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Ti350, Ti500 OPERATION & SERVICE MANUAL

1. Visual inspection of wire termination in electric motor terminal housing Pass Fail Date Inspection number Inspector Inspector registration number TiBMan019 16 SING A WERE TiBMan019 17 Trethewey Industries New Machinery Hazard Identification assessment and Control Description Autobaler Model TI350 TI500 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 Entanglement Very Low Do not reach into baler Operator Training Item No Risk control Strategies Cutting stabbing puncturing Very Low Use only safety knife for bale tie off Shearing Nil High Temperature Nil Striking Moderate Upper of 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 TiBMan019 Warnings I 2 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
2. io liess 2 What function does the retract button have a General 22 E E Cycles tlie Dale us a ask loses C Raises the fingers only ssssss e 3 purpose of the safety bar is dy Todo CAMUS E A b For emergency C Nopaf iculardisSe sense 4 Through which holes in the twine lock bar would you insert the twine Gir tie dotes sa dur loses b Two holes any IE c Ce AlholeS 5 When twining the baler at what position should the baler fingers be ME Dn mm D is a aea DU cec e f cis lu Es FUI Usos a ee er 6 What is the purpose of the plastic tabs on the base floor of the baler a Bj A Dean een a in b Place twine 4 2 e E E LS M ere f last 10 20 of the bale how would you place flattened material OMNIS CGC OC D 1 AI INNER AM PM C Flat in the al ERE aa ee OHNE El techn 8 Tying of the finished bale should be done with the d Fingers 0 ruta auge b Fingers hall Weyore uo ee C Fihgers righit down a 9 Opening of t
3. Check system pressure 2100psi y Check pressure switch is firing at 1980psi see chapter 14 y Check response to solenoid valves when cycle button is activated y If no response at the solenoids check the sockets at the controller unit and the wiring loom to the valves y No Response y Change controller unit or controller PCB Board y Call 1800 888 403 Appendix 21
4. y Ring Service Number 1800 888 403 Appendix 11 Baler is making a poor loose bale Are you tying off the bale with the pressing fingers right down and hard on top of thebale Yes a No a Are all the twines through the holes in the twine lock bar on the top right door Tie off the bale with the pressing fingers right down are on top of the bale y Are the twines free of excess slack after the initial twine up y Are the wines being tied off firmly with a non slip secure knot Ring Service Number 1800 888 403 Appendix 12 Bale is difficult to locate and handle Are you using the bale transport trolley provided with the baler y Is the bale correctly situated on the transport trolley y Have you been trained in the use of the Autobaler No Ring Service Number 1800 888 403 Appendix 13 Fingers fail to remain rigid on the way down y Is the system pressure 2200psD gt No gt Adjust system pressure y Yes y Is the pressure switch firing between 1950 2000 gt No Replace adjust switch y Yes Check system pressure Yes gt Are both sides failing to remain rigid on down stroke y No y ORT No system pressure and Gne ee Coys replace pressure switch y Yes and replace pressure switch
5. 9X LX 9A EN ONITdNOD LIVHS 13VHS3AIHG QYIHYOLOW Eu KEI LIN3N313 ONII4N09 X314 U3QIdS MAYOS ONIN907 4 9 gt VALE SPI S 2 22 T ZY 6 an mn OPERATION BOUNDARY 3350 21150 NOMINAL OUTLET ON WALL BEHIND 1 1 I 1 POSITION OF POWER I 1 I 1 2400 NOMINAL OPERATION BOUNDARY 3000 1800 FLOOR LEVEL F Trethewey OBALER Industries 5 FACLITY DRAWING 2 2 297 CCT acr marke M ee mm jm ME D PATE OF PIT UNT AO 148 06007 UST BOR ERSTATTEN CN COMICIOS ok DED PTUS ALL LIGAL MONTS RESERVED Chapter 27 Appendix 1 _Appendix 2 Y SL500 Valve Block Appendix 3 Appendix 4 q D00r Link Adjuster Door Link Appendix 5 Eject Appendix 6 Full Bale Switch Appendix 7 Door Switch 15 is required alw 2 1F polarity chang gt 3 CHILDREN must be kept away 4 DO NOT reach or lean into the Au 5 POSITION the twine cage and bal 6 WHEN opening the top d
6. 5 Chapter 10 Controller Layout and Function Serial Number 3 Up Down Power 19 019 Active Indicator Indicator Indicator Indicator To Bale Counter 8 Full Bale Light 13 Warning 20 Isolating Switch 1 Retract 11 Eject 9 ELECTRICAL HAZARD INSIDE DO NOT OPEN DANGER VOLTAGES INSIDE Power Polarity Thermo Plug Solenoids Change Accessories Full Bale Motor Port 16 Pressure Switch Port 15 18 14 40 Controller Almost the total function of you 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 the 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 controll
7. 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 TiBMan019 Autobaler EN ISO 12100 1 EN ISO 12100 2 EN 294 EN 349 EN 418 EN 811 EN 953 EN 954 1 EN 982 EN 1037 EN 1050 EN 1088 EN 60204 1 AS 4024 1 AS 4024 1101 2006 TiBMan019 Trethewey Industries Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology Safety of machinery Basic concepts general principles for design Part 2 Technical principles and specifications Safety of machinery Safety distances to prevent danger zones being reached by the upper limbs Safety of machinery Minimum gaps to avoid crushing of parts of the human body Safety of machinery Emergency stop equipment functional aspects Principles for design Safety of machinery Safety distances to prevent danger zones being reached by the lower limbs Safety of machinery Guards General requirements for the design and construction of fixed and movable guards Safety of machinery Control systems Part 1 General principles for design Safety of machinery Safety requirements for fluid power systems and their components Hydraulics Safe
8. Stringing System Initial stringing Required 3 rolls of string Recommended twine gauge Supalash 8 depending on bale weights Often problems experienced with the twine system are as result of wrong procedure or incorrect twine For the correct procedure for the initial stringing of the baler see stringing chapter in Owners Manual 1 Position the 3 rolls of twine on the string lock side of the baler ensure that the string rolls are the correct side up and drawing from the correct end of the twine roll Burn seal the end of the twine for the initial stringing only If the pressing fingers are down raise the finger assembly by activating the up button the pressing arms will raise and stop in the fully up position Turn key off Fully open the bottom door and the top door Situated on the top right hand side of the press hopper is a string lock bar Insert the twine from the outside through the string lock bar holes Continue down with the twine and through the collar immediately below string bar see stringing chapter of owners manual String lock bar has three holes through which the three string ends are inserted from the outside the two strings closest to the front come down the inside of the hopper and through the collars immediately below lock bar 9 The third twine end is inserted through the hole in the string lock bar at the back position rear of press see twining chapter Uo pde OO The rear string pas
9. Surplus slack twine inside pull out from the outside Trainer Signature of compliance 9 Twining Transverse Twine from rear Hook twine loop to rear tab Place twine under rear tab then forward under front tab Hold twine in left hand to left side Close bottom door with right hand Bring twine over the top of the bottom door from the inside Twist twine end around the tab twice and bring end into slot Latch bottom door Twine end about halfway down the front door 10 Close top door Trainer Signature of compliance 10 Initial Fill 1 Throw in material until visible Trainer Signature of compliance 11 Baler Start Up 1 With material visible 2 Turn baler 3 Press in coded key bar 4 Press cycle button marked cycle Note If baler is cycled with no or little material in the hopper the baler may make a sharp clunk this will not damage the baler Trainer Signature of compliance 12 Automatic Operation Active light will flash after cycle button has been activated When loading baler direct material evenly and towards censor eye to activate the baler Throw full boxes in any time through the cycle path Large boxes throw these in the first 5096 of the bale lattened gardboard on its flat Horizontal Overload one person at a Trainer Signature of compliance 13 Bale Procedure 1 Last 10 of bale flat
10. 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 display 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 TiBMan019 42 18 Connection Socket The connection socket contains the wiring looms from the controller to the following functions NN Solenoid valve to main compaction arms Solenoid valve to bale eject cylinder Pressure switch control wires Power boost wiring Full Bale switch 19 Light Indicator Grouping A series of vertical lights show the various fu
11. emergency bar emergency stop baler location guarding work practices etc Check the baler function and operation l e all finger units functions correctly finger units standing smoothly check damper function door latch operation DOOR LATCHI Check baler door latch operation check and repair worn door latches Check for safety operation of Latching and ease of 2 REPLACING THE FINGER LOCK SPRINGS For good reliable service the finger lock springs require replacement on a frequent basis The TI350 TI500 balers have a pair of finger locks one on each side of the baler Replace annually The finger lock has attached a chain via two shackles the chain is attached to the other end of the baler structure Attached to the finger lock unit is a tension spring the tension spring is attached to the finger by a spring which is attached to the finger by a 3 8 bolt see finger lock illustration STEPS TO THE FINGER LOCK SPRING REPLACEMENT Locate the finger lock assembly Left to Right Remove the outer mesh screens Ensure that the finger assemblies are down cylinders are fully closed Release the finger lock chain on one end this will allow finger lock to close releasing the tension in the finger lock springs Remove the existing spring by rotating the upper spring hook from the top lug use vice grip tool Unhook the spring from the bottom anchor bolt Check the anchor bolt for firmness Attach new
12. instructions Prior to moving the Autobaler ensure the fork lift capacity is at least 3 5 tonne On installation or repair ensure the machine is effectively earthed All electrical work to be carried out by qualified electrician 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 TiBMan019 19 COPY OF WARNING NOTICES ON MACHINE INCLUDING NAMEPLATE TRETHEWEY INDUSTRIES AUTOBALER FACTORS FOR EFFICIENT OPERATION OF THE AUTOBALER 1 FREE MATERIALS ONLY N OT c 2 NO TIMBER OR HARD OBJECTS 3 NO COMPRESSED SLABS OR BALES OPERATIONAL AND 4 NO BOXES CONTAINING HARD OBJECTS INSTALLATION MANUAL 4 5 DO NOT CYCLE AUTOBALER WITHOUT MATERIALS N THE HOPPER INSIDE 6 IDEALLY PLACE FLATTENED CARDBOARD FLAT INTO THE HOPPER YOU MUST READ ENSURE YOUR 7 00 NOT THE BOTTOM DOOR UNTh OPERATION AND zu a THE BALE IS TIED OFF 8 THE FINGERS ANE IN RETRACT POSITION INSTALLATION MANUAL REGULATIONS FOR YOUR TWINE 8 READ THE OPERATION AND INSTALLATION MANUAL CAREFULLY BEFORE use OF BEFORE USE THIG AUTOBALER REQUIREMENTS PHONE 1900 68 403 READ INSTALLATION MANUAL BEFORE USE locate Autobuler hom area s 16 pr
13. mounted on the top of the block On the block are two solenoid values the single ended valve operates the bale ejection system b Check the wiring in the valve plug unit for loose or disconnected wires TiBMan019 48 4 A test unit is available to test for the correct signal response from the controller these are available from the press manufacturers or your local hydraulics service agent 5 1 If the motor starts when the eject button is activated 2 And the correct electronic signal is reaching the solenoid on the eject valve yet the valve fails to respond a Replace the solenoid valve unit a Remove and dismantle the valve clean the internal working parts thoroughly in clean fuel to remove any possible contamination a Replace the solenoid valve coil Note If there is no signal from the controller to the valve a Check the wiring from the controller to the valve for damage or for loose or disconnected wires or loose fittings a Replace the main controller unit TiBMan019 49 Chapter 13 Press Movement on the Floor during Operation STRUT MALFUNCTION The likely cause of press movement in locating on the floor is a faulty damper strut See Appendix 3 Steps to check 1 Ensure that there is sufficient material in the hopper to prevent the fingers crashing on the down stroke during test 2 As the press is cycled in the up stroke finger assemblies come into contact with rubber bumpers If the damper struts are fun
14. until the installer is fully satisfied that the moisture risk no longer exists In case of severe water contamination dismantling of the following may be required to allow evaporation of the trapped moisture a Check the motor junction box if moisture is present the unit must be allowed to dry before use b Solenoid valve coils Electronic censor unit situated on the rear of the upper roppel d The electronic controller unit to check this unit if contamination is suspected TiBMan019 23 e Remove the controller from the machine f Remove the entry plate from the back of the controller If moisture is present allow to dry thoroughly if excessive water contamination had occurred to the controller unit it may require replacing with a dry unit In many cases this is the best option moisture in sensitive electronic components may take long periods to dry thoroughly Attempting a start up with a moist unit may result in serious damage to the control unit 3 Check the Electrical System for Obvious Damage 1 Check the plug unit for any damage or lose wires 2 Check the lead from the plug to the controller for damage if in doubt use an appropriate multi metre 3 Check the power connection units at the bottom of the controller for firm undamaged connection 4 Check the power entry to the motor junction box If damage or a fault is suspected call a qualified electrician 5 Do not connect to a wall socket point that shows damage o
15. 3 Operate the emergency bar when depressed the limit switch button should be contacted and the switch make an activated click sound When released the emergency bar should rise above the switch button 4 Check the limit switch mounting bolts for firmness Switch Wiring 1 The switch operates in the normally closed mode 2 The two wires attached to the outer terminals Terminal 1 and 2 3 Check the wiring from the limit switch on the emergency bar to the wiring on the door limit switch for damage or short circuits Use a multi meter Testing the emergency bar switch 1 Set the multi meter on low ohms scale or continuity light these should indicate a short between terminals 1 and 2 of the limit switch is not operated Operation of the switch should remove the short circuit Terminals 1 and 2 outer terminals TiBMan019 57 Chapter 18 Damper Strut The damper struts are situated on either side of the baler unit It is essential that these be working correctly These ensure that the finger assembly return smoothly FULL SERVICE PROCEDURE 1 Remove the damper from the Autobaler remove anchor bolts at both ends 2 Remove the small cap retainer screw on the side of the damper barrel 3 Carefully remove the cap by tapping off 4 Slide out the piston assembly and take care DO NOT DAMAGE THE SEAL 5 Replace oil with 32 grade hydraulic oil 50mm depth in the barrel approx 1 3 of a cup 100ml 6 Replace seals S
