Dover Marathon NEXGEN GALAXY 2R Operation, Maintenance And Installation Manual
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Dover Marathon NEXGEN GALAXY 2R Operation, Maintenance And Installation Manual

Dover Marathon NEXGEN GALAXY 2R Operation, Maintenance And Installation Manual

Grand forks two-rambaler
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OPERATION, MAINTENANCE,
AND INSTALLATION MANUAL
GALAXY 2R
®
GRAND FORKS TWO-RAM BALER
Vernon, AL - Yerington, NV
1-800-633-8974
www.nexgenbalers.com
NEXGEN ® is a Division of Marathon Equipment Company
OMI Manual No. 0013-Grand Forks1, Revision Date: Aug 2012
www.marathonequipment.com

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  • Page 1 OPERATION, MAINTENANCE, AND INSTALLATION MANUAL GALAXY 2R ® GRAND FORKS TWO-RAM BALER Vernon, AL - Yerington, NV 1-800-633-8974 www.nexgenbalers.com NEXGEN ® is a Division of Marathon Equipment Company OMI Manual No. 0013-Grand Forks1, Revision Date: Aug 2012 www.marathonequipment.com...

  • Page 2: Table Of Contents

    Table of Contents OPERATION Introduction ....................1-1 Pre-Operation Instructions ................1-2 The Baling Process ..................1-3 Control Panel Diagram ................1-4 Emergency Stop Control Location ..............1-5 Standard Operation - Baler Start Up ............. 1-6 Automatic and Manual Operation Modes ............1-7 Automatic Operation (Auto Mode) ..............
  • Page 3 Decals ...................... 1-43 Warning Decal Requirements ..............1-43 Decal Placement ..................1-44 Decal Images ..................1-45 Layout Diagrams ..................1-46 North Baler .................... 1-46 South Baler .................... 1-47 Loading/Weight Diagram ................. 1-48 PARTS & MAINTENANCE Lock-Out & Tag-Out Instructions ..............2-1 Service Call Center Information ..............
  • Page 4 Power Unit Drawing (2 x 100 HP) ..............2-16 Power Unit Parts List (2 x 100 HP) .............. 2-19 Motor Specifications ................... 2-22 03-0833 & 03-5753 ................2-22 03-1071 ....................2-23 Replacement Parts Lists ................2-24 Body Ram Liner ..................2-24 Baler .....................

  • Page 5: Operation

    OPERATION Introduction Thank you for purchasing a NEXGEN ® Galaxy2R ® Grand Forks Two-Ram Baler! This product is designed to give you reliable service and superior performance for years to come. The purpose of this manual is to provide the owner and/or operators with the necessary information to properly and safely install, operate, and maintain the baler.

  • Page 6: Pre-Operation Instructions

    Pre-Operation Instructions WARNING: Do not operate baler until operating instructions are thoroughly understood. Wear safety glasses and gloves when operating this equipment. ------------------------------------------------------------------------------------------ DANGER Stay clear of all internal baler parts and all moving external baler parts when in operation. DO NOT Failure to do so could result in serious personal ENTER...

  • Page 7: The Baling Process

    The Baling Process Operation 1-3...

  • Page 8: Control Panel Diagram

    Control Panel Diagram 1. Touch Screen - Most of the baler’s operations can be controlled from here. The description of touch screen controls begins on page 1-8. 2. Joysticks - Used to manually control both the main ram and the ejection ram. The touch screen controls must be set to “Manual Mode”...

  • Page 9: Emergency Stop Control Location

    Emergency Stop Control Location ® ® NEXGEN Galaxy2R Grand Forks Two-Ram Balers have four emergency stop buttons mounted at various locations on the machine. Be thoroughly familiar with the location of each button. If a conveyor system is used, the conveyor should have an e-stop button mounted on it.

  • Page 10: Standard Operation - Baler Start Up

    Standard Operation - Baler Start Up WARNING: Do NOT operate baler until operating instructions are thoroughly understood. Prior to start-up of the baler each day, check the items found in the “DAILY” list Periodic Maintenance on page 2-3. Standard operation includes baler start-up for Manual and Automatic Operation. Baler Start Up 1.

