ex63revised 022112sr

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EXCEL MODEL EX63

HORIZONTAL BALER

Owner’s Manual

FOR:

CUSTOMER _________________

SN: EX3___________

CUSTOMER SUPPORT

1-800-475-8812

EXCEL MODEL EX-63

Copyright 2012 EXCEL Service EXCEL Manufacturing, Inc. Phone 1-800-475-8812 St. Charles, MN 55972 DATE _____________

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�� CONTENTS

INTRODUCTION

1 �� FEATURES 5 10 �� TROUBLESHOOTING AND SERVICE 33

2 �� SPECIFICATIONS 7 11 �� ADJUSTMENTS 36

3 �� SAFETY PRECAUTIONS 9 ROTATING CUTTING EDGE 36

EMPLOYER REQUIREMENTS 11 PLATEN TO CUTTING EDGE 36

4 �� LOCK OUT/TAG OUT PROCEDURE 12 LIMIT SWITCH ADJUSTMENT 38

GENERAL 12 HYDRAULIC 39

EMPLOYER RESPONSIBILITIES 12 PRESSURE SWITCH 39

PROCEDURE 12 PUMP COMPENSATOR AND

RELIEF VALVE 39

5 �� BASIC PART IDENTIFICATION 13 PUMP COMPENSATOR 40

6 �� INSTALLATION INSTRUCTIONS 16 PHOTO EYE 40

ELECTRICAL REQUIREMENTS 16 12 �� DETAILED PART IDENTIFICATION 42

INITIAL SET UP 16 MAIN BALER 43

INSTALLATION SITE 16 PLATEN 46

BREATHER CAP INSTALLATION 16 CYLINDERS AND HOSES

48

HYDRAULICS 17 CYLINDERS AND HOSES – FOAM 50

CONNECTING BALER TO POWER SOURCE 17 RESERVIOR – FILTER 52

REMOVE ATTATCHED PARTS 18 PUMP – MOTOR 54

WIRE GUIDE INSTALLATION 19 VALVES AND FITTINGS 56

FINAL INSPECTION 19 CONTROLS 58

7 �� START UP AND TESTING 20 LIMIT SWITCH RAIL 64

8 �� OPERATING INSTRUCTIONS 22 PHOTO EYE 66

EMPLOYER RESPONSIBILITIES 22 ELECTRICAL ENCLOSURE 68

OPERATING CONTROLS 22 EX63F ADDENDUM 72

SEMI AUTOMATIC BALER CYCLE 24 DECALS 74

BALE TYING 25 PREVENTATIVE MAINTENANCE

CHECK LIST 76

BALE EJECTION 26 WARRANTY 77

9 �� CARE AND MAINTENANCE 28 APPENDIX A 78

CLEANING PLATEN AND REAR COVER 28 ELECTRICAL SCHEMATICS 79

FILLING OIL RESERVOIR 28 HYDRAULIC SCHEMATIC 87

WEEKLY CARE REQUIREMENTS 29 NOTES 88

SEMIANNUAL CARE REQUIREMENTS 31

YEARLY CARE REQUIREMENTS 31

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� � � � INTRODUCTION

THANK YOU FOR CHOOSING AN EXCEL BALER.

You have selected a precision-engineered product designed with advanced features for modern recycling

center baling. Your Excel Baler is built with the power of intelligent engineering and use of the highest

quality components available guarantee many years of maximum performance and reliable service from your

baler.

To maintain quality performance, it is important that all personnel involved in the installation, operation, and

maintenance of the equipment, carefully read and follow the instructions in this guide until completely

familiar with the proper safe operating procedures. This manual is arranged in the order that we anticipate

you will use it to operate the equipment.

This manual does not represent an inclusive list of Safety Precautions. It is suggested that owner/operators

read the most current publication of American National Standard Safety Requirement No. Z245.5, entitled

"Safety Requirement for Baling Equipment." Copies may be purchased from the AMERICAN NATIONAL

STANDARDS INSTITUTE, 11 West 42nd ST, New York, NY 10036, phone (212)-642-4900.

It is also suggested that owner/operators read the most current publication of "Control of Hazardous Energy

(Lock Out/Tag Out)." OSHA publication 3120. Available at regional offices of US Department of Labor,

Occupational Safety and Health Administration.

Elimination of the hazards listed in this manual does not guarantee that the equipment will meet or exceed all

standards or regulations, or will be completely safe to all personnel. The equipment should be inspected before use

to assure adequacy in safety for the function for which it will be used.

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1 �� FEATURES VERSATILE MATERIAL BALING

The EXCEL EX63 bales most plastics, cardboard, paper, aluminum cans, and other recyclables.

MAXIMUM SIZE FEED OPENING AND CHAMBER

Because the baler has a large feed opening and chamber, large quantities of material can be fed into the

machine by hand, conveyor, or machine loader.

REMOVABLE SHEAR BLADE WITH FOUR CUTTING EDGES

Material not fitting into the bale chamber, or pieces of material toward the top of the chamber, gets sheared off

by the 4 sided removable shear blade, preventing jams or pressure on the baler. After the cutting edge of the

shear blade becomes dull, it can be removed, rotated, and reinstalled with a fresh new edge.

43” OF CHAMBER PENETRATION

After the feed chamber is filled, the platen pushes the material into the bale chamber, penetrating 43" into the

chamber, completely compacting all the material with tremendous force.

RETRACTABLE DOGS

Once the material has entered the chamber, it is prevented from springing back by retractable dogs, until the

Automatic Bale Sizing System stops the machine automatically at the proper bale size.

PLATEN WIPER

As the platen retracts to allow more material to fall into the feed chamber, a wiper sweeps material from the top

of the platen back into the feed chamber.

AUTOMATIC BALE SIZING SYSTEM

When the bale reaches the correct size, the BALE TIE OFF LIGHT will illuminate and the machine will stop

cycling with the platen in the correct forward position for tying the bale. The tie off light is easily seen from all

vantage points because of it large size and location on the top of the baler.

SIX, FULLY GUIDED WIRE TIE SLOTS

Tying the bale is made easy because the wire is fully guided around the bale after it is formed. No prethreading

of the wire is required. Tying the bale with six wires assures that material is held secure in the bale, providing

you with a solid, transportable bale.

SAFE, SEMI-AUTOMATIC BALE EJECTION

After the bale is tied, open the door to the baler and eject the bale onto a forklift. The bale is ejected completely

from the chamber by fully extending the platen.

BALER DOOR SAFETY INTERLOCK SYSTEM

EXCEL’s patented bale door interlock system provides total safety in closed door baling. If an operator

attempts to open the door while the baler is in operation, the platen stops then the platen decompresses and

backs off the bale. The door also must be completely open before the platen will extend to eject the bale.

