALE TYING After a complete bale is formed in the bale chamber, the blue BALE TIE OFF LIGHT at the top of the baler will illuminate. The baler and conveyor shuts off automatically with the platen in the correct forward position for tying the bale. Turn the key switch to the HAND position.
  • Page 26 Center the wire in the guide on the underside of the bale to assure that the wire will pull up completely and out of the slot when the two ends are secured together. This will prevent the wires from being cut by the edge of the wire guide. Diagram M.

  • Page 27: Bale Ejection

    BALE EJECTION The bale is ready to be ejected from the chamber after the machine has stopped with the BALE TIE OFF LIGHT illuminated and the bale has been tied following the previous instructions. All persons must be clear from the front of the baler when the bale is being ejected. Serious injury could result from the bale falling onto the pallet.
  • Page 28 AUTOMATIC BALING (PHOTO EYE CONTROLLED) Turn the BALER power disconnect to ON. Turn the SYSTEM key switch to AUTO. Turn the PHOTO EYE CONTROL switch to ON. When photo eye beam is broken, the baler starts and cycles automatically, without warning. Depress FORWARD or REVERSE to activate auto cycle.

  • Page 29: Care And Maintenance

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

  • Page 30: Weekly Care Requirements

    OIL SELECTION TABLE Conoco ISO Grade MV 32 Product Number MV32 Oxidation Control (ASTM D-943, hr) 4500 hours Pour Point, (°F), max. Flash Point, (°F), min. Viscosity SUS at 100°F SUS at 210°F cSt at 40°C cSt at 100°C ISO viscosity Grade Viscosity Index, min.
  • Page 31 Diagram L. Lubrication Chart. 9. Check that the bale tie light works when a bale is complete. 10. Test the door safety interlock. The motor should stop and the pressure to the platen decompresses if the latch is opened. The motor will not run if the door is not swung completely open when ejecting a bale.

  • Page 32: Semiannual Care Requirements

    2. Have an oil sample tested yearly and compare the result to the oil manufacturer's specifications. If oil does not meet specifications, replace. 105 gallon of oil as recommended in the Oil Selection Table on page 24 is required to fill the reservoir. SERVICE KITS 1. EX62 6 Month Service Kit: (A-1117) HP-1049 Breather Filter...

  • Page 34: Troubleshooting And Service

    Troubles sometimes are caused by simple "faults" that can be easily corrected without the help of a service technician by first checking a few basic remedies. Before you call an authorized EXCEL Manufacturing service representative, look below for the type of trouble you are experiencing. Then perform the check and adjustments listed for the trouble.
  • Page 35 TROUBLE POSSIBLE PROBLEM SOLUTION Motor won't start or makes growling Very low voltage Check power source noise Check motor nameplate Single Phased Check power source. Must have all three phases. Open motor leads Check continuity. Clean and tighten Rotor or bearings locked Check shaft for freeness of rotation Starter coil burned out Replace starter coil...
  • Page 36 TROUBLE POSSIBLE PROBLEM SOLUTION Motor continues to run and fails to Front Limit Switch out of adjustment See Limit Switch Adjustments return platen Pressure switch out of adjustment See Pressure Switch Adjustments Relief Valve out of adjustment See Relief Valve Adjustments Baler continues to cycle with empty Photo Eye and/or Photo Eye Reflector Clean Photo Eye and/or Photo Eye Reflector...

  • Page 37: Adjustments

    ADJUSTMENTS Adjustments are to be performed by authorized service technicians only. ROTATING CUTTING EDGE The shear blade is designed to make use of four cutting edges. Follow these instructions to remove the shear blade and revolve it to a fresh cutting edge. Fully retract the platen.
  • Page 38 Diagram M. Placement of Shim Material Between Platen and Nylatron. Reassemble the parts and slide into position under the platen. Replace the bolts and tighten securely. Check platen side clearance. Add shims to the side as needed to align wire slots in platen to wire slots in floor. Reactivate the power supply.

  • Page 39: Limit Switch Adjustment

    LIMIT SWITCH ADJUSTMENTS Tools Required: 1/2" Wrench Before proceeding, make sure that the six inch long limit switch cam is set flush with the left end of the slide that it is mounted on. Also check to see that the limit switch arms are at right angles (90 degrees) to the switch bodies. Adjustment of the switches is made by loosening the nuts which hold the limit switch mounting angles to the aluminum housing.

  • Page 40: Pressure Switch

    3200 PSI on the pressure gauge. See Diagram O on the next page for correct location of compensator adjusting bolt. Never adjust the torque limiter bolt without contacting an EXCEL Manufacturing representative. (Torque limiter found on Vickers Pumps.) If this pressure cannot be attained, then the relief valve is bypassing.

  • Page 41: Pump Torque Limiter

    PUMP ADJUSTMENT The pump is factory preset and must never be adjusted. The warranty will be void if the pump adjustment is tampered with before contacting Excel manufacturing. For more information, contact an EXCEL Manufacturing representative. PHOTO EYE ADJUSTMENT Perform this adjustment with the baler in hand position and photo eye off.