  • Page 11: Automatic And Manual Operation Modes

    Automatic and Manual Operation Modes Automatic Operation (Auto Mode) 1. Start the baler as described in Standard Operation - Baler Start Up on page 1-6. 2. From the touch screen’s Main Menu, press the MANUAL MODE button and the screen advances to the “Manual Menu”. 3.

  • Page 12: Touch Screen Controls

    Touch Screen Controls The following control panel screens are available in English as standard. Spanish and French screens are available as options. Press the required option button onscreen to change the display language. Start Up Screen Go To Main Menu - Press to continue to the Main Menu Screen on page 1-9.

  • Page 13: Main Menu Screen

    Main Menu Screen Information Boxes - The top left olive-colored window displays general information and the top right window displays the status of the motors. Go To General Setup - Press to go to the General Setup Screens on page 1-10;...

  • Page 14: General Setup Screens

    General Setup Screens NOTE: You must login as the “manager” to access the General Setup screens. Motor start delay/alarm ON/OFF Delay Between Main Motor Start - Indicates the delayed time, in seconds, between each motor starting. The range can be set between 1-15 seconds and is recommended to be set at 4 to 5 seconds.
  • Page 15 Set no material detect cycle count No Material Detect Cycle Counts - Press this button to display a numeric keypad to select the number of cycles for the ram to complete before it stops because no material is detected by the selected photocells. Displays the fault. Operation 1-11...
  • Page 16 Heat exchanger ON/OFF Heat Exchanger - Press this button to switch the heat exchanger (oil cooler) to the “Auto” mode. It is recommended to keep this on “AUTO” during operation, not “OFF”. Operation 1-12...
  • Page 17 Motor stop activate/set idle time Motor Stops When Not Baling - Press this button to switch to the “ON” setting, which programs the baler to stop after a set length of idle time. Idle Time To Motor Stop Minutes - Press this button to display a numeric keypad which allows you to choose the length of idle time (in minutes) before the motor(s) automatically shut down.

  • Page 18: Grade Setup Screens

    Grade Setup Screens NOTE: You must login as the “manager” to access the Grade Setup screens. Grade setup 1 ## Select Bale Recipe - You must login as the “operator” to change the Bale Recipe. Plug Bale/ Full Eject - When “Plug Bale” is displayed, the ejector ram does not eject the bale all the way out.
  • Page 19 Grade setup 2 Bale Made Position - When a set baling pressure is reached at this position or less than, the bale ejects. You can select increments up to one-tenth of an inch. The minimum position is “67.0” inches. Baling Pressure - This is the maximum pressure limit while baling before the bale is ejected.
  • Page 20 Grade setup 3 Minimum Hopper Opening - Press the number box to display a numeric keypad where the operator can select the starting position of the main ram within the hopper opening. The range is from 1.0” to 90.0”. This setting can be increased to lessen the opening of the charge chamber in order to control the flow of material and prevent over-charging.
  • Page 21 Grade setup 4 Ram Photocell Delay - This is the time that the photocell is to be blocked before the ram activates, set within one-tenth of a second. Plug Mode Door Extended Position - The NexDoor can be used as a “plug” to hold the bale in position.
  • Page 22 Grade setup 5 Use Multi-Gather - When “ON”, the ram travels just past the shear blade before it retracts and does not fully extend. This is used to build initial bale density and to speed up bale production. When “OFF” the ram extends fully each cycle. Operation 1-18...
  • Page 23 Grade setup 6 Auto Cycle Eye - This setting is changed according to the baling material size. For example, when baling larger material, such as corrugated cardboard, select the “Upper” photocell. When baling smaller material, such as office paper, select “Either Lower”...
  • Page 24 Grade setup 7 Conveyor Feed Eye - The selection in this list determines which photocell stops the conveyor for the duration of the ram cycle. Press the required photocell to highlight and activate setting. Conveyor Feed Eye Delay - Press to display a numeric keypad and select the length of time (in seconds) the photocell is blocked before the conveyor stops.
  • Page 25 Grade setup 8 Alarm When Bale Made - Press the “Change” button on the right to activate an alarm to sound once a bale is made. Alarm status is indicated by either “OFF” or “ON” to the far right. This is used in the event of a material change once the bale is made.
  • Page 26 Grade setup 9 Press the number boxes to display a numeric keypad where you can select the bale positions at which you want straps to be placed around the bale. The range for both “Plug Bale” and “Full Eject” are 2.0 - 99.0 inches. Although “99” exceeds the maximum position, it can be selected for straps that will not be used.