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SHORT STROKE CYCLE

This feature enables the ram to cycle with shorter (8”)chamber penetration. The short stroke cycle produces

approximately 21 seconds cycle time, allowing material such as corrugated cardboard to be baled at higher

production rates.

INTEGRATED CONVEYOR CONTROLS W/CONVEYOR MOTOR STARTER

All conveyor controls are conveniently located on the control panel with the baler controls. Also, no separate

electrical disconnect is required for the conveyor. Conveyor power is interlocked with the baler power.

ADVANCED CONTROL PANEL

In addition to normal baler operation controls, advanced controls include an Upper and Lower Photo Eye

selector to start and stop the conveyor, and a Conveyor Override switch, which allows the operator to run the

conveyor at any time.

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2 � � � � SPECIFICATIONS

S T R U C T U R A L

HEIGHT - 62” LOADING 52 1/2” FRAME LENGTH - 179” * FOAM – 285” WIDTH - 77” CHAMBER - 47”L x 60”W x 30”H *FOAM 57”L X 60”W X 30”H FEED OPENING - 54”W x 35”L *FOAM 54”W X 70”L SHIPPING WEIGHT - 14,000 LBS. *FOAM 20,000 LBS. *AREA REQUIRED TO OPERATE - 10’ x 20’ *FOAM 10’ X 29’

H Y D R A U L I C S

PUMP - 34 GAL. PRESSURE COMPENSATED HORSE POWER LIMITED PISTON PUMP, 4000 PSI RATED DIRECTIONAL VALVE - D08 PATTERN, HI-FLOW CUSHION SHIFT DESIGN CYLINDERS - 2 -- 6” BORE x 74” STROKE x 4” HARD CHROME ROD OIL RESERVOIR - 105 GAL.

E L E C T R I C A L

MOTOR - 20 HP TEFC 230-460 V 3 PHASE ENCLOSURE - NEMA 12 RATED CONTROLS - UL/CUL/CE APPROVED NEMA 12 RATED

P E R F O R M A N C E D A T A

HYD SYSTEM PRESSURE - 3,000 PSI OVERALL PLATEN FORCE - 159,400 LBS. PLATEN PSI - 92 PSI CYCLE TIME - 29 SEC. - 21 SEC. SHORT STROKE BALE - 60”L x 48”W x 30”H

F I N I S H E D B A L E W E I G H T S

PET - Up to 950 Lbs. Office Paper - Up to 1600 Lbs. Newspaper - Up to 1550 Lbs. Corrugated Cardboard - Up to 1250 Lbs. Tin Cans - Up to 1300 Lbs. Aluminum Cans - Up to 600 Lbs. HDPE - Up to 1050 Lbs.

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Diagram A. EXCEL Model EX63 Structural Specifications Diagram.

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3 �� SAFETY PRECAUTIONS

The lightning flash symbol within an equilateral triangle is intended to alert the user to the

presence of uninsulated "dangerous voltage" within the product's enclosure that may be of

sufficient magnitude to constitute a risk of electric shock to persons.

The exclamation point within an equilateral triangle is intended to alert the user to the presence of

important safety reminders, and operating and maintenance (servicing) instructions in the

literature accompanying the equipment.

The key and lock symbol are intended to alert the user to the need of Lock Out/Tag Out procedures.

It is the responsibility of all persons involved in the installation and operation of this equipment to completely

understand the function and operation of the unit, and to understand and adhere to all safety precautions in this

manual. It is important to keep watch for any condition or situation which may affect the safe performance of the

equipment. If unsafe conditions are present shut equipment down using the RED EMERGENCY STOP button or

normal shut down procedure. Corrective measures, service, or baler repair must be performed by trained and

authorized personnel only.

1. READ INSTRUCTIONS

Read all safety and operating instructions before operating the baler.

2. RETAIN INSTRUCTIONS

Retain all safety and operating instructions for future reference.

3. OBEY WARNINGS

Obey all warnings on the baler and in the manual.

4. FOLLOW INSTRUCTIONS

Carefully follow all operating and safety instructions.

5. MACHINE OPERATING PERSONNEL

a) Only properly trained operators no less than 18 years old shall operate the unit. It is the responsibility of

the employer to see that operators are properly trained.

b) Do not wear loose clothing or jewelry which could catch on moving parts. Do wear safety glasses and

other safety equipment as required by your employer.

c) Never operate the baler if work ability is impaired by drugs, fatigue, illness or other causes.

d) Do not operate equipment without proper training in Lock Out/Tag Out procedures.

6. EMERGENCY STOP BUTTON

Every unit manufactured by EXCEL has a RED extended head emergency stop button. All personnel should

be aware that depressing this button at any time stops the machine from operating. Emergency Stop

button(s) must not be over ridden or defeated in any way.

7. SAFETY SWITCHES

Safety switches have been provided at certain doors and access covers. They must not be overridden or

removed in any manner which prevents them from functioning properly.

8. ACCESS COVERS

Access covers must be properly maintained and in place at all times.

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9. PINCH POINTS

All moving machinery has pinch points. EXCEL has provided guards on them where possible. Some,

because of the operating characteristics, cannot be guarded. Operators must use caution when closing doors,

etc.

10. EXPLOSIVE SUBSTANCES

Never attempt to bale volatile or explosive substances. Serious injury or death could result.

11. HOPPER

Under no circumstances is the baler to be operated with EXCEL safety hopper removed.

12. OPTIONAL EQUIPMENT

To prevent hazardous operation, use only attachments and accessories approved by EXCEL.

13. CLEANING BALE CHAMBER OR BALER

The power must be shut off to the machine at the MAIN disconnect, and locked out, when entering the baler

chamber to remove debris, or to clean around the power unit and cylinders. Refer to LOCK OUT/TAG OUT

PROCEDURE section of this manual for lock out instructions.

14. HYDRAULIC PRESSURE

Hydraulic lines should be considered under pressure at all times. Completely understand the hydraulic circuit

before disconnecting any hoses. Personal injury can result from escaping high pressure fluids.

15. BALER POWER DISCONNECT

The BALER disconnect is on the baler's electrical enclosure. To prevent unauthorized use, turn off and lock

out the BALER disconnect. See Diagram G located in Connecting Baler to Power Source under

INSTALLATION INSTRUCTIONS. Also refer to the LOCK OUT/TAG OUT PROCEDURE section of

this manual for lock out instructions.

16. ADJUSTMENTS AND SERVICING

Adjustments and repairs to this unit must be performed by qualified and authorized personnel or trained

service technicians.

17. SAFETY CHECK

Upon completion of any service or repairs, the service technician should perform safety checks to determine

that the unit is operating properly. Do not start or operate equipment which has a malfunction or is damaged.

18. MAKE CERTAIN ALL PERSONS ARE CLEAR OF THE BALER, CONVEYORS, AND

RELATED EQUIPMENT BEFORE STARTING THE MACHINE

19. FIRE EXTINGUISHER

Keep a fully charged fire extinguisher available at all times.