16. Re assemble and check for good function ELECTRONICS FOR DETAILED INFORMATION SEE STARLOGIXS 1 Check the operation of the cycle Check the door open switch The Check the operation of the eject Check the operation of the key switch and emergency stop button See illustration 5 buttons baler must not be able to cycle down with the top door open function with all doors open Press the eject button eject arms will swing into the press chamber ejecting the bale eject arms require manual retraction i e press If a strut is working correctly the assembly will slow 50mm before contacting the plastic in with your foot Note if the eject fails to eject the possible cause will be a top door limit switch adjust the limit switch When servicing the baler record the bale count on the bale counter situated on the controller Check the operation of the sensor units With the press active light on place a piece of material between the sensor eyes the motor should start and the press commences the up direction of its cycle Check emergency safety bar on the top door adjust if necessary In the case of a controller failure replace the controller unit 8 SERVICE CHECK ON FINGER LOCKS Finger lock unit see photo this page consists of a C shaped lock which hold the pressing assembly rigid on the down pressing stroke if the pressing assembly fails to remain rigid the fingers will drop and will push
17. are Firm and Moisture Boot is Fixed on Hydraulic Pressure Switch Check and Repair for Oil Leaks Comments 7 Safety Bar Operation Check That Safety Bar Functions Correctly Check Switch For Operation or Damage Check That all Bolts and Screws etc are in Good Working Order Comments 8 Full Bale Indicator Operation Check Full Bale Light Replace Bulb if Required illustration 35 Check full bale limit switch situated on the left side of the baler behind the front main bearing with the pressing fingers right down in the box hydraulic cylinders fully closed At this point the full bale limit switch situated behind the bearing should be depressed until the roller axle is just out side the switch body Adjust if required illustration 45 Check wiring connection to switch Clean any rubbish or contamination from the switch Comments 9 Structural Thoroughly check for cracks or failed welds or any signs of fatigue or structural damage and report Check all bolts especially bolts attaching the main finger pivot bearings replace broken bolts with high tensile bolts Check cylinder anchor lugs for fatigue Comments 10 Twine System Check to see that the twine lock through which the twine passes does not cut the twine adjust if required Check twine plastic clips on the baler base are in good order replace or report Comments 11 Top Door Check latch is functioning correctly Adjust and lubricate latch L
18. completed and returned Are there issues that require attention from the return of the pre installation form i e forklift power transport etc What are the issues 1 2 3 4 Have these issues been addressed Has the baler arrived on site With the baler at the site and all issues addressed has a day and time been agreed on Date Has the number of people for training been established Number to be trained Number of People Baler Serial Number Baler Type Customer Date Officer Signature Yes EC Trethewey Industries Declaration of Conformity Training Procedure Conformity Product Type Serial Number Machine Type Customer Name Baler Location Date Conformity Declaration Service Agent manual Carried __ Baler Removal from Pallet jPre commissioning Check __ Post Commissioning Check Store Documents Woolworths __ Trainee Documents Trainer Material Presented Controller Set up Baler Fit Out Pre twine Tying the Loop Twining __ Twining Transverse Initial Fill Baler Start Up Automatic Operation Tidy Bale Procedure Tying Off Maintaining Twine Tension Transverse Twine Tie Off Retracting Fingers Opening Doors Situating Bale Trolley Ejecting the Bale Full Bale made Trainees Competent I hereby declare that I we have fully complied Signed Date Safety Check List Name Location Store No B
19. 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 T 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 TiBMan019 41 8 Bale Counter The bale counter as the came suggests simply counts the number of bales being compacted The bale counter 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
20. front of the bale 13 Activate eject button with left hand and assist bale ejection with the right hand Difficulties in Bale Removal In the previous paragraph the importance of tying off the bale firmly was stressed a bale tied off firmly has minimum expansion when the bottom door is released and offers less resistance in ejecting Problems 1 When ejecting button is activated the motor starts yet the bale fails to eject a Ensure that both doors are opened to their maximum b If eject arms are working a thud feeling should be felt on the bale When the machine is new the tacky paint surface can offer some resistance especially if the compressed material has been in the press for some length of time creating a bonding effect To remove such bales may require substantial assistance from the operator by pulling firmly on top of the bale at the same time as operating the eject button this situation will improve with use 2 Motor fails to start when the eject button is activated a Ensure that the pressing fingers are raised as previously stated and that both doors are fully opened b Check the emergency stop button Check the power light on the controller if the power light is not on check the power supply to the controller d Check the press fuse 3 When the eject button is activated the motor starts but the hydraulics on the eject fails to function a Check the wiring going to the eject solenoid valves
21. guards relevant to a service 2 LUBRICANTS REQUIRED TO SERVICE AUTOBALERS 1 Tube of 8 Pro ma long life grease 2 8 or similar spray lubricant 3 32 grade hydraulic oil Note a minimum of 20 litres is required for top up purposes in a regular service Sufficient oil should be carried for maintenance which requires an oil change For a complete oil change the following amounts are required 300 series baler 200 litres 400 series baler 200 litres 500 series baler 200 litres A container or containers will be required to deposit the used baler oil In the likely event of an oil spill carry a sufficient amount of oil absorbent substance to ensure that the floor area is completely oil free on completion of the job Used oil must be disposed of via an oil recycler or in a legal manner 3 TOOLS REQUIRED FOR A PREVENTATIVE MAINTENANCE 1 Cartridge type grease gun 2 Oil pump 3 Oil funnel 4 KZD needle nose coupler TiBMan019 65 mg Orari wl BALER SPARES REQUIRED FOR A SERVICE Oil filter Pressure switch Fingerlock spring Plastic twine tabs Assorted high tensile bolts 2 Y x Y x ht nyloc Roller type limit switch omron Cable ties Spare cylinders see parts list numbers Cylinder anchor bushes see parts list number Controller mount anti vibration fasteners see parts list number Spare finger lock chains see parts list number Spare damper 4 amp controller fuse Full bale light bulb Coded key mount rub
22. into the pressing chamber in an abnormal fashion The most common cause of the problem is a finger unit Initial Check 1 8 The finger lock unit is sprung loaded forward by a tension spring known as a finger lock spring if this fails the finger lock will not function Replace if broken or stretched Check finger lock pivot the finger lock must pivot freely lubricate pivot Check that no obstructions i e plastic twine paper etc are obstructing the finger function Attached to the finger lock unit via shackle plates is a chain This chain is also attached to the body of the press by a hi tensile bolt if this chain is detached reattach Note ensure nyloc nuts are used on attaching bolts Some older models are not equipped with a roller on the top of the finger lock if the point of the finger lock has become worn Replace finger lock with a service unit Build up finger lock with weld and smooth off with a grinder Note if replacing the finger lock chain it must be the correct length if the chain is too short it will come into excessive tension when the pressing arms are fully down causing the bolts or chain to fail On the other hand if the chain is too long the finger lock will not open at the correct point causing the fingers on the pressing assembly to rise in an unclasped form This can cause the finger lock unit to fail breakage Check that the finger lock unit is functioning correctly 9 HYDRAULIC CHE
23. nut closest to the press tension up If the adjuster is over length the door won t close A correctly adjusted door When the bottom door is pushed fully closed without latching it will spring back open from 15 20 mm Lubricate all pivot points on the linkage door hinges and the door latch Door Check Complete 6 DAMPER UNIT SERVICE The damper struts are situated on either side of the baler unit It is essential that these be working correctly These ensure that the finger assembly return smoothly FULL SERVICE PROCEDURE TRONA D Remove the damper from the Autobaler remove anchor bolts at both ends Remove the small cap retainer screw on the side of the damper barrel Carefully remove the cap by tapping off Slide out the piston assembly and take care DO NOT DAMAGE THE SEAL Replace oil with 32 grade hydraulic oil 50mm depth in the barrel approx 1 3 of a cup 100ml Replace seals Shaft seal Ludowici R87 088 and Piston 8 cap seal 2 x 3mm O ring SERVICE CHECK 1 N o D md Raise the fingers to a vertical position and stop in that position this can be done by pressing the retract button found on the controller stoppers Leave strut attached to the baler Remove the strut cap total oil volume in each strut 100ml Using a long clean rule measure oil on top of the piston minimum 5mm of oil depth Add 32 grade hydraulic oil if required Before closing the cap smear grease around the cap O ring
24. signs of fault Comments Store Managers slg Technicians ler New England Highway Telephone 02 6734 5403 DEEPWATER NSW 2371 Facsimile 02 6734 5433 EMAIL michelletully autobaler com au Pre Installation Information Company Name Address Contact Phone Fax Email Autobaler Model Requested Office Use Only Serial Number Controller Number Delivery Date Requested nstallation Date and Time as the Autobaler Been Delivered Installation and Training Site Assessment Request 1 Delivery is there a 3 5 tonne fork lift available 2 Extra delivery cost may be incurred if alternative delivery is required would prefer to make by own deliver arrangements Y N 4 Will any manual handling be required Y N 5 What distance does the Autobaler have to be moved 6 Will the Autobaler be located in your Delivery Dock Y N T Is the Delivery Dock raised Y N 8 Is the Delivery Dock at ground level 9 Is there further information we should be aware of to ensure the smooth installation of your Autobaler 10 Does the site meet all the OH amp S requirements Y N Comment 11 Is the Autobaler site ready Y N 12 Power Requirement is the appropriate power available Y N l e 415V x 20 amp x 4 pin it is the responsibility of the site manager to ensure that the power connection capacity in the building is
25. spring is attached both ends b Check that spring has full tension When lock is manually pulled back it should snap closed positively unbolt one end of chain to test T Attached to the rear end of lock via two shackle plated is the release chain which is also attached to the press frame via the other end Check that the shackles are free and that chain is untangled Note if chain becomes tangled it will shorten the length of the chain possibly breaking the chain or the chain anchor bolts as the press travels in the down cycle 8 Clean the two surfaces of contact on the lock Remove grease compressed paper etc Roughen surfaces using a course file On older models only if required 9 See Flow Chart Appendix 14 Malfunction 2 Correct function of the finger system the fingers travel in downward direction rigidly locked when the fingers have travelled 80 of their downward path the lock chain comes into tension releasing the lock With the locks released the finger assembly becomes limp on the return stroke withdrawing through the side and then rotating to the vertical position and re locking Malfunction 2 Is when the finger assembly remains rigid in both directions rigid down is correct rigid up is a malfunction TiBMan019 32 Steps to Remedy 1 Remove key for safety 2 Check main barrel pivot for seizure a Lubricate main pivots b Check for string wire etc tangled between the moving surfaces barrel unit should rot
26. spring to the bolt lug at the bottom full loop end of spring Grip the top of the spring firmly using clamp vice grip pliers lift and rotate spring into the top anchor lug hole Re attach chain to the finger lock Check to see that springs are fully and securely attached Illustration Finger Lock Spring 3 REPLACING THE OIL FILTERS It is recommended that the oil is tested annually to check for the following a Oil contamination a Oil damage from overheating a Water ingressions from high pressure cleaning The hydraulic system requires a filter change every third service The filter is situated on the hydraulic tank which is situated at the side or rear of the Autobaler Filter Changing Procedure a Remove the three small studs on the tank these are located on the top of the unit see illustration 1 b Lift filter out of the unit Note the unit does not require removal from the tank C Replace the new filter taking care with the re assembly making sure that the filter is the correct way up see illustration 2 d Ensure no contamination occurs clean well before disassembly and re assembly Tighten the filter unit lid down evenly f Run the machine and check for oil leaks Illustration 1 Illustration 2 4 SERVICING OF THE FINGER ASSEMBLIES The finger assemblies consist of a left and a right hand unit 1 Check the anchor bolts on each of the main bearings if bolts are broken replace with 2 Y X ve or 2 X 75 UN
27. to smaller quantities d When removing full bales from the Autobaler always use the Auto eject e 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 f Always use the baler trolley pallet jack or fork lift to relocate full bales 0 Always be of door rebound when opening top or bottom doors always stand to the side h Never stand in front of the pressing chamber when ejecting full bales always stand to the side 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 During assembly location and operation of the baler safety compliant footwear must be worn Firm fitting work place compliant clothing must be worn Safety compliant work place gloves hearing protection and eye protection must be worn Always remove Autobaler key when machine is not in operation or is unattended Trethewey Industries recommend that the following checks be carried out TiBMan019 25 Maintenance Requirements WEEKLY a Check safety guards around moving parts Are they in place Are they damaged b Check Autobaler key switch is it functional and in good order Check stop button is it functional and in good order d Check safety bar is it functional and in good order e
28. up Yes Is the finger lock chain still attached both ends one end to the baler body the other end to the finger lock y Yes Call the Service Number 1800 888 403 Appendix 15 Does the baler cycle continuously without material over infra red eye Yes Are eyes clean and clear of contamination gt No Using soft cloth clean eyes y Yes Is the eye unit at the rear firm and vermin gt N0 gt Realign the controller and securely fasten the controller Yes Is the controller unit firmly attached to the baler Yes gt Yes gt Does the baler cycle continuously without material over infra red eye y No Yes y After adding Y cup hydraulic oil to Check for damaged or broken wires to the eye the damper is it still bumping on that side y y Yes Yes Replace eye unit at the rear Service or replace the damper unit of the baler Call Service Hotline 1800 888 403 Appendix 16 Is the baler moving on the floor y Yes Does the baler make a sharp banging or bumping sound when the finger assemblies are standing up on one or both sides Yes Are the small yellow cylinders situated on Re attach using only high each side adjacent to the large cylinders 9 tensile boils securely attached both ends Yes Top up oils in small Dampers Remove the small screws holding the cap and slide up the shaft and add 75 cup of hydraulic oil and cycle several time
