Ti100 & Ti200 OPERATION MANUAL
Contents
1. E 6 The last 10 20 of the bale how would you place flattened material aa ORM SAGE LI Dalen 7 of the finished bale should be done with the a Fingers up retracted o e che Ee ee ve gm b ELAS elion dul js 8 Opening of the top door should a Open it the best b Itdoesnt maler cie L e lt Grip the Mandl frn si nsen A 10 Ejecting the bale should a Pull as hard as can on the b Place the eject trolley in front of the baler with all doors open and in a roll away from the baler thebest estere eub vue E 11 Where should the bale transport trolley be stored when not in use a Under the right hand Bh b Under the left hand 1 ANYNDETE LE LE x 12 Real heavy objects i e boxes of magazines etc How should load them into the baler a Over t2. i SUN i n gt 4 gl x x 1 E i i lt t E o 5 io E gi IL A amp gi i a OPERATION BOUNDARY PLAN VIEW Trethewey AUTOBALER Industries 5 FACILITY L 200 DRAWING 1 2 SL 100 PAC S00 A BMG TE PRIVATE 2 PIY MC WDA MOR LONGO UST OE CRESS OM OR NOI 10 ANY IORS THOG PARTE AL LEGAL 9015 RESERVED POSITION OF POWER TLET ON WAL BEHIND 2455 NOMINAL FLOOR LEVEL 830 170 FRONT ELEVATION FACILITY ARRANGEMENT Trethewey AUTOBALER Industries SL 200 NUM FACILITY DRAWING 2 2 ws 16 INE PRIVATE PROPERTY 0 ORO OUR UST CUSI ANIS BE HOMI UR GEI 10 ANT OPPETO 704 AL WENN ALL LEGAL RESERVED j moda ema IM TN 15 100 FA 5002
3. 70 Db 70 Db 70 Db Ear Protection Must be worn if noise exceed 85 DB Earth Bonding and Electrical Test Report on Safety Inspection and Testing of Electrical Equipment This report is suitable for class 1 protectively earthed 3 phase 415V equipment The test has been carried out in accordance with AS NZS 3760 with the following electrical and visual inspections 500V Insulation Resistance Tests e Active 1 to earth Pass Fail e Active 2 to earth Pass Fail e Active 3 to earth Pass Fail Earthing continuity Pass Fail Flexible supply cord e External visual inspection of plug connection Pass Fail e Visual inspection of cord termination to equipment Pass Fail Visual inspection of wire termination in electric motor terminal housing Pass Fail Date Inspection number Inspector Inspector registration number TiBMan016Rev02Feb14 Trethewey Industries New Machinery Hazard Identification assessment and Control Description Autobaler Model TI100 TI200 Brand Developed in Co operation Between AWISA and Australia Chamber of Manufactures This program is based upon the Australian Worksafe Standard for Plant NOHSC 1010 1994 Hazard Identification Hazard Assessment Risk control Strategies Entanglement
4. Trainer Signature of compliance 12 Retracting Fingers 1 Close top door 2 Turn power on 3 Press retract button hold button until the fingers are fully retracted Trainer Signature of compliance 13 Opening the doors Open the top door beware of possible rebound Open the bottom door beware of possible rebound Open the bottom door fully Insert the bale removal trolley tines into slots in the baler floor or with auto eject models position the bale transport trolley for ejection onto the trolley When fully inserted gently pull back on trolley handle and wheel away for storage Note do not open the bottom door with the fingers down Boom oo Trainer Signature of compliance 14 Bale removal and storage safety procedure 1 Ensure that the person removing the bale is of sufficient strength and fitness to prevent personal injury 2 Heavier bales may require a three wheeled trolley supplied as an option at the customers request 3 Beware of over balance and possible back or foot injury Trainer Signature of compliance Autobaler Trainee Particulars Kit Company Address Trainee Name Print Clearly in Capitals Address Phone No Employer Date Of Training Autobaler Model Trained To Use hereby validate this assessment Signed Trainer In the safe competent use of the Autobaler Model and received a copy of
5. Warnings Copy of Warning Notices Chapter 2 Lifting amp Handling Instructions Specifications Transporting the Autobaler Safely Baler Relocation Procedure Removing the baler from the pallet Locating from truck to dock Work Method Statement Chapter 3 Safety Location of Autobaler Area of Operation Operation of Autobaler Safety Clothing Footwear Safety Essentials Chapter 4 Operation of Autobaler Bale removal procedure Twining up the TI100 TI200 Controller layout and function Chapter 5 Training Trainer Material Trainee Particulars Kit Chapter 6 Maintenance 8 Cleaning Section Maintenance Definition Weekly maintenance Check Preventative Maintenance Machine Cleaning General Housekeeping Service Intervals Recommended Lubricants Data Sheet Pro ma MBL8 Grease Material Safety Data Sheet Super hydraulic Chapter 7 Drawings TiBMan016Rev02Feb14 SCOPE Background Autobalers are a unique compacting machine featuring an open top system to facilitate loading of the baler with materials Autobalers offer considerable time savings when compared with most other baler types The time to compact is reduced on account of no doors to open and close each time materials are deposited The Autobaler can be loaded during any part of its cycle path Autobalers are a safe machine reducing many of the common injuries associated with conventional balers such as strain injuries from pushing and forc
6. Very Low Do not reach into baler Operator Training Cutting stabbing puncturing Very Low Use only safety knife for bale tie off Shearing Nil High Temperature Nil Striking Moderate Upper or lower door rebound Operator Training Crushing Low Bale ejection Operator Training Electrical Low Operator Training Other hazards noise dust Moderate noise Noise if operated with insufficient materials in hopper Operator training TiBMan016Rev02Feb14 15 Installation Instructions for the Overhead Safety Canopy FITTING OF THE OVERHEAD FRAME From within the baler lift frame the rear support legs will telescope out When the holes the telescoping rear legs appear slide in retaining bolts to hold the frame in position This operation may require two people or the use of a fork lift or mechanical lifting device Firm up the grub screws on these legs Fit the mesh sections supplied these will only fit one way Tighten up the grub screws in the saddles to secure the mesh tabs to the baler The mesh frames should be now securely attached to the baler frame Firm up grub screws on baler saddles locking overhead frame into position Note mesh hopper must be on the inside of the legs see illustration 2 Frame should now be as the picture below If you require further information on the fitting procedure please contact the manufacturers on 1800 888 403 or 02 67 345403 FITTING OF THE SAFETY CANOPY Fitted Overhead S