20. SAFETY DECALS

Replace all Safety Decals as they become unreadable or are missing. For proper decal replacement see the

Decal list under the DETAILED PART IDENTIFICATION section of this manual and then contact your

local Excel representative to obtain replacement safety stickers at no charge.

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��EMPLOYER REQUIREMENTS

1. The employer will establish a procedure for the locking and tagging out of energy sources as required by

OSHA.

2. The employer will provide training to all personnel involved in the operation, service and maintenance of the

equipment.

3. The employer will monitor the employees operation of the equipment, ensuring that safe practices are being

followed.

4. The employer will establish a program of regular inspections as outlined in the section CARE AND

MAINTENANCE.

NOTE

These safety precautions do not imply or in any

way represent an all-inclusive list. It is the owner's

and operator's responsibility to be familiar with

and enforce that the unit is operated in accordance

with safety requirements and codes including all

applicable Occupational Safety & Health Act

(OSHA) and American National Standards

Institute (ANSI) regulations.

These regulations change and therefore, it is

impossible to give a reference which will remain

current. It is strongly recommended that current

OSHA and ANSI standards publications be

available and reviewed with operators at all times.

SAVE THESE INSTRUCTIONS

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4�� LOCK OUT/TAG OUT PROCEDURE

��GENERAL

The following is an outline of the OSHA Standard for locking and tagging out equipment from hazardous energy

sources. A comprehensive publication of this standard can be obtained from OSHA. The purpose of this procedure

is to ensure that the equipment is isolated from its energy sources and rendered inoperative prior to service or

maintenance.

Lock Out/Tag Out devices shall meet requirements set forth in the OSHA Standard Publication as to durability,

standardization and identity.

��EMPLOYER RESPONSIBILITIES

The standard requires employers to establish an energy program which includes:

1. Documented energy control procedures.

2. An employee training program.

3. Periodic inspections of the use of the procedures. Compliance with the development of the Lock

Out/Tag Out Procedure shall be the responsibility of the Employer.

��PROCEDURE

The suggested procedure to comply with this standard is outlined as follows:

1. Turn system off and remove the key.

2. Lock Out the MAIN power disconnect per OSHA requirements, use main disconnect to isolate power

(see diagram F).

3. Tag Out all other controls or energy sources not capable of being locked out. Every person affected

should know and understand all Lock Out Tags.

4. Verify that all energy sources have been accounted for prior to service or maintenance work.

5. To restart the equipment, ensure that all Lock Out and Tag Out devices are removed by all employee’s

that applied the device(s).

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5 �� BASIC PART IDENTIFICATION

Diagram B. EXCEL Model EX63 Basic Parts Identification Diagram.

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5 �� BASIC PART IDENTIFICATION

The parts diagram on the previous page shows the location of key parts and baler controls. Some of the parts

require installation. These parts have been shipped packed inside the baler. As you read the description of each part

and control, find that part on your baler to familiarize yourself with its location.

1 Bale Chamber

2 Retractable Dogs

3 Removable Shear Blade With 4 Cutting Edges

4 Feed Opening

5 Platen

6 Wiper

7 Access Panel (Rear of Baler)

8 Cylinders (Inside)

9 Start Up Light

10 Bale Tie Light

11 Six Wire Tie Slots

12 Door

13 Door Latch

14 Door Cylinder

15 6 Wire Guides (Under Baler)

16 Control Panel

17 Photo Eye

18 Electrical Enclosure

19 Baler Power Disconnect Switch

20 EMERGENCY STOP - Red

21 FORWARD Button - Green

22 SYSTEM - 3 Position Key Switch and Key OFF-ON-START

23 SHORT STROKE OFF-ON - 2 Position Selector Switch

24 CONVEYOR OFF-0N - 2 Position Selector Switch

25 CONVEYOR ON OVERRIDE - Push Button

26 HOPPER OVER FILL LIMIT LOWER-UPPER - 2 Position Selector Switch

27 BALER PHOTO EYE OFF-ON - 2 Position Selector Switch

28 REVERSE Button - Yellow

29 Hand / Auto Selector Switch

30 Door Open Button - Green

31 Door Close Button - Yellow

32 Pilot Valve

33 Directional Valve

34 Oil Reservoir

35 Pump

36 Motor

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37 Drain Plug or Optional Heater

38 Temperature/Sight Gauge

39 Breather Cap

40 Oil Filter/ with replacement element

41 Clean Out Tool

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6 �� INSTALLATION INSTRUCTIONS

It is the responsibility of the installer of this baler to install it in accordance with applicable codes, local ordinances,

and the manufacturer's recommendations. The baler must also be installed in accordance with ANSI Z 245.5

(Baling Equipment- Safety Requirements for Install, Maintenance and Operation). This must be signed off upon

completion of installation, sign off is located in the disconnect box.

It is important that the installers of this baler follow the installation instructions in the order in

which they follow. All persons involved in the installation of this baler should read the manual

completely before proceeding.

��ELECTRICAL REQUIREMENTS

All wiring must be in accordance with local and national electrical code regulations.

Check the voltage and frequency marking at the installation site MAIN supply disconnect box, so it is certain that

the electrical current characteristics (voltage, etc.) are compatible with those of the baler.

If not, a qualified electrician must take whatever steps are necessary to make the voltage compatible.

Motor Horsepower Line Voltage Motor Amps

20 HP, 3 Phase 230 Volts 54 Amps Full Load

460 Volts 27 Amps Full Load

��INITIAL SET UP

After the baler arrives, inspect the overall condition of the baler for damage during shipping. Remove all the loose

parts and information papers.

Make sure that all parts required for assembly have been received. If any items are missing or appear damaged,

contact your EXCEL Manufacturing representative immediately.

��INSTALLATION SITE

Careful consideration should be given to the site selected for the baler to determine the amount of room required to

operate the baler. Ample room must be provided to load the baler feed opening, remove a bale from the baler, and

obtain access to the back and sides of the baler for maintenance work and servicing.

Use extreme caution when moving the baler into position. Watch for all persons who may be in

the path of the baler and moving equipment.

��BREATHER CAP INSTALLATION

Remove the Breather Cap from the accessories box in the chamber of the baler. Remove the shipping plug from the

oil reservoir and install the Breather Cap. For the Breather Cap installation location see Item 39, Diagram B.

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��HYDRAULICS Diagram E. Temperature/Sight

Gauge.

The hydraulic system has been completely operated and tested

at the factory. Check all hydraulic connections to insure that no

leaks have developed during transit.

Check the oil level within the reservoir. The oil in the

temperature/sight gauge on the side of the reservoir

should be even with the oil level arrow when the platen

is fully retracted.