29. y Are finger lock springs on both Replace finger lock spring sides and working gt No gt y Yes Is finger lock in good condition E g bent or broken gt No Replace finger lock unit Yes y Is the finger lock lazy and failing to come forward and lock y Yes Are finger lock bearings in good Replace finger lock bearings working order Yes Continued Next Page Yes With the pressing arms right down cylinders fully closed remove the chain connecting the finger lock to the baler The finger lock unit should snap forwards freely and lock over the finger unit abutment Caution when re attaching the chain ensure that the chain is not twisted is securely and firmly attached to the baler body SAFETY Before removing the guards to service the finger lock unit isolate the power and remove the key Illustration 2 Illustration 1 Correctly locked finger Correctly broken finger unit on descending stroke unit on ascending stroke Appendix 14 Pressing fingers are rigid and 4 See illustration 2 for correct function unbroken on the up stroke y Yes Are both sides rigid and unbroken on the up stroke Adjust the full bale switch The full bale switch should activate when the hydraulic cylinders are 25mm from being fully closed Yes Is the bale still being fed with material after the full bale indication has sounded Or Is one side only unbroken on the way
30. 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 AUTOBALER Full Bale Light Bale Counter Safety Bar Key Emergeney up er Stop Key Bar Control Panel Upper Door Handle Lower Door Handle HA b TRAINER MATERIAL Baler Serial No Date Customer Address Trainer AUTOBALER TRAINER MATERIAL INDEX Signature Controller Set Up Baler Fit Out Initial Set Pre Twine Tying the Loop Twining Twining Twining Transverse Initial Fill Baler Start Up Automatic Operation Tidy Bale Procedure Tying Off Maintaining Twine Tension Transverse Twine Tie Off Retracting Fingers Opening Doors Situating Bale Trolley Ejecting the Bale 1 Controller_ Operation 1 Turn the key on power light on 2 Door switch light on 3 Disengage emergency stop key rotation 4 Cycle button to cycle 5 Retract button to raise fingers only 6 Eject must be held in to eject 7 Red light and beeper full bale indicators ee e Trainer Signature of compliance 2 Set Up Remove The Wrapper Cut The Straps Remove all items from within the bale
31. Bale weight 450 550kgs Cycle time 32 seconds Compaction force 33000 Motor 3 phase 5 5kw Baler mass 3500kgs Shipping weight 3750kgs TiBMan019 TRANSPORTING THE AUTOBALER SAFELY r positioned on pallet The following procedure is for the safe transportation and movement of the Autobaler REMOVING THE AUTOBALER FROM THE PALLET 1 2 3 Unwrap and cut metal strapping Open baler door Insert the fork lift tines through the slots beneath the front lower door situated in the rear baler wall are fork way slots Ensure that the fork lift tines are fully through the rear wall slots Lift the baler no more than 80mm off the pallet check again to ensure sufficient tine protrusion through the rear slots Lift sufficiently i e 50mm to clear the pallet slide the pallet beneath the baler with caution With tines through the baler slots always move a close as possible to the floor b at idle speed only c in reverse to ensure good vision Note When transporting the Autobaler where lifting on a truck is required 1 2 3 Always transport on a solid hardwood pallet Never lift the baler more than 300mm unless on a pallet as the baler could slip off the tines metal to metal If lifting the baler from beneath the baler base fasten the baler to the fork mask using strap or chain When lifting the baler more than 300mm always be on level ground and never transport the baler in an elevated position W
32. C HT bolts with Nyloc nuts 2 Machines equipped with nylon main bushes lubricate using pressure pack lubricant 3 Check bearing pivot shaft securing pins bolts 4 Finger assemblies consist of finger barrel cluster coupled to the finger frame assembly by a full length hard chrome pin check that the pin fastening is secured 5 Lubricate grease nipple on main barrel 6 Check finger assembly for weld failure or fatigue T Check top cylinder anchor 5 B Remove one split pin from the anchor pin 9 Remove the anchor pin check pin and lug sleeve for excessive wear replace the pin and bush if required 10 Check the cylinder clevis for cracks fatigue or wear replace if required 11 Lubricate pivot with lithium based grease before reassembly 12 Dismantle and lubricate the bottom cylinder anchor check hydraulic cylinder fittings for oil leaks DOOR ADJUSTMENT CHECK The front door on the AutoBaler is connected to the side door pivoting via an adjustable linkage If a linkage assembly is incorrectly adjusted the bottom door latch can be difficult to open or close 1 2 3 4 Check the linkage arrangement for damage Check that all bolts are attached and in good order replace with a 2 X 72 HT bolt if required To adjust lengthen or shorten adjustment link as required In most cases the link will require lengthening to lengthen release 5 8 lock nut furthermost from the press rotate Y turn follow up lock
33. CK in Check for oil leaks in the reservoir cylinders hoses amp fittings Check for damaged or unsupported hoses Replace reservoir oil every 2 years 32 grade Hydraulic Oil Replace oil filter every 12 months Check for damage tightness and function of the solenoid valves Balers are equipped with a pressure test port on the aluminium valve block 2200 PSI system pressure and firing at 1950 PSI with SL500 boost at 2700 PSI system pressure and firing at 2400 PSI T Check oil level Oil should be showing on the dip stick Caution DO NOT OVER FILL Chapter 23 Forms Service Guide 16 Baler Installa Lubrication Dampers Hydraulics Electrics Controller Eye Operation Solenoid Valve System Safety Bar Operation Full Bale Indicator Operation Structural Twine System Top Door Guarding Finger Assembly Check Bottom Door General Operation Signage tion Procedure Conformity Document Declaration of Conformity Safety Check List Seven Essentials when Visiting a Baler AutoBaler service report Staff Training Report Pre Installation information Pre amp Post Commissioning Checks Job Completion Sheet 1 _Lubrication Hydraulic cylinder pivots top and bottom Door Hinges Use KZD Coupler attachment Side Door Pivots Use KZD Coupler attachment Side Door Slide Use KZD Coupler attachment Door Use KZD Coupler attachment Door Link Grease Finger Barrel unit 2 grease nipples per barrel Grease Ejec
34. Check power lead is it undamaged f Is it clear of any moisture 0 Check Autobaler response to opening top door Opening more then 50mm approx 2 inches should cause the machine to cease cycling 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 PREVENTATIVE MAINTENANCE a b TiBMan019 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 From time to time a qualified electrician should inspect all power leads and electrical contacts and tag the lead as required by law 26 Commissioning of aNew Autobaler This is the stage where a fully functional Autobaler is handed over for use by the end users At the conclusion of this commissioning the installer must be satisfied that the Autobaler will perform as specified and that the end users are fully conversant with the operation and the safety guidelines Initially the installer must be satisfied that The Autobaler is complete as specified by the manufacturer 7 The Autobaler is the specific model as requested The power source is as specified All accessories and attachments are as requested 7 All functions of the Autobaler operate correctly The motor rotates in a clockwise direction hydraulic oil reservoir is There a
35. FICATION CHART 001 51100 51200 COMPACTION MECHANISM QTY DESCRIPTION FINGERLOCK ROLLER ROLLER PIVOT BOLT LOCKING DIVOT CHAIN ATTACHING SHACKLE SHACKLE BOLTS FINGER FINGERLOCK BODY FINGERLOCK SPRING FINGERLOCK SPRING ANCHOR BOLT FINGERLOCK BEARING FINGERLOCK AXLE FINGERLOCK CHAIN FINGERLOCK AXLE GRUB SCREW FINGERLOCK AXLE SPLIT PIN FINGERLOCK SPACER WASHER 51100 51200 FINGERLOCK MECHANISM 00 LAVHI NOIL V3IJILN3GI LN3NOdAOJ2 COMPONENT IDENTIFICATION CHART 004 Jauxamuszioxaouszs assor 4 or GACINOW AND dno uai 602460 4 6 E OLN U SZL X GO UI S LO ldnoloNm o 013 I meer female DEN U 6 81 X 0 PQ AGOBIONIN O 9024 90 4 EB adoa EN SvO H31714 AGOE ONISVI YALTA soz4 S0 4 EN OLN US 8 XGOUISL EO ONO DVNH3INDONEO roza 0 2 gt OLN V X GO U SZ v2 DNIE O lavoloNm O 8024 013 629082 X QO Ul 521672 ONIHdS NRidS dvo Ed 114 2024 20 4 dvo ONISVO HALT 1024 1014 4921 ONISVO Y31714 500 LAVHI NOILVII411N301 LNINO4WOI ININVHGAH 7 108981 0910899 X3GTvH I UNCLE Um ONI 14109 YaMOT 30H00 ML ABM 14HS 9027 BOLNA L Hadids E Sir MAHOS LIS 13006
36. Press Fails to Press Heavy Bales Bale weights can vary significantly when pressing cardboard and paper there are several factors in the materials which can contribute to this 1 4 5 During moist weather moisture is absorbed into the materials increasing its weight and also reducing its structural strength both these factors contribute to heavier denser bales Bales pressed quickly tend to be lighter in some cases up to 20 than bales which are pressed over a longer period of time bales pressed over a longer period have a longer time for the materials to collapse and settle repressed bales are often lighter Bales pressed from the TI350 TI500 can vary in weight as previously stated depending on conditions and materials the TI350 will press a bale 300 350 kgs per bale and the TI500 will press a bale 450 550 kgs per bale Low System Pressure See Chapter 15 Adjusting System Pressure Faulty or Maladjusted Pressure Switch See Chapter 16 Pressure Switch Light Bale Low Density Bale Problems Full Bale Light Comes on Early This fault is not uncommon in some cases the light may come on each time the fingers complete the pressing cycle down regardless of how much material there is in the bale Adjusting the Full Bale Switch a The pressing fingers are to be right down and the main Hydraulic cylinders fully closed Note Be sure the cylinders are fully closed if necessary remove some materials from beneath the pressing finge
37. UTOBALER SERIAL NUMBER CONTROLLER SERIAL NUMBER CS Name and Address of Manufacturer Trethewey Industries 14 Carl Baer Circuit Deepwater NSW 2371 Australia Please Read This Document before Operating the Machinery TiBMan019 NOTES a The machines are manufactured in compliance with the accident prevention rules in force a The machines strictly comply with the instructions contained the manual to obtain the best performance from the machines Strict compliance with the rules contained will ensure optimum results and avoid any inconvenience caused by the non compliance of operation and maintenance instructions a To avoid contacting the manufacture for problems which can be easily solved closely follow the instructions given below a If after having strictly complied with the instructions given the buyer still needs the help of our technical assistance service he must supply all the technical indications necessary to determine correctly This will enable our technical assistance service to intervene quickly and efficiently on the machine a Copies of the instructions manual may be requested upon indication of the machine serial number IMPORTANT Upon delivery of the machine the customer must make sure that all the devices indicated in the paragraph on the safety manual are present and working correctly Furthermore he must mount in conformity with the instructions indicated those devises which are not mounted at the time
38. again 3 When the pressing fingers are down and the front door is closed the pressing fingers will with some models retract when the up or retract button is activated the fingers returning to an up position and remaining there 4 With the front door open under no circumstances should the pressing fingers be able to move in a downward direction Malfunctions of door limit switch a Pressing fingers moving down with the top door open b Press not cycling except in the retraction or fingers up and bale eject mode Machines fitted with a roller switch on the right hand side If the machines pressing fingers move in a pressing down direction with the top door open the most likely cause is the limit switch on the right hand side of the door not contacting correctly with the circular cam earlier models Later models have a switch arrangement adjacent to the controller The recommended clearance between the limit switch roller and the cam divot is 1mm When the gap between the switch roller and the cam divot becomes too great the cam will not push the limit switch via the roller deep enough to activate the switch thus allowing the machine to cycle with the door open Earlier models only On the other hand if the limit switch is over adjusted with the switch roller and the cam in contact or close to contact the machine may become unreliable or even stop cycling With the switch activated with the door closed as an over adjusted switch
39. aler Model 7 Serial No Controller NO 1 Check top door operation door must not open more than 30mm without activating safety Switch adjust if required Te Br m9 3 Checkemergenystp Z 1 o To 4 Checkkeyoperaion o Z 5 Check power leads for damage placementetc 1 6 Check baler situation baler must not be under where service is required holes lights walkways elevated docks etc ips EX 7 Check twine cage placement cage must be situated to prevent 8 Checkupperandlowerdoorcatchesforposiivelock To o o y O 9 Check all guarding report refitorcorrectifrequred J 10 Report unsafe operator practices 11 Report other areas of safety concerns 1 12 Check safety signage is in good order O Seven Essentials When Visiting a Baler The compacting arm assemblies must remain rigid on the first 90 of the compression stroke and fully bent on the up stroke If not A Check the finger lock spring B Check the finger lock chain for attachment at both ends C Check the finger lock for freeness and positive locking D Check that the pressure switch is firing in the correct range Top door security fingers must not be able to move down with the top door open A Check coded key for attachment and operation B Older balers check limit switch on the top door hinge C Check alignment of magnetic switch on 2005 models D Check mou
40. as organized will be responsible for the cost incurred for the trainers time if they are unable to proceed or are delayed Installation authorized on behalf of the specified company Name Title Signature Date Please list the names of the people to be trained in the safe operation of the Autobaler Groups MUST not exceed 5 people as competency based assessment will be conducted on all trainees individually 1 2 Pre amp Post Commissioning Checks Company Name Address City Contact Phone Installation Date Model Serial Number Controller Number Pre Installation Check Checks to be Carried Out Fail Pass Cleared 1 Check that the paler is free of transport DAMAGE pA 2 Check the motor rotation clockwise 0 3 The power lead is safely situated 4 Bale trolley is stored beneath the baler overhanging on the left side 5 Deposit baler wrappings and trash Post Installation Check 4 System Pressure 5 Bale full switch Safety Bar 7 8 Upper amp Lower Doors Comments poc LIP pS pcc pce 6 Coded upper door switch y BEE IS p B UE AE ASS Trethewey Representative Signature Date JOB COMPLETION SHEET CARDBOARD BALERS Store Name amp No Purchase Order No Delivery Date Requested Date of Installation Planned Date of Staff Training EQUIPMENT SUMMARY SERIAL NO Installat