7. and WEAL ween e on Pass Torque StablliLty i eee rei Pass Water washout ASTM D 1264 at 80 175 e 4 Rust prevention ASTM D 1743 ASTM rating Er Low temperature torque ASTM D 1478 40 40 SCALP GING gocce ete een enis 13 000Running eol 2934 900 Mobility U S Steel method Erow Fate cat E8 G OPE 2055 Rubber swell GM method 70hr at 100 C 210 F Volume change eee uie dr s 12 Handling Product contains petroleum oil copper and lead particles Do NOT store near heat sparks or flame Wash with soap and water after contact with skin KEEP OUT OF REACH OF CHILDREN A material Safety Sheet is available from Pro Ma Systems Warning Do NOT take internally Harmful or fatal if swallowed Contains copper and lead particles and hydrocarbons If swallowed contact a doctor immediately Wash hands after use Medical advice Contains petroleum oil copper and lead particles If swallowed do NOT induce vomiting Call physician immediately Available Sizes 450g 2 5kg 20kg 60kg and 202 5kg 3 Material Safety Data Sheet Product Name SUPERDRAULIC RANGE Date Issued 3 June 1997 IDENTIFICATION Use General purpose hydraulic oil Not classified as hazardous according to criteria of Worksafe Australia Company WESTERN OIL UN No Not Assigned 1 COOMBES DR Main Class N
8. the Training Manual Date Signed Trainee Date Special Comments Trainer witnessed the competency of Trainee Exam Questions Autobaler TI100 TI200 Series 1 If the baler is in a public access area and the baler will be unattended for a long period what precaution for public safety should you take a Sit and watch the b REMOVE a AEE 279181 970 pm bal 2 What function does the retract button have a General E b Cycles the 0 LJ c Raises the fingers Tas 3 The purpose of the safety bar is Todo oh US oa ak L b For emergency Noparicular uses 4 When twining the baler at what position should baler fingers be nde E b Hall WayGOWM E 5 Whatis the purpose of the plastic tabs on the base floor of the baler repete b Place twine Fal
9. AUTOBALER OPERATION MANUAL TI100711200 SERIES Trethewey Industries MAA 14 Carl Baer Circuit 4 2 AUTOBALE 7 New England Highway li J Deepwater NSW 2371 2 www autobaler com A x st is w TiBMan016Rev02Feb14 Owners Manual Thank you for choosing Autobaler TI100 TI200 It is our wish that you remain very happy with the performance and service given by your baler and our service backup staff For operating this baler properly please take time to read this manual thoroughly before start to operate your baler Keep this manual handy for future reference The information contained in this manual is basic information If you require information over and above what is supplied in this manual please contact the Autobaler service hotline on 1800 888 403 Models covered by this manual TI100 TI200 Autobaler Note Training is required to operate Autobalers Training is required to service Autobalers Autobalers are protected by International Patents and Patent Applications TiBMan016Rev02Feb14 3 OPERATION AND MAINTENANCE MANUAL USER MANUAL SPECIFICATION MANUAL MACHINE AUTOBALER and CYBERSMART CONTROLLER MODEL 7 100 T1200 AUTOBALER SERIAL NUMBER CONTROLLER SERIAL NUMBER Name and Address of Manufacturer Trethewey Industries 14 Carl Baer Circuit Deepwater NSW 2371 Australia Please Read This Document BEFORE Operating the Machinery TiBMan016Rev02Feb14 WARRANTY To maintain warranty the b
10. LES OPERATIONAL AND 4 00 NOT rasch or jann into the Astohajar dering operation am INSTALLATION MANUAL de eire cage and bale volley as prevent jury das f tripping 80XES CONTAINING HARD OBJECTS INSIDE ESLER opening the top door beware o hardie rebeund 5 DO NOT CYCLE AUTOBALER WITHOUT MATERIALS N THE HOPPER 7 opening Tw holism door 1 Stand 12 Te sida 2 Beware of Goer rebound 6 IDEALLY PLACE FLATTENED CARDBOARD FLAT INTO THE HOPPER ary ie Anabel for 1 Pete 2 Bale Te oft YOU MUST READ zr tor rasot wihsst stopping the baler vis tha key 7 00 NOT THE BOTTOM DOOR UNTh ina SEE MM OPERATION AND operate the Atebale unions qualified de so See OMAS oThosr tor B THE FINGERS N RETRACT POSITION INGTALLATHON MAHUAL training detada ard procedures of contact supplia or 8 READ THE OPERATION AND INSTALLATION MANUAL CAREFULLY BEFORE LISE OF evarually hanede the teles uve bale transport trol boy peovided BEFORE USE THIG AUTOBALER V ALIAS ermove key trom unattended ENSURE YOUR UNAUTHORISED COMPLIES WITH PERSONS OHSS REGULATIONS REFER TO OPERATING MANUAL POR YOUR Tun lag MUST NOT OPERATE BEFORE MOVING THE BALER OR REQUIREMENTS REMOVAL OFF THE PALLET PHONE 1900 698 403 TiBMan016Rev02Feb14 17 CHAPTER 2 LIFTING AND HANDLING INSTRUCTI
11. MEE RUE Buttery Base oil viscosity COT it WO Cede liae qe nn RI etes 148 Coat EDS Qu uis e te UR Ree ae 14 SUSA LOO CB S dee 767 SUS dt 2 109 sue t te ERE SLS Base oil viscosity 90 Dropping point ASTM D 2265 280 500 Penetration mm 10 ASTM D 217 eerte ee 280 Worked 60 Strokes 285 Worked 100 000 strokes Change 10 Trident probe viscosity ASTM D 3232 204 4009 E 15 Oil Separation ASTM D 1742 24 rait 2396 CIE Colette Aa 3 Lubrication life ASTM D 3336 no 204 bearing 10 000 rpm 163 3259 290 Oxidation stability ASTM D 942 Pressure drop at l00hr KPa DS iere 14 2 Pressure drop at 500 kPa psi 70 10 Roll stability ASTM D 1831 penetration 10 Wheel bearing test ASTM D 1263 modified 60 9 pack 160 C 325 F PIDEN 155 Load carrying properties Timken load ASTM D 2509 kg ID mmm 29 55 4 11 EP test ASTM D 2596 Load wear Index Quse Eee eg 40 Wed oxen igh irre eter tice mederi 250 4 Ball wear test ASTM D 2266 40 kg 1200rpm 75 1679 1 hr Wear scar diameter 0 40 Ball joint test ASTM D 3428 Brine sensitivity noise
12. ONS OF THE AUTOBALER TI100 Specifications TI200 Specifications Bale Weights 100 140kgs Bale Weights 175 200kgs Bale Size 750 x 750 x 1000 Bale Size 750 x 750 x 1000 mm Cycle Time 23 seconds Cycle Time 23 seconds Unit Weight 1250kg Unit Weight 1650kg Thrust Load 5350kg Thrust Load 10160kg Power 3Kw 3 phase Power 3Kw 3 phase 20amp Plug required 4pin Clipsal compatible Plug Required 4pin Clipsal compatible Height 2500mm Height 2500mm Width 1940mm Width 1940mm Depth 920mm Depth 920mm Transport Height 2050mm Transport height 2050mm Baler Capacity 2 3 bales per hour Baler Capacity 2 3 bales per hour TRANSPORTING THE AUTOBALER SAFELY When moving or relocating the baler always follow the Work Method Statement in most cases it will be a requirement of the organization that the Work Method Statement be completed signed and handed in to the appropriate person or persons for approval before carrying out the task The following procedure is for the safe transportation and movement of the Autobaler 1 BALER RELOCATION PROCEDURE 1 Before removing or lifting the baler ensure that the lifting equipment is in good order and has capacity to lift the baler check baler weight in baler specifications 2 Autobalers balers can be moved with a forklift unit or a pallet truck 3 Before moving the baler ensure that there is sufficient clearance height wise 4 Where possible attach the baler to the moving means to prevent possible overbalance 5