��CONNECTING BALER TO POWER SOURCE

All wiring must be in accordance with local and national electrical code regulations.

Observe proper Lock Out/Tag Out procedures before connecting power to the baler.

Make sure that the MAIN disconnect switch is padlocked in the OFF position. Place

an appropriate warning tag , “UNDER REPAIR, DO NOT USE,” on the switch so it

will not be energized without notifying the person making wiring connections.

See the APPENDIX section of this manual for the wiring diagram and electrical schematic. A copy of the wiring

diagram may also be enclosed inside the print pocket of the electrical enclosure.

1. Open the electrical enclosure. Refer to Diagram F for operation and lock out procedure of the BALER

power disconnect. Also, refer to LOCK OUT/TAG OUT PROCEDURE section of this manual.

Diagram F. Operating and Lockout Procedure of Baler Power Disconnect.

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2. Drill or punch a hole in the electrical enclosure to allow the electrical power line to enter the box. Protect

parts from metal chips.

After drilling or punching holes in the electrical box, extract all metal filings or chips from the box.

Do not use forced air to remove filing or chips or premature contactor failure will result!

3. Run electrical power lines from the customers MAIN disconnect switch to the electrical box.

4. Connect the electrical power line as shown in Diagram G on the next page.

Diagram G. Connecting Electrical Power to Disconnect Inside Box.

5. Close the electrical box.

Do not close the MAIN power supply switch or turn the handle to ON until instructed to do so in

the START UP AND TESTING section of this manual.

��REMOVE ATTATCHED PARTS

Open baler door and remove clean out tool from inside tube at top front of chamber. Remove the grease gun

attached to inside of bale door. Remove any other parts located inside the chamber.

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��WIRE GUIDE INSTALLATION (INSTALLED AT FACTORY)

Parts Required: 6 - Wire Guides 12 – P-1016 Bolts

12 – P-1025 Flat Washers

12 – P-1024 Lock Washers

OR

Studs 12 – P-1023 Nylock Nut

12 - P-1024 Flat Washer

��INSTALLATION STEPS

1. Block up front end of baler one foot off from floor.

2. From underneath the baler, place a wire guide into a slot, sliding the front of the wire guide to the front of the

baler.

3. Push the guide into the slot completely, so that the front of the guide rests on the tube at the front of the baler,

and so that the holes in the guide are aligned with those on the baler. See Diagram H.

Diagram H. Wire Guide Installation.

4. Use 2 – P-1016 bolts, 2 – P-1024flat washers, and 2 – P-1025 split lock washers to secure the guide. If your

baler has the factory installed studs, please use 2 – P-1024 flat washers and 2 – P-1023 nylock nut.

5. Repeat the previous steps until all guides are in place

��FINAL INSPECTION

As a final check, carefully inspect leaky hydraulic connections, loose electrical

connections, and loose or missing bolts and nuts.

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7 �� START UP AND TESTING

Do not test this baler until all involved persons have completely read and understood this

manual.

Make sure that all access covers are in position and that the baler chamber door is closed and

secured with the latch. Before proceeding with this test, make sure that all persons are clear of the

baler.

1. With the MAIN disconnect switch OFF, visually inspect all hydraulic, mechanical and electrical connections.

All connections must be tight.

2. Check oil level in the reservoir to be sure it is adequate.

3. Close the MAIN disconnect switch. Turn the BALER power disconnect located on the electrical enclosure

to ON.

Be alert for smoking, electrical arcing, or fuse failure. If any irregularity is observed, open the

MAIN supply switch immediately. Find the source of the trouble and make the necessary

corrections.

4. Have an assistant stand so that they may clearly view the fan end of the motor. This person should be

instructed to observe the rotation direction of the motor. The motor must turn in the direction of the arrow

located on the motor housing when viewed from the fan end. If the direction arrow is missing, the motor

must turn in same direction as indicating arrow on pump. If, a cooler is present, remove the cover for the

coupler to see rotation.

5. Insert the key into the key switch located on the control panel.

6. Turn the key clockwise to the START position, hold until the buzzer stops and the motor starts.

7. If the observer indicates that motor rotation is incorrect, depress the EMERGENCY STOP button

IMMEDIATELY and go on to step 8. If motor rotation is correct, skip to step 10.

8. Place the key switch in the OFF position and remove the key.

Observe proper Lock Out/Tag Out procedures before changing motor rotation.

Make sure that the MAIN disconnect switch is padlocked in the OFF position.

Place an appropriate warning tag, "UNDER REPAIR, DO NOT USE", on the

switch so that it will not be energized without notifying the person making wiring

connections.

9. To change motor rotation for 3 phase motors, switch any two motor wires. Switch the wires where the

incoming wires connect to the disconnect. Do not change factory wiring.

Make sure the motor wires are reconnected securely if it was necessary to switch them to correct

motor rotation.

Return to step 4 and repeat the rotation testing procedure to assure proper motor rotation.

10. Leave the motor running, turn selector switch to AUTO.

11. Depress the green FORWARD button. The platen will move forward and then reverse automatically after

reaching full extension into the bale chamber. It will return to its retracted position and the motor will

continue to run.

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12. Cycle the baler again by depressing the green FORWARD button. When the baler is part way through its

cycle, depress the EMERGENCY STOP button. The motor should stop running and the platen should stop

moving.

13. On optional conveyor package, test the hopper door interlock and emergency stop arm on the conveyor to

ensure they are functioning properly.

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8 �� OPERATING INSTRUCTIONS

��Employer Responsibility Regarding the Operation of EXCEL Balers.

The employer shall provide properly maintained baling equipment that meets all applicable regulatory safety standards.

The employer must insure that the installation of balers is in conformance with local codes, ordinances, and the manufacturer's

recommendations.

The employer must provide instruction and training in safe methods of work to employees before assigning them to operate, clean,

service, maintain, or repair the equipment. Such instruction and training shall include procedures provided by EXCEL

Manufacturing.

Employers are responsible for repairing, prior to placing baler equipment into service, any mechanical malfunctions or breakdowns

that affect the safe operation of the equipment.

Employers are responsible for establishing and following a program of periodic and regular inspections of the baling equipment to

insure that all parts, component equipment, and safeguards are in safe operating condition and adjusted in accordance with the

manufacturers recommended procedures. This shall include keeping detailed malfunction reports and records of inspections and

maintenance work performed.

Before operating, check to see that the loading chamber is empty and free to operate.

All operators of this baling equipment must read this manual and be at least 18 years old.

��OPERATING CONTROLS

The operating controls are located on the control panel on either side of the baler, depending upon how the baler is equipped.

Following is a brief description of the function of each control and its intended use.

Diagram K. Operating Controls.