41. ate freely 2 Check that the lock chain is attached both ends and working malfunction 2 is normally caused when the lock release chain becomes detached One or both ends 4 See Flow Chart Appendix 13 Malfunction 3 Low System Pressure One or both fingers malfunctioning in the previous chapters in finger malfunction we look at various mechanical reasons for the fingers failing to remain locked and rigid on the pressing stroke As previously mentioned the finger units need to be raised to their maximum for the locks to engage if the fingers fail to fully extend the lock or locks may not engage which will cause the fingers to collapse on the descending stroke Malfunction 4 Inadequate System Pressure Refer to system pressure chapter 13 The four main areas of Fingerlock failure in order of priority 1 Finger lock spring 2 Disconnected chain 3 Broken finger lock body 4 Frozen or damaged bearing TiBMan019 33 Chapter 3 Press Cycles Down With Front Door Open If press fingers move down with the top door open Stop immediately and call manufacturer or safety officer The front door is equipped with a limit switch or a coded switch unit when functioning correctly it ensures that 1 The machines pressing fingers will cycle up and down while ever the top door remains closed 2 When the top door is opened during the cycling process the pressing fingers immediately stop and require reactivating when the door is closed
42. ath the solenoids a Thoroughly clean solenoids before dismantling to prevent hydraulic system contamination b Situated on the solenoids are electrical wire sockets before removal carefully mark so that these go back on as they came off Same position To remove the wiring cap remove screw in cap centre With Allen key bmm remove 4 cap screws on the solenoid unit Each solenoid unit has four oil ports each port has a small O ring inserted replace the O ring if required see Parts List for O ring Number When reassembling ensure both surfaces are thoroughly clean ensure O ring are correctly fitted and in all four ports tighten down cap screws evenly NOTE Solenoid unit will only fit one way the direction should be noted before removal TiBMan019 30 T Pump Leak Leak from the hydraulic pump a Carefully check the inlet and outlet fittings into the pump for possible leaks b Replace the faulty pump return this to the manufacture or a dealer for service 8 Cylinder Leaks Hydraulic Cylinder Leak a Check fittings into cylinder for possible oil leaks b Check welding at the base of the cylinder for cracks resulting in a leak Excessive hydraulic cylinder shaft leakage As the cylinders age some leakage from the seals will occur this is normal when this becomes excessive replacement of the cylinders or the fitting of the cylinder seal kit will be required See Parts List for cylinder numbe
43. ational freeness of the vertical door latch bar and lubricate to freeness 2 Close the door until latch is in position The approximate gap between the flat surfaces of the vertical bar and the press latch lugs should be approximately 1mm 3 To adjust the door gap clearance lengthen or shorten as required the adjustable link is situated at the bottom right hand corner of the press if the link is over adjusted the door will not close if under adjusted the latch surface will collide 4 This procedure may need to be repeated until the press door opens satisfactorily under loaded conditions 5 The adjustment link is secured to the press both ends by 2 X 2 HT Bolts these should be firm but not over tightened TiBMan019 51 Door Switch Door Adjustment Door Link Adjuster TiBMan019 Door Switch 2 52 TiBMan019 53 Chapter 15 Adjusting System Pressure Testing and Adjusting the Hydraulic System Pressure Autobalers have a recommended system pressure of 2100psi With time and system wear the pressure may reduce to the point of creating functional problems in the baler system Testing System Pressure 1 A hydraulic pressure gauge with a capacity of 3000psi plus will be required 2 To attach the pressure A gauge to the baler test port A Remove the dust cap from the baler test port fitting and attach the pressure gauge B 3 Remove one of the two wires from the hydraulic pressure switch B remo
44. bers Spare eye unit The parts listed above are the parts which may be required and recommended be carried by all authorised service agents TiBMan019 66 Chapter 22 Servicing Service Period Every 4 months M M Major Maintenance every 12 months or every 660 bales Major Maintenance AA 5 09 Tas N39 Auto baler service essentials Replacing the Finger Lock Springs Replacing the Oil Filters Servicing Finger Assemblies Door Adjustment Check Damper Unit Service Electronics Service Check on Finger Locks Hydraulic Check Full Lubrication Guide Safety Check List Service Guide Lubrication Dampers Hydraulics Electrics Controller Eye Operation Solenoid Valve System Safety Bar Operation Full Bale Indicator Operation Structural Twine System Top Door Guarding Finger Assembly Check Bottom Door General Operation Signage TiBMan019 67 CLEAN all loose material from v Five AUTO BALER SERVICE ESSENTIALS vithin the balers upper and lower sections and behind the compaction cylinders Caution when cleaning around the power unit area care must be taken with wiring and wiring connectors LUBRICATE the baler in accordance with the manufactures recommendations i e lubricate all moving parts upper and lower cylinder pivots door latches and hinges side door slide plate hydraulic unit oil level etc Complete a safety audit form e door interlocks
45. bottom door is opened the side section of the press also pivots out releasing the tension on the bale for easier ejection As the bottom door is closed the above mentioned side section of the press is drawn in hence the need to keep rotating and sliding components well lubricated 2 The side section movement is a result of an adjustable connection link between the front door and the base Adjusting Front Door Latch The purpose of the link being adjustable is for adjustment on the door latch The link can be lengthened or shortened as required to give the correct clearance between the two latch surfaces as the door closes the two flat surfaces should just contract If the bottom door is difficult to close in the last 50 75mm the last adjustable link may require lengthening Note a small amount of rotation can make a big difference adjust by 74 turns A repeat of the procedure may be required until the door latch closes satisfactorily and also opens well under loaded conditions i e Full bale When the correct adjustment has been achieved tighten nuts on the adjuster The connector link is secured to the press both ends by 2 X 2 HT Bolts with nyloc nuts These bolts to be done up firmly but not over tightened replace bolts if worn Bottom Door and Latching System Service Operation and Adjustment a Check front bottom door for soundness welding etc a Lubricate hinges Door Latch Adjustment 1 With the door open check the rot
46. c concepts general principle for design EN 1050 Safety of machinery Principles of risk assessment EN 418 Safety of machinery Emergency stop equipment functional aspects EN 954 1 Safety of machinery Safety related parts of control systems EN 1088 safety of machinery Interlocking devices associated with guards EN 294 Safety of machinery safety distances to prevent danger zones being reached by the upper limbs EN 60204 Safety of machinery Electrical equipment of industrial machines TiBMan019 12 Baler Test Report Comprehensive Autobaler Test Report Date Serial No Testing Officer Electrical Test Performed By Noise Emission 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 TiBMan019 13 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 T
47. compatible with the baler requirements e g Circuit breaker must suit the baler AMPS 13 Is sufficient material available for training to be conducted Y N TI350 300kg material TI500 500kg material 14 Staff training Are all staff to be trained available for the installation time requested Y N 15 Do you require multiple training sessions for different shifts Y N 16 lam aware that extra training sessions will attract a fee of 225 00 GST and agree to pay this cost if extra training is provided Y N 17 Trethewey Industries Representative will be available to conduct your training and installation at the time requested If for any reason there are time delays i e Power or staff unavailable please contact the office directly to reappoint prior to the installation or extra charges will apply 18 Service Agent Do you have a local referred service provider Y N 19 Please provide contact details to enable all relevant information to be forwarded to them to assist in the servicing of your Autobaler Service agent details Name Address Phone Fax Trethewey Industries must be notified if the site is not ready this will enable rescheduling of the training staff and failure to do so will attract retraining charges confirm that the site is reads and the appropriate power as outlined above is connected and ready accept that if any information is not correct and the commissioning and training cannot be carried out
48. ctioning correctly finger assemblies will contact the bumpers without a bump or without making a bumping sound If a strut is faulty one or both of the assemblies will contact the bumpers with force this bump force causes the press to move on the floor Steps to correct 1 Check strut anchor points to ensure strut is connected 2 Identify faulty strut and remove 3 Dismantle faulty strut a Remove cap retaining screw a Top of cap a remove shaft assembly a check that the piston unit remains well secured to the shaft a Replace piston o ring 6 Part No on o ring models a thoroughly clean unit a recharge o ring models with AWH 45 grade a recharge older units without o rings with 90 160 grade a amount of oil as per a reassemble and refit the damper to the machine a replace anchor bolts if worn a bottom bolt 2 HT top bolt 2 x Y HT bolt with nyloc nuts If one strut only is malfunctioning it is still advisable to remove and service both left and right hand struts See strut service page 57 TiBMan019 50 Chapter 14 Doors Latching and Opening The correct operation of the front lower door is an important function of the press both for the ease of operation safety of the operator and the performance of the press For the bottom door to perform satisfactorily attention to lubrication is essential See Lubrication Guide Chapter 18 1 The bottom door is interlinked with the right hand side section of the press as the
49. ds or use tools in the compaction area TiBMan019 5 Autobaler TI350 TI500 Note When servicing a press or addressing a press problem please check the press serial and model numbers and the date of manufacture This manual will apply to earlier models however there will be issues with earlier models which will not be covered by this manual and an amendment to this manual covering earlier models is available Please contact the press manufacturer on their service agent To be equipped to service a problem press the technician before leaving to service the machine especially where a customer has phoned with a problem will need via the phone to establish the possible source of the problem so as to be equipped to deal with that particular problem However if the technician from the information given is unable to identify the possible problem he should contact the manufacturer before leaving to ensure that the correct components and testing equipment are taken to the problem machine thus minimising the down time of service and inconvenience to the customer Caution If the machine requires welding 1 Always completely remove the electronic control units connections as welding may seriously damage the controller 2 Always anchor the earth lead of the welder directly to the part being welded 3 Clean to bare metal the position of the earth clamp 4 Ensure that no electric or electronic wiring plastic etc is in the vicinity or
50. dustries AC uit Deepwater NSW 2371 Australia For Service Assistance or Advice Call Telephone 02 67 345 403 Service Line 1800 888 403 AUTOBALER WWW autobaler com au TiBMan019 Declaration of Conformity Application of EC Directive s Standard s to which Conformity is declared MD 98 37 Machinery Directive LVD 73 23 EEC Low Voltage Directive EMC 89 336 EEC EMC Directive Manufacture s Name Trethewey Industries Pty Ltd Manufacture s Address 14 Carl Baer Circuit Deepwater NSW 2371 Description of Equipment AUTOBALER Model TI350A3 C3 TI500A3 C3 Series Trethewey Industries Pty Ltd hereby declares that the product s specified above conform to the above directive s and Standard s This apparatus must not be put into service until the equipment into which it is incorporated has been declared in conformity with the essential requirements of the relevant EC directives Full Name Signature Position Date For and on behalf of Trethewey Industries Pty Ltd Deepwater NSW Australia Compliance Compliance assessed and approved by Banksia EOHS Pty Limited Richmond Vale Road Mulbring NSW 2323 Banksia Project 00723 Phone 02 4938 0044 Fax 02 4938 0111 e mail jimorr bigpond com Jim Orr BSc MAppSc PhD Director TiBMan019 SERVICE amp OPPERATIONAL MANUAL MACHINE AUTOBALER and CYBERSMART CONTROLLER MODEL TI350A3 C3 TI500A3 C3 Series AUTOBALER MODEL NUMBER A
51. e Grease TiBMan019 61 Component Lubricant Applicator Application 7 Dip stick AWH 30 40 Oil pump amp clean funnel Fill to Hydraulic recommended level TEENE 8 Filter Unit TiBMan019 62 UNAUTHORISED 3 MUST NOT OPFRATE AUTOBALER Component Lubricant Applicator Application 6 Sidedoorslideplate MBL8 Grease Grease gun KZD coupler Apply on surface 8 Lowerlatch pivot Penetratingfluid Pressurepack spra 9 Lowerlatch upperpivot Penetrating fluid Pressure pack 5 Spra TiBMan019 63 Chapter 20 Press Fails to Cycle Automatically Autobalers will not cycle automatically after the full bale indicator has responded at this point the baler will only cycle manually using the cycle button 2 The baler will not cycle automatically if the baler active light is not flashing The three most common faults for active light failure are as follows a As the baler cycles under load movement in the top door can affect the door interlock momentarily breaking the circuit and stopping the baler cycle and rendering the auto function inactive adjust as required b Automatic function can also be affected by a hydraulic pressure switch problem If the hydraulic pressure switch fails to fire at either the top or bottom end of the stroke the auto function will be negated Pressure switch adjustment or replacement may be required Automatic function ca
52. e reservoir needs to be checked with the main cylinders closed fingers down check level on the dip stick top up if required never overfill 3 JIC Hose Fitting Leaks If the oil leak is from a JIC hose end fitting tighten up the fitting on the hose end whilst holding firm the inserted male fitting Caution do not over tighten 4 O ring Fitting Ring If the oil is coming from the base of a fitting most hydraulic fitting on the machine are an O ring type check to see that the backing nut on the fitting is tight If this fails to correct the leak remove the fitting and replace the O ring seal See Part Listing for O ring part Number or replace the fitting Caution O ring must be fitted to the fitting correctly without damage When the lock nut is tightened the O ring on the fitting must not be forced against the thread on the fitting ensure that the fitting is screwed in sufficiently 5 Suction Hose Leak a Check the suction fitting into the pump remove the fitting and apply thread seal tape Caution tape must be wound onto the fitting firmly and in the opposite direction of the fitting screwing in Tape must not come closer to the front of the fitting than 5mm or thread tape contamination to the oil system may occur b Check suction hose for damage C Tighten suction hose clamps new clamps may be required double clamping may be required in some circumstance 2 clamps each end 6 Solenoid Leaks Leaks from bene