  • Page 42: Detailed Part Identification

    DETAILED PART IDENTIFICATION...

  • Page 43: Main Baler

    MAIN BALER REF. NO. PART NO. DESCRIPTION QTY. P-1035 Nylock Nut M-1050 Dog-Standard P-1095 Bolt P-1037 Gr. 8 Bolt – Torque 212 ft. lbs. P-1038 Flat Washer M-1056 Shear Edge M-6007 Shim Shear Edge P-1394 Socket Head Shoulder Screw A-1153 Scraper --- Up to Serial Number EX2359 A-1806 Scraper w/ Doubler Plate--- Serial Number EX2360 and Up...
  • Page 44 REF. NO. PART NO. DESCRIPTION QTY. A-1696 Turnbuckle -RH A-1697 Turnbuckle -LH P-1043 Nylock Nut P-1042 Bolt EP-1502 Proximity Switch A-1014 Clean Out Tool P-1052 Grease Zerk M-1614 Wear Plate A-1693 Main Baler Frame -RH A-1721 Main Baler Frame -LH Include model number and serial number when ordering parts.
  • Page 45 This page is blank...

  • Page 46: Platen

    PLATEN...
  • Page 47 PLATEN REF. NO. PART NO. DESCRIPTION QTY. M-2046 Side Platen Shim VAR. M-5852 Shim VAR. A-1406 Platen M-2025 Bearing Rear/ Bottom/Side M-2023 Lower Bearing M-2039 Floor Shim Plates VAR. S-1010 Glide Retainer P-1033 Lock Washer Split P-1029 Bolt M-2034 Top Side Bearing P-1672 Flat Washer Include model number and serial number information when ordering parts.

  • Page 48: Cylinders And Hoses

    CYLINDERS - HOSES...
  • Page 49 CYLINDERS - HOSES REF. NO. PART NO. DESCRIPTION QTY. HP-1237 Pressure Hose A HP-1249 Pressure Hose B HP-1039 O-Ring HM-1019 Splitter Manifold P-1025 Split Lock Washer P-1016 Bolt HP-1024 Adapter HP-1263 O-Ring HP-1039 O-Ring P-1035 Nylock Nut M-1054 Cylinder Pin P-1031 Bolt HP-1253...

  • Page 50: Valves And Fittings

    VALVES - FITTINGS...
  • Page 51 VALVES - FITTINGS REF. NO. PART NO. DESCRIPTION QTY. P-1046 Socket Head Cap Screw P-1047 High Collar Lock Washer HP-1010 Pilot Valve (Replacement) P-1030 Socket Head Cap Screw P-1032 High Collar Lock Washer HP-1007 Directional Valve -Main HP-2145 O-Ring Kit for HP-1007 P-1018 Socket Head Cap Screw P-1026...

  • Page 52: Pump And Motor

    PUMP - MOTOR...
  • Page 53 PUMP - MOTOR REF. NO. PART NO. DESCRIPTION QTY. HP-1066 Pump (Blue) EX2001 –EX2075 (Vickers) HP-1000 Pump (Grey) EX2076 – EX2408 HP-2626 Pump –EX 2409 – Current M-4807 Pump Key P-1028 Bolt P-1033 Split Lock Washer HP-1004 Pump to Motor Adapter Orange Cover (M-182-3) –...
  • Page 54 RESERVOIR - FILTER...
  • Page 55 RESERVOIR - FILTER REF. NO. PART NO. DESCRIPTION QTY. P-1023 Nylock Nut HP-1006 Oil Filter Assembly (Complete) 196A HP-2454 O-Ring F/Filter Housing, Cover 196B HP-1891 Gasket F/Filter Housing HP-1049 Replacement Oil Filter HP-1051 Adapter 198A HP-1244 O-Ring HP-1036 Return Hose A-1009 Reservoir Cover 200A...
  • Page 56 REF. NO. PART NO. DESCRIPTION QTY. A-2881 Reservoir Serial Number EX2409 and up M-1009 225A Reservoir Cover Weldment HP-1035 Hose HP-1062 Adapter HP-1061 O-Ring P-1038 Bolt P-1033 Lock Washer HP-1062 Adapter Include model number and serial number information when ordering parts.
  • Page 57 This page is blank...
  • Page 58 CONTROLS -To Late 2008...
  • Page 59 CONTROLS -To Late 2008 REF. NO. PART NO. DESCRIPTION QTY. P-1048 Lock Washer P-1226 Screw EP-1407 Insulating Bushing EP-1208 Conduit Connector Gasket EP-1243 Straight Cord Grip EP-1446 Straight Cord Grip EP-1248 Conduit Connector Gasket EP-1119 Insulating Bushing EP-1252 Control Box EP-1078 Contact Block EP-1077...
  • Page 60 CONTROLS Late 2008- Current...
  • Page 61 CONTROLS Late 2008- Current REF. NO. PART NO. DESCRIPTION QTY. P-1048 Tooth Lock Washer P-1226 Screw EP-1407 Insulating Bushing EP-1208 Conduit Connector Gasket EP-1243 Cord Grip EP-1446 Straight Cord Grip EP-1248 Conduit Connector Gasket EP-1119 Insulating Bushing EP-1252 Control Box EP-2323 Latch Mount EP-2322...