13. TO DOCK When loading the baler for its final destination the baler is to be loaded in such a way as to facilitate removal at the customer end ie If the baler is to be unloaded using a forklift truck baler should be situated accordingly NB if baler is to be unloaded via pallet jack then the pallet containing the baler needs to be rotated through 90 degrees TiBMan016Rev02Feb14 18 Work Method Statement Activity Contractor Person completing this Telephone statement Date Contract Number vale Licenses qualifications or Key Steps Equipment or plant required Possible Hazards personal protective equipment k 7 PPE work permits CHAPTER 3 SAFETY A Location of Autobaler a b Never place the Autobaler near any landings or elevated loading docks unless these areas have the appropriate safety arrangements and approvals Never place the Autobaler under a man hole air conditioner refrigeration unit light or any position where a service technician may have occasion to work above the machine c Never place the Autobaler on a loading dock close to the edge or the above landings edge d e Never place the Autobaler in a position where unauthorised persons have access Always consult an OH amp S officer B Area of Operation a b C Ensure that baler trolley is stored in a position away from the operator s passageway Ensure that twine rolls amp twine safety
14. UTOBALER BALE REMOVAL PROCEDURE Larger Autobaler are equipped with auto ejection systems the small 100 series have manual bale removal system Removal of the Bale Step 1 Before commencing the baling especially with smaller granulated materials place a sheet of cardboard on the bottom of the baler to prevent clogging of the baler floor grooves Step 2 Fully open both upper and lower baler doors using the bale extraction trolley supplied with the machine Insert the trolley tines into the baler lots Step 3 With the trolley forks fully inserted grip the top of the trolley handle firmly and pull back carefully drawing the bale from the chamber note for ease for extraction the bottom door of the baler must be fully opened Step 4 With the bale extracted from the baler the bale can be wheeled away and stored Safety Those responsible for the safe operation of the baler must 1 Ensure that the persons removing the bale have been sufficiently trained in the safest removal procedure 2 Must be of sufficient strength and fitness to safely carry out this task 3 Bale trolley storage to prevent a tripping hazard store the bale trolley with the forks beneath the left hand side and the trolley against the baler TWINING UP THE TI100 TI200 The following procedure is for the twining of the TI100 TI200 Autobaler Step 1 Place the roll of twine under the left hand side of the baler The roll must be the correct side up The dr
15. Where required situate traffic cones and safety barriers 6 Always transport baler units as close to the ground level as possible if forward movement is required always used another qualified person as a guide 7 Proceed slowly downhill grade always in reverse 2 REMOVING THE AUTOBALER FROM THE PALLET a Unwrap and cut metal strapping b Insert the fork lift tines beneath the front lower door Ensure that the fork lift tines are fully through to the rear baler wall c Lift the baler no more than 80mm off the pallet amp check again to ensure sufficient tine protrusion through the rear slots d With tines under the baler always move as close as possible to the floor at idle speed only in reverse to ensure good vision Note When transporting the Autobaler where lifting on a truck is required a Never lift the baler more than 300mm unless on a pallet or strapped securely to the fork lift as the baler could slip off the tines metal to metal b If lifting the baler from beneath the baler base fasten the baler to the fork mask using strap or chain c When lifting the baler more than 300mm always be on level ground and never transport the baler in an elevated position d When transporting or moving the baler on the fork lift always travel in reverse to ensure good vision e Safety Equipment Compliant safety boots high visibility vest hearing protection eye protection Head protection if required 3 LOCATING FROM TRUCK
16. afety Canopy Rear Canopy legs position Mesh mounting lugs TiBMan016Rev02Feb14 16 CHAPTER 1 Warnings Autobalers must only be operated by qualified people Only qualified people to service or repair Autobalers Before servicing or repair familiarise yourself with the relevant instruction manual The Autobaler must not be used in a manner contrary to the manufacturer s instructions Prior to moving the Autobaler ensure the fork lift capacity is at least 1 5 tonne On installation or repair ensure the machine is effectively earthed All electrical work to be carried out by qualified electrician T Always disconnect the electrical supply before servicing or repair due to electrical hazard Failure to observe Safety Precautions could lead to severe injury We recommend operators using the following personal protective equipment 1 Safety glasses 2 Safety shoes 3 Safety gloves COPY OF WARNING NOTICES ON MACHINE INCLUDING NAMEPLATE TRETHEWEY INDUSTRIES AUTOBALER READ INSTALLATION MANUAL BEFORE USE FACTORS FOR EFFICIENT OPERATION OF THE AUTOBALER N Waters Autsbul er hom alweaiod area s to present onsas 1 PREE MATERIALS ONLY accesa 12 e pacing Socks eic 1 34 polarity change is required sharps call on election 2 NO TIMBER OR HARD OBJECTS must be away rom the Autobaler st al Seven 3 NO COMPRESSED 8 OR BA
17. aler must be serviced in accordance with the manufacturers recommendations outlined in chapter 9 and the service booklet The firm guarantees the machine herby described has been designed in compliance with all regulations in force in particular safety and health regulations The machine has undergone successful testing See test certificate enclosed The warranty covers a period of 12 months It does not cover electrical motors and tools Extended warranty to 5 years is available The purchaser is entitled to the replacement of faulty parts Shipping and packing costs are at the purchaser s expense The warranty does not cover damage caused by Falls or careless handling of the machine incorrect operation and non compliance with the maintenance rules Any tampering with the machine especially with its safety devices automatically voids warranty The manufacturer will be freed from any responsibility No claim for damages shall be accepted in cases where the machine has been laying idle for a long period of time The serial number on the machine is a main reference for the warranty instructions manual and after sales service and identifies the machine in case of need Serial Number must be quoted in all correspondence NOTES The machines are manufactured in compliance with the accident prevention rules in force The machines strictly comply with the instructions contained in the manual to obtain the best performance from the machi