  • Page 27: Diagnostics Screens

    Diagnostics Screens NOTE: You must login as the “manager” to access the Diagnostics – data screen. NOTE: All other diagnostics screens (refer to pages 1-24 to 1-25) are accessible ® only by Marathon NEXGEN personnel. In the event that you need to access these screens, please call our service department at 1-800-633-8974 and proper instructions will be given accordingly.
  • Page 28 Diagnostics – model status Diagnostics – ram position Operation 1-24...
  • Page 29 Diagnostics – cylinder position Diagnostics – options Operation 1-25...

  • Page 30: Input/Output Screens

    Input/Output Screens NOTE: Input / Output screens coincide with the PLC and electrical schematic to show which components have power to them by illuminating red. If there is no power to the specific input/output, the indicator remains red. The indicator turns green if the input/output is energized.
  • Page 31 Input/output status 2 Input/output status 3 Operation 1-27...

  • Page 32: Data Screens

    Data Screens NOTE: You must login as the “manager” to access the data screens. Data cumulative Bale Counts Life Time - Indicates the number of total bales made during the life of the baler. Motor Hours - Indicates the total number of hours the motor(s) have been in operation.
  • Page 33 Data bales/day This screen displays a graph showing the number of bales made per day for the past seven days. Operation 1-29...
  • Page 34 Date/message This screen displays a list of fault messages the baler has encountered. Reset Reset - Press this button to clear the display message. Operation 1-30...
  • Page 35 The two screens shown on page 1-30 indicate that the machine has encountered a problem and operation cannot continue until the fault is corrected. The date and time of the fault are also recorded here. Refer to the Fault List below for a complete listing of possible faults.

  • Page 36: Motor Control Menu Screen

    Motor Control Menu Screen Information Boxes - The top left olive-colored window displays general information and the top right window displays the status of the motors. Circulation Pump Start - Press this button to start the circulation pump. Circulation Pump Stop - Press this button to stop the circulation pump. Motor 1 Start - Press this button to start Motor #1.

  • Page 37: Manual Menu Screen

    Manual Menu Screen Information Box - The top left olive-colored window displays general information. Conveyor On – Press to start the conveyor. Conveyor Stop - Press to stop the conveyor. Main Menu - Press to go back to the Main Menu Screen on page 1-9.

  • Page 38: Auto Menu Screen

    Auto Menu Screen Information Box - The top left olive-colored window displays general information. Data - Press to access the Data screens. See Data Screens on page 1-28. Main Menu - Press to go back to the Main Menu Screen on page 1-9.

  • Page 39: Access System Setup Screen

    Access System Setup Screen System Setup Screen - Press the upper right and lower left corners of the screen to access the System Setup screen. NOTE: This should only be used to change the time and date for date stamping . Main Menu - Press to go back to the Main Menu Screen on page 1-9.

  • Page 40: Control Panel Layout

    Control Panel Layout Operation 1-36...
  • Page 41 Control Panel Layout (cont.) Reference numbers given below refer to the control panel layout drawing page 1-36. Ref # Part # Description 030757 DINRAIL MOUNTING CHANNEL AB#19 033645 PLC AB 1764 LRP ML 232 PROCESS 034258 PLC AB MICRO LOGIC 1500 BASE 2 034172 TERMINAL BLOCK #24-10 35MM DIN 034470...
  • Page 42 Ref # Part # Description 035053 LEGEND 3/4 X 2 'MAIN RAM' TOP 035054 LEGEND 3/4 X 2 'EJECTOR RAM’ TO 035055 LEGEND 3/4 X 2 'COMPRESS’ TOP 035056 LEGEND 3/4 X 2 'RETRACT’ TOP 035057 LEGEND 3/4 X 2 'EJECT’ TOP 060120 DECAL DANGER DISCONNECT &...

  • Page 43: Nexdoor ® Diagram

    NexDoor ® Diagram Operation 1-39...