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START UP ALARM

When the baler disconnect switch is turned on, the emergency stop switch is released and the key switch is

turned to the START position, the buzzer will sound and the red light will flash for 20 seconds before the baler

and conveyor controls are unlocked and the motor starts. Any time the baler disconnect switch is turned off

then back on or any emergency switch is depressed then released or the key switch is turned to the off position,

the start up sequence will need to be initiated again.

BALER POWER DISCONNECT SWITCH - Electrical Enclosure

This switch controls the main power to the baler. See Diagram F in the INSTALLATION INSTRUCTIONS section of this

manual. Turn the switch to the OFF position and lock it out when baler is not in operation.

LIGHTS BLUE/RED – Start up/Automatic Light and Bale Complete Light.

Red flashing light indicates machine is going through start up and visual indication that baler is in auto mode.

Blue flashing light indicates a bale is complete and ready to be tied.

EMERGENCY STOP - Red Extended Head Push Button and conveyor emergency stop

Depressing this button stops all baler functions in the event of an emergency. When pushed, the button remains depressed

and the baler will not operate. To restart the baler, twist the EMERGENCY STOP clockwise and follow the proper start up

procedure. Each conveyor is equipped with an emergency stop arm which when activated will stop both the baler and

conveyor, when released this arm will return to original position..

SYSTEM - 3 Position Key Switch

The key switch in the START position will start the motor when baling is initiated. The key switch in the ON position allows

the baler to operate in either manual or automatic after the motor is running. Turn the key switch to OFF and remove the key

to discontinue baling.

HAND/AUTO – 2 Position Selector Switch

The HAND/AUTO switch sets the system to manual or automatic baling.

SHORT STROKE - 2 Position Selector Switch

When set to ON, the platen partially penetrates into the chamber, approximately 8”. When set to OFF, the platen has full

chamber penetration.

BALER PHOTO EYE - 2 Position Selector Switch

When set to ON, and the SYSTEM is set to AUTO, the photo eye is activated. The baler starts and cycles automatically

when the photo eye beam is broken after the baler feed chamber becomes full. Turn the switch to OFF to bale or for

semiautomatic operation.

FORWARD - Green Push Button

When the SYSTEM is set to AUTO, depressing the FORWARD button activates auto cycle and starts the platen moving

forward. When the platen reaches full extension into the bale chamber, it reverses automatically and returns to its original

starting position. When the SYSTEM is set to HAND, depress and hold the FORWARD button to manually move the platen

forward. The platen will stop when the FORWARD button is released while in hand.

REVERSE - Yellow Push Button

When the SYSTEM is set to AUTO, depressing the REVERSE button activates auto cycle and starts the platen moving

backwards and retracts fully. When the SYSTEM is set to HAND, depress and hold the REVERSE button to manually back

the platen up. The platen will discontinue moving when the REVERSE button is released while in hand.

DOOR OPEN – Green Push Button

The door open push button opens the latch when depressed. This will only work if the HAND/AUTO switch is in the hand

position. When initially depressed, the platen will back off to relieve pressure on the door.

DOOR CLOSES –Yellow Push Button

The door close push button closes the latch when depressed. This button will only work if the HAND/AUTO

switch is in hand position and the bale door is completely closed position

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CONVEYOR OFF-ON - 2 Position Selector Switch

In the ON position, the conveyor starts and stops automatically and is controlled by the baler photo eye. The conveyor does

not operate when set in the OFF position. Upon first start up or after an emergency stop has been depressed, the override

button must be depressed in order to initiate the conveyor.

CONVEYOR ON OVERRIDE - Push Button

Depressing this button activates conveyor auto cycle. Also, depressing this button starts and operates the conveyor,

overriding the baler photo eye function. The CONVEYOR OFF-ON must be set to ON for this switch to operate the

conveyor.

HOPPER OVER FILL LIMIT - 2 Position Selector Switch

Photo eyes are placed at high and low positions in the hopper to regulate incoming material. This switch selects which photo

eye is active. The lower photo eye operates the baler and the conveyor. The upper photo eye operates the conveyor only.

When the HOPPER OVER FILL LIMIT is set to LOWER, the chamber fills for one charge, the baler cycles and the

conveyor stops. When the HOPPER OVER FILL LIMIT is set to UPPER, the conveyor will continue filling the hopper until

material reaches the upper photo eye, so that another charge is ready when the platen reverses.

��SEMI AUTOMATIC BALER CYCLE

1. Turn the BALER power disconnect switch to the ON position.

2. Set the selector for SHORT STROKE to OFF or ON.

3. Set the selector for BALER PHOTO EYE to OFF.

4. Turn the key switch to START. For 20 seconds, the red light will flash and the buzzer will sound.

5. Turn the selector switch to AUTO.

6. Load the feed chamber until it is full.

Before depressing the FORWARD button, clear all unauthorized personnel from the area.

6. Depress the FORWARD button. The platen will move forward, compacting the material in the bale chamber. After the

platen reaches full extension into the bale chamber, it will reverse automatically and return to its original starting position.

7. Follow steps 5 and 6 until the blue BALE TIE OFF LIGHT at the top of the baler illuminates. After a complete bale is

formed, follow the directions for Bale Tying and Bale Ejection.

8. If you wish to stop baling before a bale has been completed, retract the ram and turn the key switch to the OFF position and

remove the key. Turn the BALER power disconnect switch to the OFF position.

To prevent unauthorized use of the baler, always Lock Out the BALER power disconnect and remove the

key when the baler is not in use.

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��BALE TYING

After a complete bale is formed, the blue TIE OFF LIGHT at the top of the baler will illuminate. The baler and conveyor will stop

automatically with the platen in the correct forward position for tying the bale.

1. Turn the key switch to the HAND position. Turn the BALER PHOTO EYE SWITCH to OFF.

2. From the top of the baler, thread the end of the wire which is not looped down through the six slots in the front of the platen. See

Diagram L.

3. If the wire does not feed smooth through the wire guides, the slots may have a blockage in them, use the clean out tool to clean

slots

SAFETY GLASSES REQUIRED. Do not insert wire when persons are in front of the baler. Injury

could result.

Diagram L. Threading Wire Ties Around the Bale.

3. Push the wire until it comes out the bottom of the corresponding slot in the door.

4. Pull the wires through to allow enough slack for securing the two ends together.

5. Thread the looped end of the wire ties through the corresponding slots on the top of the bale and then out the same slot in the

top of the bale chamber door.

6. Center the wire in the guide on the underside of the bale to assure that the wire will pull up completely and out of the slot

when the two ends are secured together. See diagram M. below. This will prevent the wires from being cut by the edge of

the wire guide.

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7. Standing in front of the baler, tie the two ends of each of the six wires together.

Diagram M. Centering Wire Ties in the Guides.

��BALE EJECTION

The bale is ready to be ejected from the chamber after the machine has stopped with the BALE TIE OFF LIGHT illuminated and the

bale has been tied following the previous instructions.