53. e walls of the hopper without disturbing the material above when the fingers are withdrawn from the hopper they rotate locking in a vertical position for the compression cycle See appendix 1 Malfunction 1 Limp Finger Set 1 When the press is cycled and is returning both sets of fingers in a fully raised position Observe that both fingers are actually standing completely up 2 As the direction of the cycle changes from up to coming down and one finger fails to remain ridged and rotates to horizontal position the horizontal finger will then push in through the side of the hopper with no pressing effect at all This malfunction may occur on each stroke or at random depending on the problem Steps to remedy 1 Isolate the machine power by removing the key from the panel Note pressing fingers should be completely down Cylinders fully closed 2 Remove the rear mesh safety screen from the problem side of the press 3 Locate C shaped lock Clean from around locking system rubbish cardboard etc 4 Earlier model presses have no bearings on the Fingerlock pivot and may simply require lubrication both on the pivot and the side contact plated recommended lubricants Pro ma lube spray Check that the lock pivot bolt is not over tensioned 5 Later model machine locks pivots on sealed bearings No 6203LU Check lock for freeness replace bearings if required 6 Lock is preloaded forward with a tension spring a Check that the
54. 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 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
55. er 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 in 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 release 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 A
56. escription of auto eject function a Eject of full bale with emphasis on need for manual assistance and care to be taken by standing aside pressing chamber Commissioning and Training Procedure 1 Trainers and service people must always have a manual when training or attending the baler 2 Trainers must have all training documentations and must be completed by each trainee 3 Site Inspection Ensure the baler is situated to comply with all OH amp S requirements 4 Unwrap the baler Remove the baler from the pallet following the baler removal procedure 5 Remove the components from within the baler chamber attach the twine cage to the lower mesh on the right hand side situate the hopper mesh fit over head screen 6 Complete the baler pre delivery check 7 Commission the Baler 8 Train the Staff Following the Staff Training Procedure Autobaler trainee material 9 Complete the Pre Post Installation check 10 the require forms to the company Trainee questionnaires trainee details and all original documents are to be returned to Trethewey Industries 11 Invoice for payment can only be processed when all the documents have been returned to Trethewey Industries TiBMan019 28 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 B When the holes the telescoping rear legs appear slide in r
57. ess make sure that those being trained are fully of the safety aspects associated with the operation of the Autobaler Training is to be conducted as follows Preparation of the twine for insertion into the Autobaler n Feeding of twine through the twine lock and collars 7 Feeding of twine through hole in rear of pressing chamber a Affixing of twine to cup head bolts explaining need for double knots a Placement of twine under lugs on the base of the pressing chamber n Allowance for length of twine from hole in rear of pressing chamber 7 Fixing of twine from rear wall under lugs up the inside of bottom door and fixed on attachment Closing of front doors and explaining of safety features i e Autobaler key emergency stop button safety bar coded key switch and door opening cut out Explanation of electronic eye function TiBMan019 27 Demonstration of operation of Autobaler with no material pressing chamber Explanation that material should be visible above top door level prior to activation of Autobaler Feeding of material to be baled explaining reasons for non operation and motor cut out 7 Explanation of bale full signals 7 Demonstration on how to tidy up final bale a Explanation on why bottom door should never be opened during baling process Tying of bale retraction of fingers Opening of bottom door with emphasis on possibility of rebound 7 Placement of bale trolley and d
58. estring baler Bale Trolley FINISHING OFF THE BALE When full bale light comes on 1 Remove excess material from above the pressing fingers 2 Place top cap 3 Press cycle button OR Remove excess 1 Stand fingers up press retract 2 Remove excess 3 Place cap 4 Press cycle button Autobaler Trainee Particulars Kit COMPANY cbacit ttes trai Sn EE LR Trainee Name Print Clearly in Capitals Autobaler Model Trained To Use ME EMEN ENTERS MS EAE Trainer witnessed the COMPETENCY n In the safe competent use of the Autobaler Model and received a copy of the Training Manual hereby validate this assessment Autobaler Training Handout Person in Training E A L MPH Phone BO une cdi diia ne ES BE Namesor Trainer sera a Autobaler Model Trained To Use Trainee Exam Questions Autobaler TI350 T1500 Series 1 Ifthe 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 Sitand watch the ai b Removetlie Kyo Ge
59. etaining 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 B 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 6734 5403 FITTING OF THE SAFETY CANOPY Fitted Overhead Safety Canopy Rear Canopy legs position Mesh mounting lugs TiBMan019 29 Chapter 1 Oil Leaks 1 Determine leak 8 Cylinder leak 2 Check oil level 9 Pressure by pass valve 3 JIC hose fittings leak leak 4 O fitting leak 10 Electronic switch leak 5 Suction hose leak 11 Hose leak 6 Solenoid leak 12 Regen leak 7 Pump leak 13 Parts Listing If an oil leak in the hydraulic system occurs 1 Determine Leak Determine the leak point leaks are often difficult to locate clean oily areas and place a sheet of cardboard beneath the effected area and observe for leaks this may require the machine to operate for a period 2 Check Oil Level The level of oil in th
60. etract Trainer Signature of compliance 18 Opening Doors Open top door Attach rebound chain to bottom door on the last link 3 Open bottom door latch unlock rebound chain 4 Fully open door Note Never attempt to open the bottom door with the pressing fingers down They must be retracted in fully up position Trainer Signature of compliance 19 Situating Bale Trolley WITH DOORS FULLY OPEN _ Situate bale trolley Central to the baler Out 75mm from contact Roll away from baler direction Trainer Signature of compliance 20 Ejecting the Bale Note Push eject arms back in using foot All doors fully open and bale trolley situated Stand to the left of the bale area With right hand grip the left cross twine Pull firmly at the same time pressing and holding the eject button until the bale is firmly on the trolley Roll bale away on the trolley Push bale sideways off trolley to unload Start again at step four Initial Set Trainer Signature of compliance Chapter 25 Parts Listin Chapter 26 Drawings 13 er PE vo gne pen gt e 8 i jig 5 2 22 jaje IS le 88251 JZ js 58 S zie ZEE E 5 e giri gt ss s 5 2 2 8 Se sis sis 5 3 53 55 88S Sia Sik sla IDENTI
61. evel should be within 100mm from tank top 17 Middle side wall pivot pump per pivot using KZD coupler 18 Upper side wall pivot Y pump per pivot using KZD coupler 19 Upper amp lower cylinder anchors main hydraulic cylinder pivots situated both sides of the baler Using KZD coupler lever cylinder clevis to one side and squirt grease into pivot TiBMan019 59 CONTARON 20 21 23 24 25 then lever clevis the other direction and squirt grease into the pivot Rotate anchor pin ensuring grease has penetrated pivot The anchor pin should turn freely Repeat this procedure on all pivots upper amp lower as well as on both sides If difficulties are experienced with grease penetration removal of the anchor pin may be required Once removed grease pin and inner clevis and refit ensure that pin is fastened securely Upper amp lower damper anchors using KZD coupler grease upper amp lower pin ensuring good grease penetration Damper service see damper service Chain shackles grease pivots and slide lightly Barrel grease nipples 2 nipples situated on each finger barrel 5 to 10 pumps per barrel Main bearings grease sides of bearings lightly Finger lock roller these are situated on each side of the baler grease lightly TiBMan019 60 Lubrication Points Component Lubricant Applicator 22 Application Grease Coupler side Grease Coupler side Grease Grease Grease blind ee ica plates Greas
62. haft seal Ludowici R87 088 and Piston 8 cap seal 2 x 3mm O ring SERVICE CHECK 1 Raise the fingers to a vertical position and stop in that position this can be done by pressing the retract button found on the controller 2 If a strut is working correctly the assembly will slow 50mm before contacting the plastic stoppers Leave strut attached to the baler Remove the strut cap total oil volume in each strut 100ml Using a long clean rule measure oil on top of the piston minimum 5mm of oil depth Add 32 grade hydraulic oil if required Before closing the cap smear grease around the cap O ring Re assemble and check for good function Fig 6 Fig 8 RECOMMENDED LUBRICANTS Only lubricants recommended by the manufacturer are to be used in the Autobaler Failure to use the recommended lubricants will result in voidance of the baler warranty Autobalers have high pressure pivot points and therefore must only be lubricated with high pressure long life lubricants HYDRAULIC OIL CASTROL HYSPIN 32 GRADE GREASE MBL8 SPRAY LUBRICANT MBL8 SPRAY LUBE For further details and possible supply of the recommended lubricants Please phone TOLL FREE 1800 888 403 OR 0267 345 403 TiBMan019 58 Chapter 19 Lubrication Lubrication Chart The life and performance of the machine will be determined by how well the press is serviced and maintained Though this applies to the whole life of the press it is especially important dur
63. he machine by 25 Regen block number TiBMan019 47 Chapter 12 Bale Ejection System The way the bale is made the way it is capped and the type of materials being pressed can determine how difficult it will be to remove the bale from the press Capping of the Bale After the full bale light has come on and fingers are down firmly on top of the compressed materials 1 Open the top door only then 2 Activate the up button the arm will rise and stay up 3 Level the cardboard on top of the compressed material Amounts of cardboard raised up in the centre distribute to the outer sides of the hopper close the top door and activate down button 4 Fingers should now be down firmly on top of the compressed material open fully the top door only Remove any loose amounts of cardboard Unhook twines from the left hand side of the hopper With the top door fully open take hold of twine below the collars right hand side and draw across the bale top 8 Cut the twine allowing enough length to go through the loop and tighten off as firmly as possible 9 Do the same with the twine from front to back tie a non slip loop in the back end of the twine untie the front from the tab on the top of the bottom door pull tight and tie off 10 With the front top door remaining open activate the up button fingers will rise and stay up 11 With pressing fingers up open the bottom door to its maximum 12 Place transport trolley in
64. he top door should a Openitihe best Can aaa Det Ido Mallorca ee Ba ea C Grip The handle TMV nee a a na 10 Ejecting the bale should a Stand aside and hold finger on b Push button and walk C Push button and stand in front 11 Where should the bale transport trolley be stored when not in use a Under the right hand b Under the left hand Ea nee tU a E OE 12 Real heavy objects i e boxes of magazines etc How should load them into the baler a Over the top 13 Ifthe baler operates with the top door open must a Continue as normal rei Erik 14 Was the knot test passed Yes No SAFETY ESSENTIALS 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 ejecting the bale stand to one side to prevent injury form the ejecting bale 4 Always place the bale transport trolley centrally to the bale to prevent bale side roll 5 On inclines chock bale trolley to prevent run away
65. hen transporting or moving the baler on the fork lift always travel in reverse to ensure good vision Safety Equipment Compliant safety boots high visibility vest hearing protection eye protection and head protection if required TiBMan019 22 POSITIONING THE AUTOBALER ON THE PALLET The baler is lifted beneath the lower front door Never lift beyond the forklifts capacity 1 Ensure that the baler chamber is completely empty of any loose baler components or materials 2 Insert the fork lift tines through the slots between the bottom of the lower door and the base these front tine slots correspond with slots in the rear wall 3 Before attempting to lift ensure that the fork lift tines are fully through the rear slots Dismount the fork lift and check to ensure fork lift tines are fully inserted 4 Lift the baler 200mm off the floor 5 Slide the pallet equally under the baler from the side ensure that the pallet can be lifted from the front 6 Lower the baler gently onto the pallet and strap the baler to the pallet if transporting a long distance BALER LOCATING FROM TRUCK TO DOCK When loading the baler for its final destination the baler is to be loaded in such a way so as to facilitate the removal at the customers end i e if the baler is to be unloaded using a forklift truck the pallet will need to be situated to facilitate this but if the baler is to be unloaded using a pallet jack then the pallet containing the baler needs
66. iBMan019 Hydraulic 32 Grade 14 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 Atadistance 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 019 72 6604 Ear Protection Must be worn if noise exceed 85 DB 15 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 a Active 1 to earth Pass Fail a Active 2 to earth Pass Fail a Active 3 to earth Pass Fail Earthing continuity Pass Fail Flexible supply cord a External visual inspection of plug connection Pass Fail Visual inspection of cord termination to equipment Pass Fail
67. ifold are various hydraulic and electronic components as follows i Main System Solenoid ii Eject Solenoid iii Power Boost Unit iv Relief Valves v Pressure Switches vi Electronic Attachments vii X Fitting and hosing systems 4 Eject Cylinder Dimensions 5 Main Hydraulic Cylinders TI350 4 4 x 18 stroke cylinder TI500 4 5 x 18 stroke cylinder 6 The hydraulic system filtering The hydraulic system has a replaceable cartridge filter situated for service convenience on the top of the oil reservoir The system is also filtered by a pre filter unit situated in the hydraulic reservoir on the suction line Hydraulics The electric model balers are powered by Teco 5 5Kw 2 pole 3 phase foot and flange mount electric motor coupled to a Haldex 1300 488 two stage pump Diesel powered balers are powered by a Yanmar 6 5Kw diesel motor Model L1000AE DE coupled to a Haldex 080405 1300487 two stage pump TI350 model balers are equipped with manifold M10230 1 Main system solenoid valve CTOP4 FD68412 voltage 24V DC Eject system solenoid FD68614 CTOP4 voltage 24v DC Power Boost valve unit M22593 1 Power boost models are equipped with two pressure switches One pressure switch is situated in manifold M10230 1 and adjusted to a firing pressure of 1950 psi The other pressure switch is situated in power boost block M22593 1 and has a firing pressure set 2700 psi Eject cylinder TI500 balers 375 bore x 8 stroke x 175 r