  • Page 44: Jam Prevention

    Jam Prevention Do not enter the baler for any reason until the baler has been Warning: locked-out and tagged-out per Lock-Out & Tag-Out Instructions on page 2-1 There are two types of jams which could occur with a two-ram baler; a jam at the shear blades or an oversize bale which is difficult to eject.

  • Page 45: Over-Sized Bale Jam

    Over-Sized Bale Jam Warning: Do not enter the baler for any reason unless the baler has been locked- out and tagged-out per Lock-Out & Tag-Out Instructions on page 2-1. The following instructions explain how to remove a jammed bale. 1. If the bale fails to eject in Automatic Mode, set the baler to Manual Mode. 2.

  • Page 46: Changing Materials And Baler Shutdown

    Changing Materials and Baler Shutdown Changing Materials • To prevent contamination between bales, stop the supply of the present material to the feed conveyor. Run the conveyor empty into the baler feed hopper. Make sure the conveyor is cleared of all material. Turn the conveyor off.

  • Page 47: Decals

    Decals Warning Decal Requirements When your baler leaves the factory, several WARNING DECALS are installed for your protection. These labels are subject to wear and abuse due to the nature of the baling operation. The following decals must be maintained. Additional decals may be purchased through your distributor or from Marathon Equipment Company by either calling the service department at 1-800-633-8974 or going online to www.parts1stop.com.

  • Page 48: Decal Placement

    Decal Placement Refer to the page 1-45 for decal images. Operation 1-44...

  • Page 49: Decal Images

    Decal Images 06-0116 06-0039 06-0038 06-0041 06-0052 06-0129 06-0120 06-0121 06-0117 06-0133 06-0249 06-1839 06-0250 06-2750 06-2751 06-2684 06-2686 06-2690 06-3050 06-3044 06-3123 06-3053 06-3051 Operation 1-45...

  • Page 50: Layout Diagrams

    Layout Diagrams North Baler Operation 1-46...

  • Page 51: South Baler

    South Baler Operation 1-47...

  • Page 52: Loading/Weight Diagram

    Loading/Weight Diagram Operation 1-48...

  • Page 53: Parts & Maintenance

    PARTS & MAINTENANCE Lock-Out & Tag-Out Instructions Before entering any part of the baler, be sure that all sources of energy have been shut off, all potential hazards have been eliminated, and the baler is locked-out and tagged-out in accordance with OSHA and ANSI requirements. If the ram is pressing against a load, move the ram rearward before shutting the baler down.

  • Page 54: Service Call Center Information

    Service Call Center Information During normal business hours, please call: 1-800-633-8974 ATTN: NEXGEN ® Service Department or log on to: www.parts1stop.com Normal Business Hours: Monday - Thursday 7:00am - 5:30pm Friday 7:00am - 4:30pm Saturday 7:00am - 12:00pm (Central Standard Time) Maintenance 2-2...

  • Page 55: Periodic Maintenance

    Periodic Maintenance DANGER: Only authorized and trained personnel should perform the following procedures. Lock-Out and Tag-Out the baler per as specified in Lock-Out & Tag-Out Instructions on page 2-1. After Start-Up Replace the return line filter after the start-up technician has completed the initial startup of the machine.

  • Page 56: Quarterly (Or Every 500 Hours Of Operation)

    9. After the first 160 hours of operation, the return line filter should be replaced. After this replacement, the return line filter maintenance/replacement schedule is extended to every 600-1000 hours of operation. Quarterly (or every 500 hours of operation) 1. Change the return line oil filter element in the oil filter housing (filter/housing is located on the side of reservoir at the end of oil return line from oil cooler).

  • Page 57: Holddown Bar Maintenance

    Holddown Bar Maintenance DANGER: Only authorized and trained personnel should perform the following procedures. Lock-out and tag-out baler per instructions specified on page 2-1. HOLDDOWN BARS prevent the ram from “Riding Up” over material in the charge chamber. They also prevent the ram shear blade from coming in contact with the body shear blade.

  • Page 58: Shear Blade Maintenance

    Shear Blade Maintenance DANGER: Do not perform any maintenance to the ram shear blade or body shear blade until the disconnect switch has been locked-out and tagged-out per Lock-Out & Tag-Out Instructions on page 2-1. CAUTION: Shear blades are sharp. Wear leather gloves and safety glasses when handling blades.