18. and give assurances on the type of baler which will best suit your requirements Autobalers are built to comply with the highest national and international standards Autobalers are protected by International Patents and Patent Applications Manufacturing Plate _ TRETHEWEY INDUSTRIES Pty Ltd A B N 84 072 739 827 Innovative Design amp Manufacturing New England Highway uu DEEPWATER NSW 2371 Tel 02 6734 5403 Fax 02 6734 5433 i C EMAIL trethewey northnet com au WEBSITE www autobaler com MODEL S N BATCH No RATED VOLTAGE NUMBER OF PHASES FREQUENCY ul FULL LOAD CURRENT AMPS Date of Manufacture TiBMan016Rev02Feb14 7 DECLARATION CONFORMITY 98 37 EC Machinery Directive 73 23 EEC Low Voltage Directive 89 336 EEC EMC Directive Name of manufacturer or supplier Trethewey Industries Pty Ltd Full postal address including country of origin 14 Carl Baer Circuit Deepwater NSW 2371 Australia Description of product Paper amp Cardboard Baling Machine Name type or model batch or serial number Type Autobaler Make Trethewey Industries Pty Ltd Model TI100 TI200 Location 14 Carl Baer Circuit Deepwater NSW 2371 Australia Supply 415V ac 3 Serial No Mass Weight Standards used including number title issue date and other relative documents See attached sheets Place of issue Address of Authorised representative in Europe Name of authorised rep
19. aw end of the twine feeds from the entire of the roll from the top side Twine type must comply with OH amp S requirements recommended twine type is Superlash8 Step 2 From the drawn end lay the twine back approximately 200mm as shown Step 3 Tie a knot in the end to form a non slip loop as per illustration Step 4 In some instances a double know ma be required as shown The reason for this will be explained in a later step 5 Hook the looped twine end on the baler tab as per illustration 5 and take the twine to the opposite side as per illustration 6 then bring the twine back to left hand side as illustrated and cut off at this pint using the safety knife supplied illustration 7 This will give the correct length of twine required Repeat this process three times to give the required amount to twine up the machine Illustration 6 Step 6 Fully open all doors and step into the baler chamber note before entering the baler turn the baler key to the off position Hook the twine loop over the domed hook as illustrated on the left hand side 1 Step 7 Take the twine down under the tab on the left side on the bottom then across and under the tab on the right hand side then up to the domed hook on the right hand side To attach the twine end to the domed hook on the right hand side rotate the twine end around the domed hook twice then tie off using one tie off loom only Repeat procedure o
20. cage are positioned close to the right hand side of the Autobaler to prevent tripping If cage is provided with hooks use these to affix cage to safety barrier Ensure that electric lead is not in a hazardous position and is not left lying on the floor particularly if there is a chance of water being on the floor C Operation of Autobaler a b C Always keep hands and arms out of the Autobaler hopper during operation Always when entering the pressing chamber for re stringing etc wait until the motor stops and turn the key to the Off position Never attempt to load heavy objects over the top door during the baling process reduce boxes of books brochures etc to smaller quantities When removing full bales from the Autobaler always use the Auto eject or eject trolley When ejecting full bales never pull on the twine in such a manner that if the twine breaks or the knot fails a fall will result which may cause an injury Always use the baler trolley pallet jack or fork lift to relocate full bales Always be aware of door rebound when opening top or bottom doors always stand to the side Never stand in front of the pressing chamber when ejecting full bales always stand to the side eject models only Never attempt to operate Autobaler with the front door open Never attempt to clean lubricate or work in the vicinity of the cylinders during operation SAFETY CLOTHING FOOTWEAR a During assembly location an
21. clothing Keep containers closed when not in use Spills amp Disposal Extinguish or remove all sources of ignition and stop leak if safe to do so Contain the spill with sand or earth and take up with a vacuum truck or absorb with absorbent material sand or earth Place used absorbent in suitable sealed containers and follow state or local authority regulations and guidelines for disposal of the waste Clean area with detergent and water Do not allow product to enter drains sewers or water courses inform the local authorities if this occurs Fire Explosion Hazard Combustible Combustion products include oxides of carbon Keep storage tanks pipelines fire exposed surfaces etc cool with water spray Shut off any leak if safe to do so and remove sources of re ignition Use foam C02 or powder to extinguish fire OTHER INFORMATION Long term animal experiments have shown that any health risks are associated with the level of aromatic and polycyclic constituents in the product These constituents are removed during the manufacturing process to a level at which no health risks are expected as a result of normal handling CONTACT POINT Emergency Response 02 4732 3305 END XXX CHAPTER 7 POSITION OF ELEVATED POWER OUTLET ON WALL REFER ELEVATION T 1 1 1 i i i 1 15 E 59 m E i i 1 D 1 I us SS 1 x AA 1
22. d moving parts Are they in place Are they damaged Check Autobaler key switch is it functional and in good order Check emergency stop button is it functional and in good order Check safety bar is it functional and in good order Check power lead is it undamaged Is it clear of any moisture Check Autobaler response to opening top door Opening more then 50mm approx 2 inches should cause the machine to cease cycling T0200oc gU If any of the above checks reveal damage or malfunction the machine should be shut down and the key removed until the fault is repaired C PREVENTATIVE MAINTENANCE a Every 4 months or every 500 bales the operation of the Autobaler should be checked by a qualified person to ensure that all safety features are functioning correctly and are undamaged b From time to time a qualified electrician should inspect all power leads and electrical contacts D MACHINE CLEANING To keep your Autobaler in top working condition frequent cleaning is required Power Unit Never attempt to service the power unit without first thoroughly cleaning the unit Remove the retainer screws holding the hinged mesh covers Note Always disconnect the power socket from the power source plug before attempting any guard removal Remove the key from the controller and attach an in service note to the baler Keeping the power unit clean will prevent overheating and system contamination NOTE Power uni