  • Page 62: Electrical Enclosure

    ELECTRICAL ENCLOSURE...
  • Page 63 ELECTRICAL ENCLOSURE REF. NO. PART NO. DESCRIPTION QTY. EM-1067 EX62 Main Electrical Box EM-1068 Panel EP-1144 Disconnect Kit 200 - 230 Volt EP-1327 HANDLE,DISCNCT 230V EP-1004 Disconnect Kit 415 – 460 Volt EP-1085 HANDLE,DISCNCT 460V EP-1443 Fuse 100A JTD 200 Volt...
  • Page 64 REF. NO. PART NO. DESCRIPTION QTY. EP-1382 Terminal Block Blue EP-1389 Terminal Block Yellow EP-1790 Terminal Circuit Separator EM-1263 Terminal Jumper Bar 2-Hole EM-1264 Terminal Jumper Bar 3-Hole EM-1265 Terminal Jumper Bar 4-Hole EP-1835 Terminal Jumper Screw/Washer EP-1806 Vertical Marker 1-10 EP-1807 Vertical Marker 11-20 EP-1808...
  • Page 65 Cord Grip (Left Hand) EP-1409 Cord Grip (Right Hand) OPTIONAL COMPONENTS/KITS EM-1484 EX62 Conveyor Comp Connectors / Grips EM-1425 Conveyor Comp 200 -208 Volt 2 HP EM-1426 Conveyor Comp 230 Volt 2 HP EM-1427 Conveyor Comp 415 Volt 2 HP...

  • Page 66: Limit Switch Rail

    LIMIT SWITCH RAIL...
  • Page 67 LIMIT SWITCH RAIL REF. NO. PART NO. DESCRIPTION QTY. EM-1010 Slide Nut P-1008 Lock Washer P-1003 Screw EM-1008 EP-1501 Slide P-1271 Bolt EM-1009 Driver P-1045 Bolt P-1048 Lock Washer EP-1021 Limit Switch Arm P-1079 Flat Washer EP-1019 Limit Switch EP-1208 Conduit Connector Gasket EP-1243 Straight Cord Grip...

  • Page 68: Photo Eye

    PHOTO EYE...
  • Page 69 PHOTO EYE REF. NO. PART NO. DESCRIPTION QTY. P-1004 Bolt P-1008 Split Lock Washer EM-1013 Reflector Mounting Bracket EP-1062 Reflector EP-1058 Photo Head EP-1159 Relay EP-1157 Terminal Base EP-1063 Mounting Bracket EP-1583 Clamp P-1001 Bolt EM-1015 Cover P-1007 Flat Washer EP-1411 Cord 82”...

  • Page 70: Decals

    DECALS...
  • Page 71 DECALS REF. NO. PART NO. DESCRIPTION QTY. D-1009 Motor Rotation Arrow D-1001 Small EXCEL Logo D-1008 WARNING - Access Panel D-1015 Bale Tie Light D-1024 Lock Out/Tag Out D-1082 200 Voltage D-1040 208 Voltage D-1002 230 Voltage D-1083 380 Voltage...

  • Page 72: Hopper Bolt Pattern Diagram

    HOPPER BOLT PATTERN DIAGRAM The following diagram illustrates the location of holes on the baler to which optional hopper devices can be fastened. Holes in optional equipment must match the dimensions shown. The four holes shown on the baler are threaded for 3/8-16 UNC fasteners.
  • Page 73 EX62 PREVENTATIVE MAINTENANCE CHECK LIST CUSTOMER NAME ADDRESS SERIAL NUMBER INSPECTION DATE WEEKLY PROCEDURES Test Photo Eye Check Platen to Shear Edge Check Baler Disconnect & Lower Clearance Padlock Upper Check Oil Level Test Bale Tie Light Shims Required Adequate...

  • Page 74: Warranty

    Warranty applicable in Continental United States only. EXCEL Models EX77, HV 9 & HV 10, 2R63, 2R9, 2R10 Signature 100, 150 & Signature 200 balers and appropriate conveyor systems will carry a warranty of: 1 year (2080 hours operation) parts and labor.
  • Page 75 This page is blank...

  • Page 76: Electrical Schematics

    Appendix A Electrical Schematics Specific Schematics 208/230V- ES-1232 ES-1211 460V- ES-1214 575V- ES-1233 415V CE- ES-1211 ES-1212 ES-1213 Common Schematics ES-1215 ES-1216 ES-1414 HM-1208 HM-1070...
  • Page 89 NOTES...
  • Page 90 This page is blank.

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