68. ing fingers are still fully raised clear of the box 3 Load materials into the hopper over the top of the top door TiBMan019 38 oo c AS 12 13 When the materials are level with the top of the top door First turn on the key and secondly press down button From this point the press will automatically cycle while ever materials bridge the censor eyes When the full bale light is illuminated remove surplus materials from above the fingers Note if excessive materials are protruding above from between the fingers a Open top door b Push up button pressing arms will return to vertical position and stop C Distribute and flatten top of bale d Close the top door and press the down button Fingers will stop on the top of the pressed material Open the top door fully Draw side strings across the top of the bale from beneath the collars Unhook the looped ends from the domed hooks Cut the strings from below the collars join the two ends by inserting cut end through the loop pulling tight and tying off A Undo string from the front door tale B Tie a loop in the cross string pull tight cut and tie off With top door still open activate up button the finger will stand and stop vertically Open the bottom door fully and eject the bale see bale ejection String Problems A 1 2 String becomes detached from the domed hooks Excessive slack in the twine can cause this Ensure that the strings are fir
69. ing the first twelve months of the presses life Hydraulic System Replace filter every 12 months Where conditions are dusty replace more often Hydraulic Oil a Oil type AWH 40 recommended a Tank capacity 50 2081 approximate value TI500 208L approximate value Oil Change Period Recommended oil change period every 1500 bales or every 2 years under dusty conditions oil change will be required more often asd MAINTENANCE PERIOD Upper door latch pivot one pump of grease each service per pivot Emergency bar pivots oil pivot and ensure that the bar is working freely Connector link pivots connecting top door with rotary twine lock Grease both ends Upper door hinges using KZD needle nose coupler pump per coupling Lower door hinges using KZD coupler Y pump per pivot Side door slide plate the side door assembly slides on this plate grease generously Connector link an adjustable link Grease both ends see link adjustment for adjustment Lower door latch clevis grease lightly Lower latch clevis lightly grease 10 Secondary latch slide grease lightly 11 Latch bar support small lug welded to the vertical latch bar lightly grease 12 Eject cylinder anchor points grease lightly 13 Eject axle pivots using KZD coupler one pump 14 Filter change annually see filter service details 15 Lower side wall pivots using KZD coupler pump each 16 Dip stick with the main cylinders fully closed the oil l
70. ion amp Commissioning Completion Checklist please tick on completion Positioned Installed and Commissioned as per supply agreement YES Relevant Accessories provided as per supply agreement Cleaning Signage YES Warning Signage YES Maintenance Signage YES Operators Manual YEs Cleaning Instructions YES Bale Trolley YES Bale Twine rolls YES Twine Safety Cage YES Extension Hopper YES Overhead Cage Canopy YES Baler checked for Travel Damage YES 3 Phase 20 Amp 4 pin plug provided YES 3 Phase rotation checked YES Check all fittings for hydraulic oil leaks YES Limit Switches checked and functioning correctly YES Adequate Signage to Push Buttons as per AS1543 1985 Section 4 4 3 YES Electrical Cable Length is acceptable and is supported off the floor YES Comments The above has taken place to my satisfaction Store Managers Name SIN ea Technician Manufactur New Englar DEEPWATEH NSW 2371 Facsimile UZ 6 34 5433 EMAIL michelletully autobaler com au Chapter 24 Training Safety procedures for training 1 2 3 Autobaler Location Bale trolley location store trolley away to prevent trip hazard or injury Twine cage correctly attached and twine placed in cage Point out safety devices a Safety bar operation b Emergency stop button Key switch d No reaching into baler e No standing or climbing on the baler f Turn the baler off when unattended 0 Care and posit
71. ion when ejecting baler h Importance of reading and observing all safety instructions i Bale location in approved designated area MACHINE OPERATION Motor rotation check To test press retract button if fingers go up rotation is correct Fitting of upper mesh hopper Location of twine cage Initial stringing Complete stringing Double knot and why Twine under left tab then under right tab Transverse twine length fitting etc Bottom door closing Twine transverse front door tie off Close top door Place flat cardboard in base prior to loading Initial loading to top door height to prevent fingers banging in empty chamber Initial starting of press Explain eye location and function Continue to load Large boxes should be loaded during the first 7596 of capacity for the last 2596 load flat boxes to create a flat cap for the bale Red light illuminates Cycle several times to level top Remove excess if required Place cap on bale Open top door explain door switch safety Always turn key off or press Emergency stop to neutralise unit Explain how opening top door releases twine via the twine lock Unlock twine from left hand hooks i Pull twine across from right hand side Cut to correct length Tie off Pull transverse twine across and tie loop Twine from tab to loop and tie off Close top door Turn on system press retract button Open bottom door 33 Place bale trolley 34 Eject bale 35 Wheel away 36 R
72. iving the correct filter 5 Situated between the cap and filter body is the o ring seal Ensure that the seat is properly located in the seal groove place cap and tighten down evenly and firmly Note do not over tighten cap screws TiBMan019 45 Hydraulic Directional Control System component identification list 6 2 3 Manifold MID230 1 Rexroth main valve CTOP4 FD68412 Rexroth eject valve CTOP4 FD68614 Solenoid Units 24V DC Solenoid Power Supply Cap left hand side Solenoid Power Supply Cap right hand side Eject solenoid power supply cap Thermo switch System pressure check port 10 Hydraulic pressure switch 11 System pressure release adjustment 12 Power Boost pressure release adjustment and hydraulic pressure switch OANDARWN TiBMan019 46 Hydraulic Regeneration Unit Regeneration Valves TI350 500 Balers are fitted with a pair of cylinders on each side of the baler TI350 has 4 x18 clevis mount hydraulic cylinders these are attached with 1 hard chrome pivot pins Note when servicing or replacing the cylinders always use hard chrome pivot pins never use the pins supplied standard with the cylinders as these will fail and damage the baler anchor lugs TI500 Balers are fitted with 5 x 18 hydraulic cylinders these also are fitted with hardened chrome pivot pins for the above reasons Each oylinder is fitted with a regeneration block These regeneration blocks improve the cycle time of t
73. k adjustment TiBMan019 24 Safety 1 Location of Autobaler a Never place the Autobaler near any landings or elevated loading docks unless these areas have the appropriate safety arrangements and approvals b 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 Never place the Autobaler on loading dock close to the edge or the above landings edge d Never place the Autobaler in a position where unauthorised persons have access e Always consult an OH amp S officer 2 Area of Operation a Ensure that baler trolley is stored in a position away from the operator s passageway b Ensure that twine rolls amp twine safety 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 hazardous position and is not left Iying on the floor particularly ifthere is a chance of water being on the floor 3 Operation of Autobaler a Always keep hands and arms out of the Autobaler hopper during operation b 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
74. m after stringing String loops are not sitting into the domed hood correctly in the hooks Loops tighten on the hook Incorrect loop The loop must be a no slip loop l e double the twine end back along itself for about 300mm and tie a loop knot near the end then come back 100mm and tie another loop knot this gives a double loop knot See Appendix 21 illustration 2 Loop is hard to unhook when the press is full of compressed material In the previous paragraph is an explanation on how to do a double knot When the tension is too great to unhook simply cut the top loop when ready to tie off the bale and use the loop section between the two knots to tie the other end String lock is cutting the twine Twines vary in diameter especially if a twine not recommended is being used The twine lock system is adjustable if the twine is being cut as a result of over adjustment remove one of the bolts on the twine lock connector bar linking the top door with the twine lock bar lengthen the connector bar by rotating one rotation may be sufficient depending on twine diameter Twine damage If the twine is being damaged and the bales are coming out with loose twines the twines are being pulled through the locking bar during the pressing operation This will require that the adjustable link be shortened Note if the bar is over adjusted the lock will cut or damage the twine TiBMan019 39 Power In 2 Ignition Key 4 Emergency Stop
75. may be the machine would only start and run in a When the eject button was activated b When the up button was pressed press would start if fingers were down Return to the top position stopping there To Correct 1 Close the top door 2 Adjust the limit switch in or out as required to 1mm clearance on the closest point of the limit switch roller Securely lock in this position Caution do not over tighten switch lock nuts use a mild locking agent Use a multi meter check switch for correct function Switch replacement number TI350 215GQ21B TI500 215GQ21B Replace switch if damaged or faulty 1 Using a multi meter check the switch function With the door closed the switch should be in closed mode with the top door open the switch should be in an open mode 2 Wiring check See appendix 8 TiBMan019 34 Balers fitted with a key coded switch on the left hand side If the baler cycles with the top door open check the following 1 Ensure that the coded key is securely attached to the key bar on the top door Replace rubber mounts if required 2 Ensure that the coded key is fully inserted when engaged 3 Check the coded switch for contamination entry 4 Replace the coded switch if faulty Appendix 7 Coded Key Bar Chapter 4 Press Fails to Start See Flow Chart Appendix 19 Chapter 5 Press Starts but Fails to Cycle See Flow Chart Appendix 20 Chapter 6 Press Continually Cycles 1 The m
76. n also result from the sensor failure situated at the rear of the baler hopper is the receiver section of the eye unit This may require replacement Contact your local service organisation for a replacement unit or contact the baler manufacturer on 1800 888 403 TiBMan019 64 Chapter 21 Maintenance Instructions This should include safe working procedures for carrying out all preventative maintenance and repairs This should also include any special tool requirements for maintenance 1 SERVICING PROCEDURE Before attending a service site the following may be required 1 Source from the baler owner or operators the following a When the internal services are due b Date and time suitable to carry out the service accurate location of the baler d Whether site induction and training is required to enter the site e What type of clothing and footwear are required f Machine type and serial number g Does the baler require attention i e repair adjustment etc over and above a regular interval service so that likely parts required can be taken 2 Personal Protective Equipment required a A high visibility shirt or vest b Regulation safety glasses c Regulation footwear d Hearing protection e Hand cleaner f Towel roll 3 Before commencing the service a Isolate the power source from the machine b Clean the area to be working in Remove the baler key and place an out of service sign if required d Remove the
77. nctions of the baler a The up indicator light top light illuminates when the cycle button is activated and baler arms are rising a The down light will illuminate when the baler direction is down a 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 a Door open light will indicate when the top door is open or the machine has developed a system fault such as an overheated system or pressure related problem a 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 not 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 Valve 4A TiBMan019 43 Chapter 11 The Hydraulic System The basic hydraulic system in the 50 00 Autobaler models consists of 1 200L hydraulic oil reservoir 2 5 5Kw three phase motor coupled to a dual stage pump or a 10hp diesel motor 3 A manifold system situated at the rear of the baler attached to this man
78. nting of magnet switch e Fasteners Is the baler operating smoothly When the finger assembly is standing up the action must be smooth with no bumps or jar A Check damper struts small yellow cylinders for attachment B For operation add 1 3 cup light oil if required Bottom door closer must close with ease A Grease all door slide B Adjust the bottom door adjust link until door closes with ease in most cases shorten line by one rotation tighten adjustment lock nuts firmly Check for oil leaks Correct the leak if present Check the reservoir oil level Lubricate baler if required Cylinder anchor pins top and bottom Door hinges Door slides at bottom Door latch Filter change if required 6 Monthly Periods General check Baler operation Twine Tabs Eject Operation Structural soundness Service Requirements Action Taken Autobaler Service Report Name Location Store No Baler Model No Serial No Controller No Date Baler Counter Reading Service grease points and lubrication Comment 1 Finger Locks ae 2 Emergenoybarpivts J 3 Bottom door link adjustment 4 Upperdoorhinge J 5 Safety 6 Lowerdoorhnges 7 Bottom doorslide _ J 8 Connectorlink 9 Lower door latch clevis J 10 Safetylatchforiowerdoor 11 Latch clevis ET 12 Secondary latch side J 13 Latch bar suppot 14 Eject cylinder anchor point 15 Eject a
79. od Eject cylinder TI350 balers 3 bore x 8 stroke x 175 shaft Main cylinders TI500 TI500 5 bore x 18 stroke x 2 shaft rod TiBMan019 44 Basic hydraulic system information a Oil Type Hydraulic a Oil Grade 32 Grade a Hydraulic oil supplied at Delivery AWHAO Gulf Western a Maximum operating oil temperature 65 degrees celsius a Main system pressure 2250psi a Power boost system pressure 2850psi a Main system pressure switch firing 1950psi a Power boost system firing 2700psi a Filter Cartridge number 150GN a Oil Change interval o In dusty conditions every 12 months o Normal conditions every 4 years a Filter Change every 12 months IMPORTANT Hydraulic components may vary from model to model when ordering spare parts quote the part numbers stamped on that particular component Hose replacement if a hose replacement is required 1 Remove the damaged hose 2 Listthe size and psi rating on the hose 3 List the fitting numbers on both ends 4 Measure the total hose length Hydraulic tank top filter unit 3 4 2 5 1 1 Tank top filter unit assembly 2 Filter unit cap 3 retainer screws to replace the internal filter a Remove the cap crews and cap b Remove the tension spring c Lift out the filter unit element and replace When fitting the new element ensure that the filter cartridge element is the correct way up 4 Filter number When ordering filter cartridges quote the number on the cap to ensure rece