23. d operation of the baler safety compliant footwear must be worn b Firm fitting work place compliant clothing must be worn c Safety compliant work place gloves hearing protection and eye protection must be worn d General Always remove Autobaler key when machine is not in operation or is unattended 1 Before commencing the baling process ensure that the bottom door is latched correctly to prevent the door bursting open during process 2 Never climb onto the baler from any side or reach in during operation or stand on elevated objects 3 When removing the bale grip the handle of the eject trolley firmly and pull back with care 4 Always place the bale transport trolley centrally and in the floor channels to prevent bale side roll 5 On inclines ta others ke care to prevent run away and potential injury to 6 Use only the safety knife for twine cutting 7 To prevent strain injury ensure that the doors and latches open freely lubrication may be required 8 Remove baler key if in a safety sensitive zone 9 Never operate a faulty machine tag out and call 1800 888 403 10 Autobaler operators must be licences to legally operate Autobalers 11 Note smaller framed people or people of low strength and fitness can sustain injuries from over exertion with bale removal and location ensure tat the operator is of sufficient strength and fitness to safely perform this task CHAPTER 4 OPERATION OF A
24. e machine is tagged out of service that the tag be attached to the isolating switch via a padlock this will ensure that the machine will remain inactive and safe for the technician 2 Power In Power to the controller unit enters through the 3 phase power cable at the power in point It is essential that the lead and plug be kept in good working order and free from possible damage and moisture entry Note all repairs to the electrical components must be carried out by those qualified to work with 3 phase power If power at anytime becomes absent at the controller power light out check the power entry system from the controller back to the main power source 3 Serial Number Every controller unit has its individual serial number When ordering parts for the controller or the electrical system always quote the controller serial number as well as the baler serial number and date of manufacture 4 Ignition Switch The controller ignition switch has a security type key If the baler is not in use or is a public area it is advisable for the key to be removed If additional keys are required these will need to be specially ordered from Farnells from the baler manufacturer or the manufacturer s agent or representative 5 Emergency Stop Button The emergency stop button is fro emergency use The emergency stop disables all electrical functions within the baler systems To activate the emergency stop simply push the button firmly in To rel
25. ease the emergency stop button to the active mode rotate the button clockwise until the button pops forward 6 Magnetic Door Switch The magnetic door switch is activated at the top of the upper door adjacent to the controller unit One half of the magnetic switch is attached to the controller via plug socket 7 the other section of the Switch is attached to the door It is essential that these sections of the switch be correctly adjusted to each other The two halves of the switch must never come into contact with each other or serious switch damage may occur correctly adjusted switch will have each section squarely situated to each other and will have a minimum of 1 5mm clearance to each other with a maximum clearance at any time of 4mm More clearance than this will create a door open light to illuminate on the controller During operation the movement in the top door may create a switch movement either apart of out of line with each other this will depend on the machine and active the door open light If switch adjustment is required adjust then carefully close the door ensuring that the two sections of the magnetic switch have the required clearance to prevent switch damage 7 Door Magnetic Switch Plug This is the plug as described in 6 that is attached to the controller from the second half of the Magnetic Door Switch 8 Bale Counter The bale counter as the came suggests simply counts the number of bales being compacted The bale c
26. for 20 minutes If irritation occurs seek medical advice Skin Remove contaminated clothing and wash skin thoroughly with soap and water Inhaled Remove affected person from contaminated area and seek medical advice If not breathing apply artificial respiration and seek urgent medical advice Advice to Doctor PRECAUTIONS FOR USE Exposure Standards Worksafe Exposure Standard time weighted average TWA 5 mg m3 oil mist short term exposure limit STEL 10mg m3 oil mist Engineering Controls Special ventilation is not normally required due to the low volatility of the product at normal temperatures However in the operation of certain equipment or at elevated temperatures mists or vapour may he generated and exhaust ventilation should he provided to maintain airborne concentration levels below the exposure standard or where no exposure standard is allocated as low as is reasonably practicable Personal Protection Avoid contact with the skin and eyes and avoid breathing vapours or mists When exposure is likely personal protectiv quipment in a combination appropriate to the degree and nature of exposure should be selected from the following list 1 Eye protection 2 PVC gloves 3 PVC apron and sleeves or full PVC covering 4 PVC or rubber boots Where the concentration of vapour or mist is expected to approach the exposure limit the following additional equipment is recom
27. he top door csscee eee b Openithe top WOOL eae desine nomeo ni 65 13 If the baler operates with the top door open must a Continue aS MON Malic eeu ie etus beo oe Potes oe Galas b Shut the machine off remove the key and place out of order soci ci CL 6 TAKE GAS dt ila daa taire la ng 1 14 Was the knot test passed Yes L No 6 MAINTENANCE amp CLEANING SECTION Always disconnect Electrical Supply before Changing Any Equipment A MAINTENANCE DEFINITION Standard Maintenance A service provided at four monthly Average usage A baler producing up to 5 bales per day recommended preventative maintenance period not to exceed four months and to be serviced according to the standard servicing schedule High usage a baler producing more than five bales per day recommended service period not to exceed four months and to be serviced according to the standard servicing schedule Major Maintenance A serviced preformed every 12 months or every 660 bales and to be serviced according to the standard servicing schedule A major service has the additional service elements 1 Oil filter change 2 Hydraulic oil test and changed if required 3 Finger lock spring change 4 Main cylinder pivot pin check for wear or fatigue WEEKLY MAINTENANCE CHECK Check safety guards aroun