  • Page 59: Body Shear Blade Adjustment

    Body Shear Blade Adjustment DANGER: Do not perform any maintenance to the ram shear blade or body shear blade until the disconnect switch has been locked-out and tagged-out per Lock-Out & Tag-Out Instructions on page 2-1. ---------------------------------------------------------------------------------------------- It is necessary to periodically adjust the Body Shear Blade in order to maintain the 0.015”...

  • Page 60: Torque Sequence

    Torque Sequence The following torque sequence must be used as part of the Body Shear Blade Adjustment procedure described on page 2-7. NOTE: This procedure assumes that the body shear is in the full up position. The Lateral Bolts on the front face of the shear header need to be backed off prior to shear adjustment.

  • Page 61: Bale Door Holddown Bar

    Bale Door Holddown Bar The bale door utilizes a top holddown bar assembly (shown on right) that is designed to guide and hold the bale door when it is retracted. This holddown bar assembly contains a shim plate (lower picture) that is sometimes shipped loose with the baler and may need to be installed when the gap between the upper contact surface...

  • Page 62: Troubleshooting

    Troubleshooting ONLY thoroughly trained and experienced service personnel should perform trouble- shooting and maintenance on this baler. Do NOT enter the baler for any reason until it has been locked-out and tagged-out per the Lock-Out & Tag-Out Instructions on page 2-1.
  • Page 63 Problem Possible Cause Solution EJECTOR WILL 1) Compression ram not in 1) Move to HOME position. NOT MOVE HOME position. FORWARD 2) Compression ram HOME 2) Check for false signal. Replace position photocell malfunction. photocell. 3) Bale length counter 3) Check for wheel rotation. malfunction.

  • Page 64: Pressure Settings For 2 X 100 Power Unit

    Pressure Settings for 2 x 100 Power Unit Pump Relief Valve Settings Install the 5000 psi pressure gauge in port MP1. Lower pressure to the minimum settings on all relief valves on Motor #1 and Motor #2 pumps SV6, SV7, SV8, SV9, SV10, and SV11 by turning the adjustment screws counter-clockwise.

  • Page 65: Main Manifold Rod Relief Pressure Setting

    Main Manifold Rod Relief Pressure Setting NOTE: This process requires TWO people. Install the 5000 psi pressure gauge in port MP1. Start Motor #1. Retract the main ram fully. Loosen the adjustment screw locknut on the rod relief valve and turn the adjustment screw counter-clockwise to lower the pressure setting.

  • Page 66: Tie System 12 Gpm Pump Pressure Setting

    Tie System 12 GPM Pump Pressure Setting NOTE: This process requires TWO people. Lock out power and install a 5000 psi pressure gauge in the port provided at the 12 gpm tie system pump. Install the four tie test pins into the tie system mounting plate. Turn on power and the start motors.

  • Page 67: Hydraulic Schematic (2 X 100)

    Hydraulic Schematic (2 x 100) Maintenance 2-15...

  • Page 68: Power Unit Drawing (2 X 100 Hp)

    Power Unit Drawing (2 x 100 HP) (1 of 3) Maintenance 2-16...
  • Page 69 Power Unit Drawing ( 2 x 100 HP) (2 of 3) Maintenance 2-17...
  • Page 70 Power Unit Drawing ( 2 x 100 HP) (3 of 3) Maintenance 2-18...

  • Page 71: Power Unit Parts List (2 X 100 Hp)