80. of delivery to facilitate transport When ordering spare parts it is necessary to state e Machine Model e Serial Number and Year of Manufacture e Reference Number Without serial number no spare parts will be delivered DEFINITIONS User The person body or company who has brought or rented the machine and intends to employ the users trained and inducted in the safe use amp operation Operator The physical person authorised by the user or a representative of Trethewey Industries to operate the machine after having been suitably trained on the use and specific risks of the machine Authorised Person The physical skilled person authorised by the user to carry out maintained or setting up operation on the machine Dangerous Zone Any person who finds himself in a dangerous zone as marked on the baler either entirely or partially PURPOSE OF MACHINE a This machine has been designed to be mainly used in recycling stations or similar applications a This machine has been designed for the compaction of cardboard paper and similar fibourous materials a Use differing from the above is to be considered inappropriate and prohibited The machine operator must be trained and informed of risks and must have the instruction manual at his disposal a The operator must not work with any guards or safety devices inoperative or missing The baler must not be operated RISKS During the pressing phase the operator must never put han
81. oor bew 7 WHEN opening the bottom door 1 Appendix 8 yoy HIS vs HoLeims Wood AS 10079 4100725 201223 vi HOLIMS 7142 FLULIWSNUYL yl Appendix 9 Baler won t respond when cycle button is activated Is the power key turned on y Is the emergency stop button disengaged y Is the red power light illuminated Yes 74 Is orange door open light on y Yes Ensure that the top door is fully closed y Ensure that the top door is fully engaged press in y The baler motor starts when the cycle button is activated by the pressing fingers fail to re open y Check the motor rotation direction must turn clockwise y Ring Service Number 1800 888 403 a No a Check that the power is on at the wall socket y Check the circuit breaker at the power board y Ring Service Number 1800 888 403 Appendix 10 Baler fails to eject the bale Are all doors fully open y Is the power light illuminated Yes No a Are you holding the eject button in until the bale is fully ejected See above procedure y Check the circuit breaker at the power board y Are you assisting the ejection process with your right hand
82. osent ara a accesa le te Le pacing docks HE pelerity change is reine sharps en election muvi be from the Actoteber st all Seven 4DC NOT rasch or jana Into the Actobajar dering operation he Twine cage and tele volley as 20 prevent ung due GALLY opening fre door beware of possible hardie rebound TALEN opening he dotiem door 1 Stand le tre side 2 Beware of poesitie Got rebound tor 1 ir 2 Bele eff tar tha the babe vis ihe rene gem egre UNAUTHORISED PLEVEN operano the unjens qualifies to de See CHAS tor PERSONS training detal ard training procedures of comas tre Astobajer supplier ar REFER TO OPERATING MANUAL RER amasi totalan mo beten MUST NOT BEFORE MOVINA THE BALER OR Y ELTE emeve tuy ran Acces AUTOBALER REMOVAL OFF THE PALLET TiBMan019 20 SPECIFICATIONS TI350A3 Transport width 2250 Operating width 2070 Depth 1470 Transport height 2090 On pallet height 2250 Height with canopy 2700 Compaction chamber 750x750x1100 Bale weight 300 350kgs Cycle time 28 seconds Compaction force 33000kg Motor 3 phase 5kw Baler mass 3000kgs Shipping weight 3250kgs TI500A3 Transport width 2250 Operating width 2070 Depth 1930 Transport height 2025 On pallet height 2250 Height with canopy 2700 Compaction chamber 700x1100x1100
83. ost common cause with the press continually cycling is obstructions over the censor eyes check the eyes that they are free of obstructions clean both eyes with a soft clean rag 2 The press continually cycles with clean clear eyes 3 See flow chart Appendix 15 Eye TiBMan019 35 Chapter 7 Press Noises Press Noises causes solutions It is important that the press be operated in a manner that created the minimum levels of noise especially if the machine is situated in confined space Possible areas of noise and their control 1 The press is equipped with a high speed motor coupled to a two stage pump These in combination and situation in a confined space can create excessive noise levels A motor pump silencing box option is available from the manufacturers or their service agents The press is emitting a high level squeal from the hydraulic system If the squeal is constant and the press is not cycling the possible problem is the hydraulic pressure switch See Chapter 15 for pressure switch adjustment or replacement The pressing fingers are making a loud banging sound on the down cycle This will happen as a result of insufficient material in the press The press makes a bumping sound as the fingers rise in the up direction The possible cause is a faulty damper strut See chapter 18 Squeal from main pivots This may occur during damp weather Lubricate using pressure pack TiBMan019 36 Chapter 8
84. path from the bottom port on the cylinder to the top port and this change causes the cylinders now to commence closing thus commencing the down pressing path of the cycle When the cylinder is fully closed full pressure is again reached the pressure switch fires and solenoid valves are activated oil flow to the top of the cylinder ceases and is directed to the tank Switch Malfunction 1 If the pressure switch is set too high the press will not cycle it will reach the up stroke and bypass in the main system via bypass valve 2 If the pressure switch is set too low Low bale weight will occur The pressing fingers also may become unreliable as the pressing fingers are stood up progressively more pressure is required If the pressure switch is set to low it may fire before the finger assemblies are fully up If the fingers are not fully up the locks on the finger units will not activate and the fingers will malfunction on the down pressing stroke Pressure Switch Adjustment q Ensure that there is sufficient cardboard material in the press to prevent the fingers of the unit crashing at the bottom end of the pressing stroke Activate and send pressing fingers down Turn off power key Ensure that both wires to the pressure switch are firmly connected Insert a 3mm Allan key into the pressure switch between the two wire connections Rotate the Allan key in clockwise gt of one turn leave Allan key inserted by rotating the
85. procedure as in the pressure switch adjustment TiBMan019 56 Chapter 17 Emergency bar Operation The emergency stop bar is situated on the top of the top door The emergency bar is often subjected to damage from fork lifts loading skips etc It is therefore important that its function and maintenance be understood The bar consists of eight components 1 Emergency bar support Bracket Emergency bar Connection Bolt Sleeve Spring Washer Nut Limit switch ae ES The emergency bar if operating correctly when depressed should stop the press during any part of its cycle To recommence the cycle the appropriate button will need to be activated on the controller Emergency bar operation T Ensure that the emergency bar bracket is firmly attached to the door check for damage bending etc Check the emergency bar when depressed that is returns freely via compression spring The purpose of sleeve is to control the down movement of the emergency bar to protect the limit switch from damage mn Limit Switch Fitting Correct limit switch fitting 1 With the emergency bar fully up and working freely the clearance between the button on the limit switch and the bottom of the emergency bar should be a minimum of 1mm 2 Adjust the limit switch vertically in the slotted holes in the switch mounting plate so that when the emergency bar is fully depressed the emergency bar is not in contact with the plastic switch housing
86. r Following the lifting directions remove the baler from the pallet Chapter 5 in manual p Trainer Signature of compliance Baler Fit Out Fit the mesh hopper and canopy Chapter 4 Position the twine cage to the baler side Situate the baler trolley Plug in baler power socket motor must rotate clockwise Ensure all bolts holding the mesh hopper and canopy are tight HA 3 Trainer Signature of compliance 4 Initial Set NOTE twine roll must be right way up Turn on power engage key press retract button to stand fingers up Draw each twine from centre of twine roll Heat seal twine end or use tape around Open baler doors fully Trainer Signature of compliance Pre Twine Insert sealed twine end through open hole in twine lock bar Front two twine on inside of the baler chamber and insert through eyelets collars Rear twine in rear twine lock hole and down the back outside and into chamber through hole in back Trainer Signature of compliance 6 Tying the Loop 1 Tie double loop in twine ends side twines only 2 Take looped ends across and hook onto hook on opposite side E 50 75mm Trainer Signature of compliance T Twining 1 Take twine down and hook under plastic tab directly below Trainer Signature of compliance 8 Twining 1 Take side twines across under the tab on the right hand side 2
87. r is in poor repair 4 Check Hydraulic System for Oil Leaks 1 Check the fluid level in the reservoir the oil should be showing on the dip stick If no oil is present then add oil awh 40 until oil is present Caution Do not over fill 2 Check oil tank for transport damage 3 Check hydraulic hoses for damage if damaged replace hoses check with manufacturer for correct hose type 4 Systematically check all fittings hose ends and fittings can be bumped during transport and location 5 Check safety bar 1 Check for free operation 2 Check to see that bar is functioning correctly 6 Insert all strings through string lock as in stringing set up in the operator s manual 1 Open and close the top door several times then open the top door fully 2 Pull each string through the lock bar and check to see that the lock bar is not cutting or damaging the string twine If damage is occurring the adjustment on the string lock connector may need adjustment to adjust undo one of the connector link bolts rotate one revolution reconnect and re test 7 Bottom Door adjustment check Situated on the right hand side of the baler on the bottom of the lower door is an adjustable link connector A correctly adjusted door will spring open 10 20mm when pushed closed and is unlatched On the bottom link are two hexagonal nuts The link can be lengthened or shortened as required by adjustment of these two nuts Note See manual for door lin
88. rawings Appendices 127 149 SCOPE Manufacturing Plate l TRETHEWEY INDUSTRIES Pty Ltd A B N 84 072 739 827 Innovative Design amp Manufacturing New England Highway DEEPWATER NSW 2371 Tel 02 6734 5403 Fax 02 6734 5433 EMAIL trethewey northnet com au WEBSITE www autobaler com AU99 000 48 AUPR 8089 AUPR 8445 AUPR 3941 AUPR 4116 AUPR 8930 MODEL 99 BATCH No RATED VOLTAGE NUMBER OF PHASES FREQUENCY FULL LOAD CURRENT AMPS Date of Manufacture TiBMan019 DECLARATION OF CONFORMITY 98 37 EC Machinery Directive 73 23 EEC Low Voltage Directive 89 336 Directive Name of manufacturer 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 TI350 TI500 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 representative Position of authorised representative Full postal address if different from manufacturers Address of Authorised Representative in Europe
89. re no hydraulic oil leaks 7 There is no damage to any safety barriers The twine lock operates efficiently There are no safety concerns regarding the location of the Autobaler 7 A qualified electrician has checked the power source lead and electrical contacts The installer must now Ensure that one or more of the end users are completely trained in the safe use of the Autobaler 7 Ensure that those trained are fully aware of safety procedures associated with the safe use of the Autobaler carry out a full training session incorporating these factors At the completion of the training session the installer must Complete the Job Completion form detailing precisely what was delivered and accepted by the end user Complete the Training amp Trainee Particulars forms detailing the names of those who attended the training session These persons will be sent a certificate stating that they are competent to operate the particular Autobaler as well as have the overall knowledge to train others in its operation Training the end users should be carried out as follows Ensure that the person who has ultimate responsibility for the operation of the Autobaler is amongst those to be trained initially i e Head Store man or Cleaner 7 Carry out the training using the end users as much as possible from the stage of inserting the twine initially to the removal of a full bale At all stages of the training proc
90. rmly y No e y Note y Over adjustment will also y create problems closing y Yes No a y Lengthen the bottom door link Does the vertical latch bar rotate on the adjuster by one turn freely a No y Yes Using penetrating fluid or oil to y free latch bar Is there damage on the door or latch system y Call Service Hotline 1800 888 403 Is the Power Socket Inserted y Yes Is the supply switch turned on y Yes Check power supply to wall socket y Turn on baler isolating switch y Release emergency stop button y Turn on baler key y Is the balers red power light illuminated y Yes Check electrical leads to motor y Check power connections on controller y Change controller unit or control PCB y Call 1800 888 403 Appendix 19 gt No No No gt Insert the power socket Turn on the supply switch Check controller fuse Note Correct value fuse must be fitted see starlogix manual y Call 1800 888 403 Appendix 20 Press starts when the cycle button is activated y Baler starts but fails to cycle y Check motor rotational direction y If rotating anti clockwise change polarity to run clockwise y Motor starts and runs clockwise y
91. rs 9 Pressure Bypass Valve Leak Oil leaking from the pressure bypass valve mounted to the aluminium block a Check to see valve is firm or b Remove valve unit and replace O rings Renew O ring on outer cap 10 Electronic Switch Leak Oil leaking from the hydraulic electronic switch unit mounted to the aluminium block a Tighten up the pressure unit if this fails replace the seal See Parts List b If oil is coming from the top of the switch unit from behind the wires from inside the switch unit replace the entire switch 11 Hose Leak Hoses can develop leaks and fractures as a result of age or damage or a hose fault if a leak occurs in a hose replace the hose See Parts List for correct hose 12 Regen Leak Regen valve leak Unit on cylinder a Tighten fittings b Renew O rings on O ring fittings Dipstick ipstic m Chapter 2 Pressing Fingers Malfunction Malfunction of the pressing fingers The pressing fingers are the 2 clusters of 9 fingers one set on each side of the press On the pressing stroke down these fingers come into the upper hopper through slots in walls of the upper chamber These fingers compress the materials in the upper hopper into the lower chamber When the compression stroke is complete and as materials are placed into the upper hopper during normal operations these fingers return to an upper position as these fingers return they also relax and withdraw through the slotted sid