28. ing of materials into fixed sized areas Many injuries also occur due to material breakdown with knives and other injury creating devices AUTOBALER REQUIRES NO MATERIAL BREAKDOWN Autobalers are an extremely versatile machine being able to compact a large range of materials i e paper cardboard plastics rubber tyres wool and most otherwise compactable materials Autobalers come in a ten model capacity range from 80 to 500 kg to best suit particular customer requirements Autobalers are a quality machine offering unparalleled safety amazing efficiency and huge labour savings Trethewey Industries have vast experience in the manufacture of quality baling machines having produced in excess of 500 agricultural baling machines Five years ago Trethewey s developed the Autobaler for commercial use in particular to be used in Supermarkets and Recyclers Trethewey Industries are situated on the New England Hwy at Deepwater NSW Trethewey Industries location is ideal for servicing our national markets Trethewey Industries focus is to develop machines which totally satisfy customer requirements in performance quality service economy and safety Autobalers were developed to give the maximum efficiency and safety possible Autobalers are designed for loose materials and are not recommended for solid materials i e hard wooden or metallic objects as these may cause machine damage The manufacturers are happy to assess your needs and make recommendations
29. ion Test Hydraulic Test Autobaler Quality and Reliability Test Full Mechanical Test Test Report No Testing Officer Operational Test Report No Testing Officer Lubrication Test Report No Testing Officer Testing Officer Signature TiBMan016Rev02Feb14 Hydraulic Pressure and Performance Test Report on Safety and Hydraulic Performance This report is suitable for pressure systems below 2500 psi System Pressure Required System Pressure on Test System Pressure Spikes Pressure Switch Firing Range Pressure Switch Firing Test Hydraulic Delivery Hose Rating Fluid Type and Grade Cylinder Brand and Type Duration of Cycle Test Date Inspector Signature TiBMan016Rev02Feb14 Hydraulic 32 Grade Noise Emission Test Report Baler Noise Emission report the test done from five positions a From each side at a distance of 1m from the machine b Ata distance of 1m above the machine Decibel monitor type and number Test one metre from front Test one metre from left side Test one metre from right side Test one metre from back Test one metre above machine Injury precautions required Date of Inspection Inspection No Inspector Signed TiBMan016Rev02Feb14 Tenma 72 6604 70 Db 70 Db
30. mended 1 Short elevated exposures eg spillage goggles and correct respiratory protection should be worn NB If the vapour mist concentrations exceed the exposure limit by more than 10 times air supplied apparatus should be used 2 For prolonged elevated exposures Full face air supplied or self contained breathing apparatus should be worn CONTAMINATION If contamination occurs change clothing and discard internally contaminated gloves and footwear Launder contaminated clothing before reuse Observe good personal hygiene Eye wash fountains and safety showers should be available for emergency use REFERENCES For detailed advice on Personal Protectiv quipment refer to the following Australian Standards HB 9 Handbook 9 Manual of industrial personal protection AS 1337 Eye protectors for industrial applications AS 1715 Selection use and maintenance of respiratory protective devices AS 1716 Respiratory protective devices Flammability Combustible liquid will not burn unless preheated Refer to AS 1940 Storage and handling of flammable and combustible liquids and AS 2865 Safe working in a confined space for more specific information on these subjects SAFE HANDLING INFORMATION Storage amp Transport Classified as a class C2 combustible liquid for storage and handling purposes Store in a well ventilated place away from ignition sources oxidizing agents foodstuffs and
31. n both side twines j EA Step 9 Transverse twine from rear to top 1 Hook twine loop onto the domed hook on the rear inside wall of the baler 2 Place the twine under the tabs on the floor near to front as illustrated 3 Holding the twine end in the left hand close the bottom door using the right hand 4 Twine will then come up the the lower door over the top and attach to twine tab as in step 10 let Step 10 Twine end will come over the top of the bottom door and attach to twine tab by rotating the twine around the twine tab twice then GANE into tab slot as illustrated WW Tu if fin A CONTROLLER LAYOUT AND FUNCTION Warning 20 Isolating Switch 1 Full Bale Light 13 Bale Counter 8 Retract 11 Serial Number 3 Eject 9 Power In 2 Ignition Key 4 ELECTRICAL Emergency go Stop 5 Up IndicatorDown IndicatorPower IndicatorActive IndicatorPower to motor port i ert 15 Thermo Plug Accessories 16 Solenoids full bale pressure switch 18 19 Controller Almost the total function of your Autobaler is via the Cybasmart control unit The various functions of the controller are as follows 1 Isolating Switch The isolating switch is situated on the upper end of the controller The purpose of the isolating switch is to isolate the power to the unit when ever a service or repair is carried out It is therefore the manufacturers recommendation that when ever th
32. nes Strict compliance with the rules contained will ensure optimum results and avoid any inconvenience caused by the non compliance of operation and maintenance instructions To avoid contacting the manufacturer for problems which can be easily solved closely follow the instructions given below If the help of our technical assistance service is still required after having strictly complied with the instructions given the buyer must supply all the technical indications necessary to effectively determine the problem This will enable our technical assistance service to intervene quickly and efficiently on the machine Copies of the instructions manual may be requested upon indication of the machine serial number IMPORTANT Upon delivery of the machine the consumer must make sure that all the devices indicated in the paragraph on the safety manual are present and working correctly Furthermore those devises which are not mounted at the time of delivery to facilitate transport must be mounted in conformity with the instructions indicated When ordering spare parts it is necessary to state Machine Model Serial Number and Year of Manufacture Item Reference Number Without the Serial Number no spare parts will be delivered DEFINITIONS Chapter 1 Copyright Manual INDEX Warranty Scope Manufacturing Plate Declaration of Conformity Compliance Baler Test Report Hazard Identification Installation of Overhead Safety Canopy