All persons must be clear from the front of the baler when the bale is being ejected. Serious injury could

result from the bale falling onto the pallet.

1. Turn the SYSTEM key switch to the HAND position.

2. Depress the REVERSE button and retract the platen 3” to 4” (75 mm to 100 mm) from the bale.

3. Depress the DOOR OPEN button, at this point the platen will also backup.

The bale chamber door is under pressure and may spring open suddenly when the door latch is opened.

Stand clear of the swing path of the door as it is being opened.

4. Open the bale chamber door completely to activate the safety interlock system.

5. Place a fork lift in front of and lower than the door opening for the bale to land on and be moved away with once it is ejected.

6. Push the FORWARD button. Keep depressing it until the platen reaches full extension and the bale is ejected.

7. Depress the REVERSE button and hold to fully retract the platen.

8. Turn the SYSTEM key switch to the OFF position. Turn the Baler power disconnect switch OFF and lock out.

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Observe proper Lock Out/Tag Out procedures before cleaning the baler.

9. After the bale has been removed, clear the inside of the baler chamber and the area of debris.

10. Clean wire guides if necessary using the clean out tool provided.

11. Restart Baler using KEYSWITCH

12. Close and secure the bale chamber door, by depressing the DOOR CLOSE button, to activate the safety interlock system.

13. Turn the SYSTEM key switch to AUTO and begin forming another bale.

AUTOMATIC BALING (PHOTO EYE CONTROLLED)

1. Turn the BALER power disconnect to ON.

2. Turn the SYSTEM key switch to AUTO.

3. Turn the PHOTO EYE CONTROL switch to ON.

4. Depress FORWARD or REVERSE to activate auto cycle.

5. Load the feed chamber.

When photo eye beam is broken, the baler starts and cycles automatically, without warning.

The baler cycles automatically when the feed chamber becomes full.

6. Continue filling the chamber. When a complete bale is formed, the blue BALE TIE OFF LIGHT at the top of the baler

illuminates.

7. After the blue BALE TIE OFF LIGHT illuminates, turn the PHOTO EYE CONTROL switch to OFF. Follow the Bale

Tying and Bale Ejection instructions earlier in this section.

8. If you wish to stop baling before a bale is completed, turn the PHOTO EYE CONTROL switch to OFF, then the SYSTEM

key switch to OFF.

Never leave the baler unattended with the Photo Eye Control On.

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9 �� CARE AND MAINTENANCE

EXCEL Manufacturing recommends that users of our baling equipment adopt a program of regularly scheduled

maintenance procedures. The following schedule should be followed to insure against premature failure of

mechanical or hydraulic components. A PREVENTATIVE MAINTENANCE CHECK LIST is provided in the

APPENDIX of this manual, which may be copied for your convenience. Warranty coverage is dependent upon

your maintenance records.

Employer Responsibility Regarding the Maintenance of EXCEL Balers

It shall be the responsibility of the employer who uses baling equipment to insure the proper caring for, cleaning,

inspection, and maintenance of the equipment. In the case of employers who maintain their own equipment, the

employer will provide training to competent personnel for this purpose.

It is also the responsibility of the employer to establish and follow a program of periodic and regular inspections of

baling equipment, and to insure that all parts, auxiliary equipment, and safeguards are in safe operating condition

and adjusted in accordance with the manufacturer’s recommended procedures. The employer must maintain records

of these inspections and of maintenance work performed.

The employer is Responsible for providing adequate work area around the baler to permit safe maintenance,

servicing, and cleaning practices. The employer must insure that all surrounding floors are free from obstructions,

and from accumulation of water, grease or oil.

��CLEANING OUT BEHIND PLATEN AND REAR COVER

All balers tend to accumulate material behind the main platen as the machine is cycled. This is due to the built in

clearance along the sides and bottom of the platen which allows material to migrate to the area behind the platen.

Allowing this material to build up may cause baler malfunction and even lead to structural failure. Therefore, it is

necessary to clean out this area on a regular basis as part of a routine maintenance program. This procedure should

be performed every 40 hours, or as necessary.

To avoid personal injury, observe Lock Out/Tag out procedures per OSHA

requirements before cleaning out this area. Wear safety glasses to keep debris out of

eyes.

Lock out power and put on safety glasses. Remove rear cover and sweep out all material on floor. Also, clean

debris from limit switch rail.

��FILLING OIL RESERVOIR

EXCEL recommends the use of a premium grade antiwear hydraulic oil in our systems. The following table lists

specifications for Mobil and Conoco products recommended by EXCEL. Other brands of oil are acceptable if they

meet the specifications and oil cleanliness code listed in the oil selection table on the next page.

Initial oil selection, cleanliness and on going maintenance procedures are vital to the trouble free operation and

longevity of your baler. Regular oil filter and air breather changes are a necessary part of care and

maintenance. Yearly oil sampling and testing by your local oil distributor can help determine if there is a need to

change the oil or replace the oil additives. The advice of your local oil distributor is also invaluable when selecting

the oil for a new machine.

When filling the system, DO NOT pump oil directly from the barrel or bulk truck. Filtering of new oil is

required.

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When filling the system it is not acceptable to pump the oil directly from the barrel or bulk truck without filtering it.

New oil rarely meets the cleanliness codes required by pump and valve manufactures. New oil should be filtered

with a maximum 10 micron filter as the tank is filled.

OIL SELECTION TABLE

Conoco ISO Grade MV 32

Product Number MV32

Oxidation Control (ASTM D-943, hr) 4500 hours

Pour Point, (°F), max. -45

Flash Point, (°F), min. 400

Viscosity

SUS at 100°F 164

SUS at 210°F 47

cSt at 40°C 32

cSt at 100°C 6.2

ISO viscosity Grade 32

Viscosity Index, min. 145

Rust Test, ASTM D665 A @ B PASS

Foam Test, ASTM D892 I, II, III,ml/ml, max. PASS

Alternate Oils include: Exxon Univis M32, Texaco Randall HD-36, Mobil DTE-13M

��WEEKLY CARE REQUIREMENTS

1. Check the baler disconnect switch for function. Make sure a padlock is available for servicing.

2. Check the hydraulic reservoir oil level. The oil level in the sight gauge on the side of the reservoir should be

at the oil level arrow when the platen is fully retracted. If it is not, add oil as specified in the table above.

Grease the six nylatron wear pads at the sides (three per side) of the baler. Also grease the two door latch hinges

and two door hinges. See the Diagram L. on the next page for grease point locations. Lubricate the baler every 35

to 40 hours of operation. High use will require lubrication more often.

Use cardboard or wood to search for suspected leaks. Do not use hands. High pressure fluid flow

can penetrate skin and cause serious injury.