92. rs Check the closing mark on the cylinder shaft to be certain cylinders are fully closed b Locate full bale switch situated on the left hand side of the press motor side on the front corner Note The switch can be adjusted by removing lower left mesh guard bale switch is mounted to a plate which on turn is mounted under the bearing anchor bolt d The switch can come out of adjustment as a result of this plate rotating moving the switch roller away from the frame section which activates the switch in some machines there are bolted switch activators to see Appendix 6 e Using a lever gently rotate the plate back until the switch roller axle is a little into the brass housing do not over travel switch NOTE Do not lever against the switch the switch is very fragile and will not take any force at all You may need to relax the bearing anchor bolt under which the plate is mounted f The back edge of the switch anchor plate should be parallel with the press frame bar g Hold the bolt head firmly and tighten nyloc nut until it is very firm Caution The bolt can rotate causing the anchor plate also to rotate out of adjustment h The full bale switch can be finely adjusted on the full bale switch adjustment nuts i If the full bale switch is damaged or faulty replace See parts list j Final check Cylinder fully closed k Roller axel TiBMan019 37 Chapter 9 Stringing Systems Procedures and Problems
93. s Are the finger assemblies still bumping hard y Yes Service or replace damper unit y Call service hotline 1800 888 403 Appendix 17 Does the baler to compact heavy bails and stand the finger units up reliably y Yes y gt No gt Adjust the system pressure Is the system pressure 2200 psi y y Yes Check the reservoir level y Check the pressure switch firing at 1950 y 2100 Check the motor y pump coupling for Yes sound connections y y Check the system bypass valve replace Check the suction hose O rings for cavitations y y Check solenoid valves for contamination or seal damage Y y Me Check the pump for soundness es Check regeneration system for contamination or seal failure y Yes y Check hydraulic compaction cylinders for piston leakage y Call Service Hotline 1800 888 403 Appendix 18 Is the bottom door difficult to close and open Yes Have the hinges and bottom slide been lubricated 3 No gt Lubricate using spray lubricant on hinges and grease on slide Yes Do the pivot bolts on the adjustable door link at the bottom 2 907 794 consen NN SE of the door rotate freely Yes Release the inner lock nut on the Does the bottom door latch bar gt Yes gt adjustable link at the bottom and collide with the latch lugs shorten by rotating outer lock nut one rotation per time lock fi
94. ses through the twine lock bar and back inside the press through the hole in the rear panel of the press The above initial procedure is for new balers or when fitting new rolls of twine Stringing for each bale 1 Take the string end inserted through the collars and the rear door 2 On the two side strings pull some string through the collars and tie in each string a double non slip loop 3 Draw the strings across the baler as per to the inside of the opposite hopper wall and loop the string loop over the doomed hook 4 Pull string down towards the bottom of the press and place the twine under plastic tab 4 then across under tab 5 5 Repeat the procedure on both side twines If the twine has surplus slack pull surplus through from the outside before closing the doors 6 With the doors still open draw the string across from the rear wall approximately 2 4 metres Place twine under tabs 6 and 7 Close the bottom door and bring the twine up the inside of the front door over the top of the bottom door and attach to the square tab on the front of the bottom door by rotating the twine several times around the tab 7 See twining chapter in owners manual amp Appendix 21 Before loading the Baler 1 Check that side strings are securely attached to the domed hooks situated on the left hand wall 2 Check that strings are under tabs securely Loading of the Baler 1 After stringing close securely both doors 2 Press
95. switch of one turn this should prevent the pressure switch firing at the top end of the stoke as it normally would T Start the press and activate the up button press arms should rise and stop in the fully up position if the switch still activates allow the arms to travel down and stop Rotate the Allan key further in until press does stop at the top Caution switch can be damaged if the key is rotated to far 8 When the press pressing arms have reached the top position and no longer changing and coming down with motor still running Very slowly start releasing switch adjustment by rotating inserted Allan key in an anti clockwise out direction until the switch activates and the arms proceed down Caution Beware of Moving Cylinder 9 Stop press turn off key 10 Atthe point where the switch fired rotate Allan key still inserted in the pressure switch a further 1 8 of one turn anti clockwise out 11 Test to see machine cycles reliably remove Allan key TiBMan019 55 Pressure Switch Replacement The pressure switch will require replacement when 1 The switch fails to respond to the adjustment 2 When oil is leaking from inside the switch 3 Behaves unreliably If the pressure switch is suspected of being faulty replace Note If the switch is sourced from the manufacturer it will be pre set and should operate when fitted If the pressure switch is not pre set then the technician will need to follow the setting
96. t Bar Pivots at Rear of Press Grease Side Doorslide Plate at Bottom Comments 2 Dampers Lubricate Pivots Top and Bottom Check Oil Level See Oil Level Checking and Refilling Procedure Check for Leaks replace seals Check for Operation Comments 3 Hydraulics Check System Pressure 2200psi illustration 27 Check Pressure Switch Firing 1900 psi illustration 31 Check Hoses for Damage Check Hydraulic Oil Level 32 grade Lubricate cylinder pivot pins remove pins and lightly grease using long life lithium based grease alternatively use a good grade chain lube type pressure pack Check split pins on the cylinder anchor pins replace if required Check all hydraulic hose and pipe fittings for leaks Check hydraulic system filter replace if required Normal replacement period 12 months more often in dusty conditions Comments 4 Electrics Check Wiring for Damage or Lose Unsaddled Wiring Check Power Plug and Point Check Electrics Generally Report or Repair Damaged or Dangerous Situations Comments 5 Controller Check Controller for Correct Function Check for and Report Damage Check all Fittings to the Controller for Firm Positive Connection Check Controller Anchor Screws Clean the Sensor Eye Glass Comments 6 Solenoid Valve System Check All Wiring to Valve System for Damage or Contamination Clean Thoroughly Check Screws are Firm on Solenoid Wiring Caps Check Wires are Firm on Solenoid Wiring Caps Check Wires
97. tened material on flat 2 When full bale light comes on 3 Remove excess materials by cycling manually by pressing cycle button several cycles 4 Forneat top add large flattened material and manually cycle by activating cycle button 5 NOTE Baler will not cycle automatically when full bale light and indicator are activated Trainer Signature of compliance 14 Tying Off Open the top door Remove any loose materials from above the fingers Unhook the twines on left side by pulling on the twines then lifting of the hook or if very tight cut top loop Pull twine across and insert twine end through looped end of twine and tie off Trainer Signature of compliance 15 Maintaining Twine Tension Loop through Pull tight With left hand hold tension by gripping the twine on the loop 4 Tie off twine 5 Repeat on both twines pee Trainer Signature of compliance 16 Transverse Twine Tie Off Pull transverse twine through the hole 100mm and cut Lower cross twine end tie a loop as in side twines see illustration Undo twine off front tab Pass loose end through loop and pull tight and tie off NOTE Pressing fingers must be down and on the top of the bale when tiring off the bale Trainer Signature of compliance 17 Retracting Fingers Close top door Press in key lock bar 3 Turn on power release the emergency knob 4 Press button marked r
98. the heat affected area CUSTOMER SERVICE NUMBER 1800 888 403 TiBMan019 6 Table of Contents Declaration of Conformity Baler Test Report Hydraulic Pressure and Performance Report Noise Emission Test Report Earth bonding and Electrical Test Hazard Identification Warnings Specifications Transporting the Autobaler Safety Maintenance Requirements Commissioning of Autobaler Commissioning and Training Procedure Woolworths Job completion and Training Procedure Installation of Overhead Canopy Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Chapter 18 Chapter 19 Chapter 20 Chapter 21 Chapter 22 Chapter 23 Chapter 24 Chapter 25 Chapter 26 Chapter 27 TiBMan019 Oil Leaks Pressing Fingers Malfunction Press Cycles Down with Front Door Open Press Fails to Start Press Starts but Fails to Cycle Press Continually Cycles Press Noises Press Fails to Press Heavy Bales Stringing Systems Procedures and Problems Controller Layout and Function The Hydraulic System Bale Ejection System Press Movement on the Floor during Operation 50 Doors Latching and Opening Adjusting the System Pressure Pressure Switch Emergency Bar Operation Damper Strut Lubrication Press Fails to Cycle Automatically Maintenance Instructions Servicing Forms Training Parts Listing D
99. to be situated to facilitate this which would be a 90 degrees BALER CHECK BEFORE COMMISSIONING Trethewey Industries balers undergo a thorough quality check before they are despatched from the factory This ensures that they are all in perfect order Due to varying conditions during the transporting procedure the balers will require a pre start up check The installer should be a person trained qualified and approved by the baler manufacturers for the purpose of pre start up and machine commissioning When installing a baler the pre start up check should be as follows 1 Thoroughly check the baler for obvious damage from transport and handling 2 Check the baler for moisture contamination The manufacturers recommendation is that balers not be transported in a manner that will cause water contamination to the electrics and the electronics Check the electrical system for obvious damage Check hydraulic system for oil leaks Check Safety Bar Insert all strings through string lock as in stringing set up in the operator s manual Bottom Door Adjustment RAND 1 Check the Baler for Damage from Transport amp Handling Walk around the baler and inspect for any damage that may have occurred during transport If any damage has occurred record the damage found and contact the manufacturer immediately 2 Check the Baler for Moisture Contamination If water contamination has occurred the baler should not be connected to the power supply
100. ty of machinery Prevention of unexpected start up Safety of machinery Principles of risk assessment Safety of machinery Interlocking devices associated with guards Principles for design and selection Electrical equipment of machines Part 1 General requirements Electrical Equipment Safety of Machinery 10 Trethewey Industries Pty Ltd 14 Carl Baer Circuit Deepwater NSW 2371 14 November 2003 ASSESSMENT REPORT AUTOBALER FOR COMPLIANCE WITH MACHINERY DIRECTIVE 98 37 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 Jim Orr Banksia EOHS Pty Ltd Richmond Vale Road MULBRING NSW 2323 Ph 02 4938 0044 Fax 02 4938 0111 Email jimorr bigpond com au Banksia Project 00998 4 RO Jim Orr BSc MAppSc PhD 6th February 2010 TiBMan019 11 INSPECTION amp ASSESSMENT METHODS This follow up assessment of the improvements of the machine was carried out on the machine at Campbellfield following the initial assessment on 15 August 2003 and Inspection report No was assessed for compliance with the Essential Health and Safety requirements of Annex ofthe EC Machinery directive 98 37 EC and the following harmonised EN standards EN 292 Safety of machinery basi
101. ubricate hinges Check top door limit switch if functioning correctly Check coded witch that they enter centrally adjust if required illustration 16 Comments 12 Guarding Check that mesh guards are secure and free of damage repair or report Comments 13 Finger Assembly Check Check bearing anchor point bolts replace if required Lubricate as mentioned in lubrication section Check centre pivot bar for secure fastening i e circlips etc Check finger lock operation see finger lock service manual Comments 14 Bottom Door Difficult to close situated at the right hand bottom of the door is a connecting and adjustment link Adjust as required Comments 15 General Operation Report any abnormalities If the baler is moving on the floor or bumping severely as the pressing arms are standing the cause will be in the small yellow cylinders situated on either side of the press Service as in damper service if this fails to correct the bumping remove the small yellow cylinder dismantle the cylinder and service or repair as required Comments 16 Signage Report missing safety signage Report damaged signage Comments E Trethewey Industries Baler Installation Procedure Conformity Document Has the client agreed on a dispatch date Has the correct model required by the client been checked to conform to his requirement Has the pre installation form been sent to the client Has the pre installation form been
102. ve the wire spool fitting carefully 4 Cycle the baler until full system pressure is reached Adjusting the Hydraulic system pressure C D 1 Remove cap C from the system relief valve D 2 Insert a 3 16 Allen key into the relief valve D through the open plug port 3 To Increase the system pressure rotate the adjustment screw in approximately 1 4 turn per 500psi 4 Systems that fail to respond to adjustment could have the following issues a Insufficient hydraulic oil top oil up to recommended level b Coupling key sheared off check coupling c Hydraulic pump wear d Inner strainer filter blocked creating pump cavitation e Cylinder internal failure permitting oil to escape past the piston seals TiBMan019 54 Chapter 16 Pressure Switch The pressure switch plays a vital role in the operation of the machine the pressure switch is simply an adjustable switch in the hydraulic system The system pressure is set at approximately 2100 2250 psi and fixed The pressure switch is set to fire at approximately 2000 psi or as determined When the cylinders reach their full stroke on the up part of the cycle full pressure is reached in the system this causes the pressure switch to fire sending an electronic pulse to the yellow controller The electronic controller in turn sends the appropriate response to the solenoid valve in the hydraulic system the solenoid valve then activates changing the flow direction of the oil
103. xle pivot 16 Lower side wall rear hinge 17 Middle side wall rear hinge 18 Upper side wall rear hinge NNI 19 All moving parts 20 Cylinder pivot pins a 21 Damper strut pivots I 22 Chain plates 23 Clean amp check mounts on sensoreye 24 Remove all material from hydraulic area ensuring all moving parts are free Safety list checked ok Service Compliance Declaration Autobaler Service Booklet Maintenance Record Complete and attach tear out section and return found behind the left front panel in service pouch Service Compliance Declaration Service Agent Provider Signature Any other comments Print Name Position Date Authorised Persons Signature STAFF TRAINING REPORT This is to certify that on the following Staff Members of were trained to competently and safely operate and clean the following equipment EQUIPMENT SUMMARY TYPE MODEL SERIAL No s ontroller clero Please Print leno Please Print Names ee o 2 2 Please Print M DOING Please Print eek ler Please Print Nam erac ae Please Print Ni Signed ete x ee ena Please Print The equipment was fully operational at time of training and showed no

Ti350, Ti500 OPERATION & SERVICE MANUAL

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Ti350, Ti500 OPERATION &amp; SERVICE MANUAL

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Ti350, Ti500 OPERATION & SERVICE MANUAL