33. note pressing fingers need to be fully retracted 2 When the lower section is full close the top door and deposit materials over the top door until visible 3 Activate the cycle button 4 Cycling the baler with o material or insufficient materials will cause a loud bump Trainer Signature of compliance 8 Baler Operation 1 TI100 amp TI200 balers have automatic function 2 Button or automatic activation is required for each cycle 3 Peddle or foot activation is optional on TI100 amp TI200 units Trainer Signature of compliance 9 Tidy Bale Procedure 1 Last 10 of the bale flattened material laid flat 2 When full bale light comes on i Remove excess material by cycling manually by pressing the cycle button several cycles may be required ii For neat top place large flattened material on the top of the bale and activate cycle button Trainer Signature of compliance 10 Tying Off Open the top door Remove loose or protruding materials from above the fingers Unhook the twines on the looped ends cut upper loop if too tight and use lower loop to tie off Untie plain twine end and insert through the loop Pull tight and tie off securely RON gt Trainer Signature of compliance 11 Transverse Twine Tie Off 1 Unhook from rear baler wall 2 Release plain end from the tab on the outer front lower door 3 Pass the plain end through the looped end Pull tight and tie off securely
34. obaler has an interval service that the appropriate service leaf be dated and filled out according to the service and signed by the service technician v It is recommended that a service interval not exceed 4 months or every 500 bales Autobalers must be serviced within this period during the warranty period An integral component of the service is a comprehensive safety check to ensure interlocks and all other safety devices and guards are in good safe working order G RECOMMENDED LUBRICANTS i Recommended hydraulic oil AWH 32 Castrol i Autobalers have high pressure pivot points which require high pressure grease therefore it is recommended that only Pro ma MBL grease be used in the service of Autobalers or a grease with equivalent lubrication properties see data sheet If maintenance periods are exceeded or lubricants used which are outside the manufacturers recommendations Autobaler warranty may be voided H DATA SHEET PRO MA MBL 8 GREASE Benefits Of Use 1 Performs within high and low temperature operating ranges 2 Resists water and water washout 3 Provides oxidation stability 4 Protects against rust 5 Protects against extreme pressure 6 Works well with high loading or severe shock loading 7 Extends lubrication periods 8 Prevents excessive seal swelling The Base Grease Used in MBL Grease has the Following Specifications NEGI ente bibat 2 Soap Type Lithium Complex d ome aru
35. ot Assigned PENRITH Subsidiary Risk Not Assigned Poisons Schedule Not Allocated Hazchem Code Not Assigned CAS No Not Relevant PRODUCT PROPERTIES Appearance amp Odour Clear and bright oily liquid Mineral oil odour Chemical Reactivity Stable Reacts with oxidising agents Solubility in Water Negligible Property Value UOM Temp Specific Gravity 0 87 15 Melting Point Not Available Vapour Pressure Expect lt 0 0005 kPa 20 IBP Typically 280 deg C FEP Not Available Evaporation Rate Not Available Dens Air 1 gt 1 Fire Explosion Hazard Flash Point 11 gt 224 deg Autoignition 11 gt 320 deg Volatiles Not Available LEL Expected 1 v v UEL Typically 10 PRODUCT INGREDIENTS Blending Ingredient Proportion Method CAS No Highly refined mineral oil High gt 99 4 m m Complex mixture of additives Low lt 0 6 m m HEALTH HAZARDS HEALTH EFFECTS Acute Swallowed Slightly toxic may cause gastric irritation Eye Product may cause slight to moderate irritation to the eyes Skin Mildly irritating to skin Prolonged and repeated skin contact may cause dermatitis due to defatting effect Inhaled Inhalation of the vapours generated at elevated temperatures or mists can cause irritation to the nose and throat FIRST AID Swallowed If swallowed do NOT induce vomiting seek medical advice Eye Flood eyes with plenty of water
36. ounter performs an important function Service intervals are time base or in situation of above average use are based on the number of bales completed Refer to the Service Section of you Operators Manual for service intervals 9 Eject The eject button activates the eject system removing the completed bale from the baler chamber To operate the eject the bale must be complete with twines or fasteners secured pressing fingers fully retracted both doors fully open and the bale transport trolley situated correctly in front of the bale to be ejected The operator must stand to the side and safe from the passage of the ejecting bale When ejecting the bale the eject button must be kept activated until the bale is fully ejected into the trolley 10 Cycle Button The cycle button activates the cycle mode when activated the baler arms will come down if in the retracted position If the baler arms are down the baler will do a full cycle i e arms up then back down This should result in the system being activated the system active light will be illuminated When materials are deposited into the baler chamber and the infra red beam emitting from the controller to the receiver on the rear wall is broken the baler will automatically start and do a full cycle while ever the infrared beam remains broken the baler will continue to cycle until the beam is cleared of material 11 Retract Button The purpose of the retract button is to raise the pressing arms
37. resentative Position of authorised representative Full postal address if different from manufacturers Address of Authorised Representative in Europe Declaration declare that as the authorised representative the above information in relation to the supply manufacture of this product is in conformity with the stated standards and other related documents following the provisions of the above Directives and their amendments Signature of authorised representative Date TiBMan016Rev02Feb14 Trethewey Industries Autobaler TiBMan016Rev02Feb14 Trethewey Industries Pty Ltd 14 Carl Baer Circuit Deepwater NSW 2371 14 November 2003 ASSESSMENT REPORT AUTOBALER FOR COMPLIANCE WITH MACHINERY DIRECTIVE 98 37 EC THIS REPORT IS PREPARED BY RISKPLANT CONSULTANTS PTY LTD FOR RISK MANAGEMENT PURPOSES AND ITS CONTENTS ARE PROVIDED EXPRESSLY FOR THE NAMED CLIENT FOR ITS OWN USE NO RESPONSIBILITY IS ACCEPTED FOR THE USE OF OR RELIANCE UPON THIS REPORT IN WHOLE OR IN PART BY ANY THIRD PARTY Prepared by Roger Lim MIE Aust CPEng MSIA RiskPlant Consultants Pty Ltd ABN 78 086 256 206 PO Box 115 BLACKBURN NORTH VIC 3130 Ph 03 9877 4519 Fax 03 9877 4569 NATA Accredited No 14155 Machinery Safety Inspection Services TiBMan016Rev02Feb14 10 Baler Test Report Comprehensive Autobaler Test Report Date Serial No Testing Officer Electrical Test Performed By Noise Emiss