    Power Unit Parts List (2 x 100 HP) Reference numbers given below refer to Power Unit Drawings starting on page 2-16. Part # Ref # Description 02-1025 FLANGE C61 1 1/2 SPLIT W/BOLTS 99-7622 FILTER ELEMENT F/997166 05-3199 BOLT 1/2- 13 X 3 1/2 SHCS GR 8 03-1071 1MOTOR MOTOR 20HP 208-230/460 256TC T...
  • Page 72 Power Unit Reference Numbers (cont.) Part # Ref # Description 99-7227 PIPE 3 SCH 160 X 11 1/2 SQ CUT 99-7299 SOCKOLET 1 1/2 X 3-5 6000 PSI 99-7181 FLANGE SADDLE C61 1 1/4 X 3 WE 99-7182 FLANGE SADDLE C61 1 X 3 WELD C 02-1071 FLANGE C62 2 WELD COMP 02-0873...
  • Page 73 Power Unit Reference Numbers (cont.) Part # Ref # Description 99-7292 1 1/2 PL X 9 1/2 X 9 1/2 99-0853 FLANGE C62 1 1/2 SPLIT 02-0878 FLANGE C61 1 SPLIT W/BOLTS 02-0663 FLANGE C61 1 1/4 SPLIT W/BOLT 99-7311 2 SCH 160 X 21 5/8 STR CUT 99-7312 2 SCH 160 X 4 STR CUT...

  • Page 74: Motor Specifications

    Motor Specifications 03-0833 & 03-5753 REL. PHASE/ FRAME TYPE VOLTS S.O. HERTZ 405TC 3/60 1785 230/460 AMB°C / NEMA CODE AMPS DUTY S.F. ENCL. INSUL. DESIGN LETTER 224-112 CONT 40/F 1.15 TEFC STATOR RES.@25 °C TEST TEST ROTOR OHMS S.O. DATE (BETWEEN LINES)
  • Page 75 03-1071 PERFORMANCE DATA AT 460V, 60HZ, 20.0HP (TYPICAL PERFORMANCE – NOT GUARANTEED VALUES) GENERAL CHARACTERISTICS FULL LOAD START 59.0 LB-FT TORQUE: CONFIGURATION: NO-LOAD BREAK-DOWN 9.41 AMPS 213.0 LB-FT CURRENT: TORQUE: LINE-LINE RES. @ 0.426 OHMS A PH / PULL-UP TORQUE: 85.4 LB-FT 25 °C.: 0.0 OHMS B PH...

  • Page 76: Replacement Parts Lists

    Replacement Parts Lists The NEXGEN ® Galaxy2R ® Grand Forks Two-Ram Baler contains parts that will require replacement during the life of the baler. On the following pages are parts lists categorized by baler model and replacement part. The part number and quantity are listed for each part.
  • Page 77 Reference numbers given below refer to Body Ram Liner drawing on page 2-24. Description Part Number Liner Package - Body Body Side Liner-Discharge Side (under 32-7758 holddown bar) Body Side Liner-Ejector Side (under holddown 32-7759 bar) Body Floor Liner - Main 32-5796 Body Floor Liner - Rear 32-4107...

  • Page 78: Baler

    Baler Description Part Number Relay Safety Monitoring 3 Output 24V 03-4152 Transducer Position 164 FT 03-3440 Reflector for Position Transducer 03-4939 PLC AB Micro Logic 1500 03-4877 PLC AB Power Supply 03-4328 Power Supply 24VDC 5 AMP (Panel View Plus) 03-4323 Operator Interface PROFACE 03-5852...

  • Page 79: Conveyer

    Conveyer Description Part Number Relay Safety Monitoring 3 Output 24V 03-4152 Transducer Position 164 FT 03-3440 Reflector for Position Transducer 03-4939 PLC AB Micro Logic 1500 03-4877 PLC AB Power Supply 03-4328 Power Supply 24VDC 5 AMP (Panel View Plus) 03-4323 Operator Interface PROFACE 03-5852...

  • Page 80: Installation

    INSTALLATION General Requirements CAUTION: Review this manual before beginning installation. Study the jobsite and installation requirements carefully to be certain all necessary safeguards and/or safety devices are provided to protect all personnel and equipment during installation and as a completed system. This baler should be installed in accordance with the most current version of ANSI standard Z245.5 at the time of manufacture.

  • Page 81: Foundation Plate Dimensions

    Foundation Plate Dimensions Baler Foundation Requirements: A minimum 6” steel reinforced 3000 psi concrete slab with a minimum 3/4” steel foundation plate per foundation detail. The 3/4” steel foundation plate is recommended to prevent possible floor damage to the concrete slab. Marathon Equipment Company is not responsible for any floor damage if the recommended 3/4”...

  • Page 82: Typical 2R Layout

    Typical 2R Layout (Typical Left Hand shown, Right Hand opposite) NOTE: Anchor pads must be anchored to the floor using 1 x 6” anchor bolts. Do NOT anchor the ejector housing. Installation 3-3...