4. Check hydraulic pump, valve, cylinders and hoses for leaks. Check for any damage, kinks, etc.

5. Inspect the power unit. Remove dust and dirt from outside of the reservoir, control box, and electrical

enclosure. Wipe off any grease, oil, or moisture. Inspect motor for excessive dirt, friction, or vibration.

Keep the ventilation openings clear to allow free passage of air.

6. Remove the rear cover and clean out behind the platen. Clean off the limit switch rail.

7. Inspect the limit switches and rail. Make sure the arms are 90 degrees from the body and that all connections

are secure. Inspect the cylinders, inspect and grease cylinder pins, etc.

8. Test all the baler controls and make sure each is operating properly. Check the photo eye operation. See the

description of each control under Operating Controls in the OPERATING INSTRUCTIONS section.

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Diagram L. Lubrication Chart.

9. Check that the bale tie light functions when a bale is complete. Check that the start up/auto light and alarm

function on start up.

10. Inspect the door cylinder condition. Make sure bolts are secure.

11. Inspect the door latch. Check general condition, welds and structure. Inspect the hinge pins for wear.

12. Inspect the door of the baler. Check general condition, welds and structure. Inspect the hinge pins for wear.

13. Lock out the baler power disconnect, open the baler door and clean the wire tie slots in the front of the platen.

14. Clean the wire guides or more often as needed.

15. Check the clean out tool, this may be required more often for high usage situations.

16. Inspect the platen wiper condition and make sure it pivots freely.

17. Inspect the condition of the dogs. The dogs should pivot freely.

18. Check all nuts and bolts. Make sure all are tight and secure.

19. Walk around baler and inspect overall condition of equipment, including decals and structural. Make sure

overall baler is clean and free of debris.

20. Check to see that all access covers are secured in place.

After the first week of use, check the tightness of all the wires and monthly thereafter. This check should be done

by a qualified electrician.

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MONTHLY CARE REQUIREMENTS

1. Disconnect and lock out power to the baler. Check the tightness of all wires.

This check should be done by a qualified electrician.

2. Change the oil filter and breather filter after every 3 months or every 500 hours of operation.

��SEMIANNUAL CARE REQUIREMENTS

1. The motor is equipped with double shielded ball bearings having sufficient grease to last indefinitely

under normal service. Where motor is used constantly is dirty, wet, or corrosive atmospheres, add one

quarter ounce of grease per bearing every three months. Use a good quality rust inhibited polyuria based

grease, such as Chevron SRI.

2. Check the wear liner. Liners showing excessive wear should be replaced.

3. Inspect the shear edge. Remove the bolts and rotate to a clean edge if necessary. See the section entitled

ADJUSTMENTS.

4. Check the platen to shear edge clearance. Make adjustments if necessary. Check the nylatron wear pads

which the platen rides upon. See the Platen to Cutting Edge Clearance Adjustment instructions in the section

entitled ADJUSTMENTS.

5. Check the alignment of the wire guide slots in the platen with the wire guide slots in the baler floor. See the

section entitled ADJUSTMENTS. Inspect the condition of the side bearings.

6. A qualified service technician shall check and record pressure settings of the pressure switch, pump

compensator and relief valve.

7. Check motor to pump coupler to ensure it is not separated.

��YEARLY CARE REQUIREMENTS

1. A qualified electrician or service technician must check all electrical connections and check motor resistance.

Recording successive readings helps to prevent future failure.

1. Have an oil sample tested yearly and compare the result to the oil manufacturer’s specifications. If oil

does not meet specifications, replace. 105 gallon of oil as recommended in the Oil Selection Table on

page 29 is required to fill the reservoir.

SERVICE KITS

1. EX63 6 Month Service Kit: (A-1117)

(1) Breather Filter

(1) Oil Filter element

(12) Floor Shims

(2) Side Shims

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10 �� TROUBLESHOOTING AND SERVICE

Troubles sometimes are caused by simple "faults" that can be easily corrected without the help of a service

technician by first checking a few basic remedies.

Before you call an authorized EXCEL Manufacturing service representative, look below for the type of trouble you

are experiencing. Then perform the check and adjustments listed for the trouble.

If your baling equipment is still in warranty, these checks and adjustments could save you time and the cost of an

unneeded visit from a service representative. They also could save you the cost of a diagnosis not covered by your

warranty. (Refer to the warranty on the inside of the back cover to verify what is covered.)

If your baling equipment is out of warranty, these checks and adjustments could save you the cost of an unneeded

diagnosis.

For your nearest authorized EXCEL Manufacturing service representative, phone 1-800-475-

8812. Please have baler model and serial number ready before calling.

Electrical trouble shooting is to be performed by qualified electricians only.

TROUBLE POSSIBLE PROBLEM SOLUTION

Material jams under cutting edge. Cutting edge to platen tolerance exceeds

1/16".

See Cutting Edge Adjustment.

Cutting edge is not cutting. Edge is dull. Remove or replace cutting edge and rotate as

needed.

Wire slots do not line up. Side clearance adjustment. Add side shims.

The platen is in extended position

and will not return.

Rear limit switch. Foreign object holding Rear limit switch arm

open.

Pressures out of adjustment. Check pressure settings.

Bale tie position is not correct. Bale Tie Limit Switch out of adjustment. See Limit Switch Adjustments.

Motor runs hot. Blocked ventilation. Clean external and internal ventilation

systems.

High ambient temperature of over 105

degrees F.

Provide outside sources of cooler air or reduce

number of cycles per hour.

Motor does not run. Emergency Stop button depressed. Twist to release.

Key Switch in OFF position.

Disconnect in OFF position.

Blown fuse. If blown, replace.

Blown Control Voltage fuse. Replace.

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Motor does not run. (cont.) Thermal overload tripped. Press Reset button.

Main switch open. Close switch.

Motor won't start or makes growling

noise.

Very low voltage. Check power source.

Check motor nameplate.

Single Phased. Check power source. Must have all three

phases.

Open motor leads. Check continuity. Clean and tighten.

Rotor or bearings locked. Check shaft for freeness of rotation.

Starter coil burned out. Replace starter coil.

Thermal overload relays tripped or

tripping.

Incoming leads to incorrect terminals. Correct lead terminal locations.

Low voltage at motor terminals. Improve power supply and/or increase line

size.

Single Phased. Check power source. Must have all three

phases.

Loose wires from fuses to starter/ from

overload to motor.

Tighten wire connections.

Incorrect amp setting. Correct amp setting on overload.

Excessive vibration. Motor mounting. Check alignment between motor and pump.

Be sure motor mounting is tight and solid.

Pump. Disconnect pump from coupling and restart

motor. If vibration stops, the unbalance is in

the pump. Replace the pump.

Coupling. Remove coupling and restart motor. If the

vibration stops, the unbalance is in the

coupling. Replace the coupling spider.