38. splay as a overheat warning 17 Warnings The bale counter display also doubles as a display screen showing various problem indicators i e pressure switch overheating etc 18 Connection Socket The connection socket contains the wiring looms from the controller to the following functions 1 Solenoid valve to main compaction arms 2 Solenoid valve to bale eject cylinder 3 Pressure switch control wires 4 Power boost wiring 5 Full Bale switch Light Indicator Grouping series of vertical lights show the various functions of the baler The up indicator light top light illuminates when the cycle button is activated and baler arms are rising e The down light will illuminate when the baler direction is down e The third light down red is the power light This light should illuminate when the key switch is turned on 2 The eject button is released and indicates power at the baler Door open light will indicate when the top door is open or the machine has developed a system fault such as overheated system or pressure related problem e The active light indicated that the baler system is active and will automatically start and cycle when materials break the infrared beam 20 Warning Warning symbol indicates the presence of dangerous voltage within and is a warning to those qualified to ensure a power supply is disconnected before opening of the unit To those who are not qualified to work with high voltage a warning no
39. t must be cleared of accumulated material pieces on a regular basis to prevent overheating Cylinder enclosures As with the power unit service totally isolate the power remove the key and fix an in service sign Undo screws and remove side meshes to give good access to both sides Clean all loose materials from this area of the machine Often materials become compacted behind the hydraulic cylinders adding additional strain to the machine remove these materials This should be done at least every monthly depending on the use of the baler Baler Chamber Using a soft cloth clean the outside of the machine to keep it in good appearance Never use petrol or mineral solvents to clean the machine as this may damage the paint E GENERAL HOUSE KEEPING Daily remove material build up around the baler especially between the rear of the baler and the wall A material build up creates a fire and vermin hazard Keep the access area to the baler free of all materials to prevent a trip hazard and other OH amp S concerns F SERVICE INTERVALS i Autobalers require regular maintenance intervals to ensure that they perform and operate safely reliably and efficiently Autobalers must be serviced by qualified service people who have been instructed in the service of Autobalers Autobalers must be serviced according to the service requirements as laid out in the maintenance manual supplied with each Autobaler iv It is a requirement that when an Aut
40. t to open the unit with authorisation 21 Fuse The controllers electronic system is protected by a fuse To access the fuse unscrew the fuse holder Fuse Type 32mm glass fast blow fuse Fuse Value 4A AUTOBALER Bale Counter Safety Bar Key Control Pans Full Bale Light Emergency Stop Upper Door Handle Lower Door Handle y A gt si M ae TRAINER MATERIAL E e AUTOBALER TRAINER MATERIAL A A Baler Serial No Date 1 INDEX Controller Operation Set Up Baler Fit Out Initial Set Tying the Loop Transverse Twining Initial Fill Baler Operation Tidy Bale Procedure Tying Off Transverse Twine tie off Retracting Fingers Opening the Doors Bale Removal and Storage Safety Procedure Customer Address Trainer Signature 1 Controller Operation 1 Turn the key on power light on Engage coded key bar door open light on Disengage emergency stop key rotation Cycle button to cycle Retract button to raise fingers only Red light and beeper full bale indicators ogg RON CAUTION WARNING Trainer Signature of compliance 2 Set Up 1 Remove the protective wrapping 2 Move all sundry items from within the baler 3 When moving or relocating the baler carefully follow the lifting instruction and safety procedure Trainer Signature of compliance 3 Baler Fit Out 1 Fit the mesh hopper above the baler 2 Position the t
41. to a vertical out of the chamber position and to remain there This function is used when the bale is complete tied off and ready to be ejected 12 Power Boost Button The power boost button provision is used only after the full bale light and indicator has signalled a full bale This button applies extra power to fully close the four main power hydraulic cylinders to give a constant bale size and length 13 Full Bale Light and Siren When a full bale has been achieved the full bale light and siren will signal full bale When these come on the automatic function feature of the baler will cease The baler though can be manually operated to draw down surplus materials A large piece of material can also at this point be placed in the chamber the baler manually cycled to form a flat tidy top bale 14 Power to Motor Port The power to motor port couples the motor and the controller together The power socket can be removed by rotating the power to motor socket nut 15 Polarity Change Port This port can be interchanged with the Power to Motor Port 14 to reverse the polarity of the motor Note motor must always rotate in a clockwise direction 16 Thermo and Accessories Plug pug cap on spare port must always be attached This port has the wiring to the thermo unit which detects overheated hydraulic oil and closes down the machine when the oil exceeds 60 degrees celsius This will show on the door open light and also on the controller di
42. wine cage to the side of the baler 3 Situate the baler removal and storage trolley 4 Fit canopy to balers with auto cycle provisions Trainer Signature of compliance 4 Initial Set 1 Turn the controller key on Press retract button check motor rotation for clockwise direction stand fingers up and clear of the bale chamber 3 Check that twine roll is correct side up draw twine and cut to length as on the illustration below all three twines are the same length Trainer Signature of compliance 5 Tying the Loop Tie the double loop in twine ends Open all doors Attach the outer loops of the twine to the left hand side of the baler Down to tab on left side then across the floor then under the tab on the right hand side Rotate the twine end around the eye bolt twice then tie off with one loop Repeat his process on all three twines 50 75mm gt 4 50 75 i Trainer Signature of compliance 6 Transverse Twining Hook twine loop or domed hook on rear will of baler Position twine under rear twine tab on the baler floor Position twine under front floor tab Close bottom door and brine twine up the inside of the front door and over the top and fix twine end to twine tab by rotating once then fixing the twine in the tab slot gt ON Trainer Signature of compliance 7 Initial Fill l Fill the lower section of the baler chamber with the top door open
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