  • Page 83: Machine Assembly

    Machine Assembly (Connecting Ejector Ram to Main Body) 1. Using a crane, fork lift, or machine roller, position the Main Ram body into the desired location (do not drag the body into place). 2. Assemble the Ejector Ram body to the Main Ram body. Slide the Ejector Ram into the Main Ram body until the facing surface of the Ejector Body contacts the Main Ram body facing surface.
  • Page 84 Machine Assembly (cont.) Level the machine. Use shims under the main ram body and the ejector ram body to compensate for any unevenness in the floor or pad. Place the Bale Table on the floor or pad in front of the ejector opening. Center the bale table to the bale eject opening.
  • Page 85 Machine Assembly (cont.) 5. Set the accumulator for the wire tier in an out-of-way, but convenient location. Allow enough space for handling equipment for the purpose of changing wire spools. Anchor the accumulator to the floor or pad. NOTE: A typical layout is shown below, your installation may differ. For more information on the wire tie system, see the Wire Tie manual.

  • Page 86: Electrical And Hydraulic Installation

    Electrical and Hydraulic Installation DANGER The motor control panel contains high voltage components. Only authorized service personnel should be allowed inside. See Lock-Out & Tag-Out Instructions on page 2-1. Volts WARNING: Before making any electrical connection, be sure that the disconnect switch has been locked-out and tagged-out.

  • Page 87: Installation Start-Up

    Installation Start-Up 1. Check to make sure that all electrical and hydraulic connections have been made. 2. Turn the disconnect switch to the ON position. 3. Check the rotation of the motor. This will require TWO people. a. Remove the cover on the pump. b.
  • Page 88 INDEX Anchoring ..............3-1 Machine Assembly ........... 3-4 ANSI ............1-1, 2-1, 3-1 Maintenance Auto Mode ............1-7, 1-34 Holddown Bar ............2-5 Periodic ..............2-3 Shear Blade ............2-6 Baler Start Up ............1-6 Manual Mode ............1-7 Baling Process ............1-3 Motor Specifications ..........
  • Page 89 PREVENTATIVE MAINTENANCE SCHEDULE FOR NEXGEN 2R HORIZONTAL BALER The following items are part of a preventative maintenance schedule that the factory mandates be used to maintain this baler at factory specifications. If this schedule is not kept, any damage done to the baler or its components will not be covered under warranty.
  • Page 90 5. The preceding and following items should be completed by certified mechanics only, and then only after all safety precautions have been taken and baler is locked out and tagged out. EVERY 10 HOURS OF OPERATION 1. Inspect the baler and power pack for hydraulic leaks. 2.
  • Page 91 material is not building up profusely behind the ram. The wiper blade should be checked to ensure that it is working properly. 3. All Emergency Stops and safety interlocks should be checked for functionality. With the baler on, engage or disengage each emergency stop and interlock individually to ensure that all baler functions cease immediately once the switch is activated.
  • Page 92 Time to complete: The 200 hour maintenance procedure will take approximately two to three hours to complete. If hold down or shear beam adjustments need to be made, it could take longer. Please note the section on shear beam and hold down maintenance below.
  • Page 93 EVERY 2000 HOURS OF OPERATION 1. The hydraulic fluid in the system must be changed at this point. The existing oil may be reused, but a sample of the fluid must be analyzed in a laboratory to determine the state of the fluid, and if any additives should be put in to return the fluid to manufacturer’s standards before doing so.
  • Page 94 are designed so that once one side wears, the bar can be flipped over and the other side used. To do this, the bolts must be completely removed, the bar pulled out, flipped, and reinstalled. Time to complete: The hold down maintenance will take approximately one to two hours to complete.
  • Page 95 10 HOUR MAINTENANCE SCHEDULE COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE:...
  • Page 96 50 HOUR MAINTENANCE SCHEDULE COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE:...
  • Page 97 200 HOUR MAINTENANCE SCHEDULE COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE:...
  • Page 98 600 HOUR MAINTENANCE SCHEDULE COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE: DATE: COMPLETED BY: COMPLETED BY: DATE:...
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