Motor. If the unbalance does not stop after checking

the other possibilities above, the unbalance is

in the motor. Check the bearings.

Motor runs noisy. Bad bearings. Disconnect from pump coupling and check. If

noise does not stop, replace bearings.

Bad pump or coupler. Disconnect from coupling and check.

Pump makes noise. Low oil level. Add oil.

Restricted intake pipe. Flush the system. Clean intake pipe.

Defective bearing. Replace pump.

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Motor and pump run but baler does

not run.

Low oil level. Add oil.

Incorrect pump and motor rotation. See Start Up and Testing section for checking

motor rotation.

Key sheared on pump or motor shaft. Replace key and any damaged parts.

Pump coupler separated or bad Replace couplers

Noise like stones in the pump -

usually intermittent.

Air leak in suction system. Replace O-ring on suction end of pump.

Check all connections for possible leaks.

Motor continues to run and fails to

return platen.

Front Limit Switch out of adjustment. See Limit Switch Adjustments.

Relief Valve out of adjustment. See Relief Valve Adjustments.

Baler continues to cycle with empty

chamber.

Photo Eye and/or Photo Eye Reflector

dirty.

Clean Photo Eye and/or Photo Eye Reflector.

Photo Eye and/or Photo Eye Reflector

out of adjustment.

See Photo Eye Adjustments.

Motor runs but the platen does not

move.

Door not opened or closed completely. Open door to activate door safety switch or

close door and latch completely to activate

door safety switch.

Wires do not feed easy Not in tie position. Move main ram to tie position.

Wire slots restricted. Use clean out tool to clean slots.

Wire guides worn or bent Replace wire guides

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11 �� ADJUSTMENTS

Adjustments are to be performed by authorized service technicians only.

��ROTATING CUTTING EDGE

The shear blade is designed to make use of four cutting edges. Follow these instructions to remove the shear blade

and revolve it to a fresh cutting edge.

1. Fully retract the platen.

2. Lockout the power to the baler.

3. Loosen the bolts which secure the shear blade.

4. Remove the burrs on the cutting edge if necessary, so it seats properly.

5. Turn the blade to a fresh cutting edge and secure with the bolts. Use only P-1037 bolts. Add thread locker

to each bolt. Torque the bolts to 212 foot pounds.

��PLATEN TO CUTTING EDGE CLEARANCE ADJUSTMENT

Follow the Rotating Cutting Edge adjustment instructions above before doing this procedure.

1/16” plus or minus 1/32” is the recommended distance from the top of the platen to the cutting edge. An excessive

gap will hinder the cutting performance, and cause debris to jam between the platen and the top of the bale chamber.

Do not use more than ¼” shim material thickness. If the tolerance cannot be held, it may be necessary to replace the

nylatron wear pads.

The top of the platen must be free from debris. Observe Lock

Out/Tag Out procedures to clean.

Follow these instructions for setting the gap distance.

1. Place the SYSTEM key switch in the HAND position.

2. Depress the FORWARD button until the platen’s front edge is under the cutting edge.

3. Turn the SYSTEM key switch to OFF and Lock Out the power supply.

4. Remove the access panel to the back of the baler.

5. Remove the bolts at the bottom of the platen as shown in Diagram M.

6. From the front of the baler, use two chisels to wedge the platen upwards against the cutting edge by driving

the chisels under the front of the platen.

7. Pull the two glide retainers back and off the platen. Remove the nylatron wear pads from the retainers. It

may be necessary to tap retainers on floor to break nylatron loose.

8. Place the appropriate amount of shim material between the glide retainer and nylatron wear pad as shown in

Diagram M.

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Diagram M. Placement of Shim Material Between Platen and Nylatron.

9. Reassemble the parts and slide into position under the platen.

10. Replace the bolts and tighten securely.

11. Check platen side clearance. Add shims to the side as needed to align wire slots in platen to wire slots in

floor.

12. Reactivate the power supply.

13. Reverse the platen.

14. Run the platen forward. Stop the front of the platen under the cutting edge once more.

15. Check the distance from the top of the platen to the cutting edge. It should be 1/16” plus or minus 1/32”.

Never run the platen into the cutting edge. Extreme caution must be used while performing this

adjustment

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��LIMIT SWITCH ADJUSTMENTS

Tools Required:

½” Wrench

Before proceeding, make sure that the six inch long limit switch cam is set flush with the left end of the slide that it

is mounted on. Also check to see that the limit switch arms are at right angles (90 degrees) to the switch bodies.

Adjustment of the switches is made by loosening the nuts which hold the limit switch mounting angles to the

aluminum housing. When retightening, do not over tighten these nuts, or the aluminum housing will be distorted.

NOTE: The tie-off switch has a special one-way action and is not interchangeable with the front, rear or short

stroke limit switches.

Refer to Diagram N to make these adjustments.

Diagram N. Limit Switch Adjustment Diagram for standard baler.

Foam Baler Limit Rail Settings:

39 1/2” changes to 89"

47 1/4” changes to 99 3/4”

69 3/4” changes to 122 1/4”

��REAR LIMIT

The rear limit switch is 1/4” from the left end of the aluminum housing to the edge of the limit switch mounting

angle. This should stop the ram 1 ½” to 2” from the end of its stroke.

This may be checked by temporarily removing the limit switch. Allow the cylinder to “Bottom Out” and take a

measurement to be compared with a measurement taken after the switch is adjusted. The difference should be 1 ½”

to 2”.

For the Foam Baler the measurements change as follows for the limit rail; 39 ½” changes to 67 ½”; 47 ¼” changes

to 99 3/4”; and 69 ¾” changes to 121 1/4”.

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��TIE-OFF LIMIT

Adjustment of this switch will affect the size of the finished bale. The 39 ½” measurement shown in the diagram

will produce approximately a 48” bale. It is not possible to tie off bales larger than 48”. If a smaller bale is desired,

move the switch to the right. This will increase the 39 ½” measurement, which should not exceed 45 ½”. Any

adjustment made to the tie off limit should also be equally made to the short stroke limit.

SHORT STROKE LIMIT

To maintain 8” of chamber penetration, the short stroke limit switch is 47 ¼” from the left end of the aluminum

housing.

��FRONT LIMIT

There should be 69 ¾” from the left end of the aluminum housing to the edge of the limit switch mounting angle.

This should stop the ram 1” to 1 ½” from the end of its stroke.

This may be checked by switching the selector switch to HAND and extending the ram completely. Measure the

distance from the front face of the ram to the baler door and compare this to the same measurement taken with the

machine cycling on AUTO. The difference should be 1” to 1 ½”

��HYDRAULIC ADJUSTMENTS

Adjustments to the hydraulic system must be carried out by authorized service technicians.

Pressure settings specified by the factory must never be exceeded. Exceeding these pressures will

void the warranty, cause permanent damage to the baler, and may result in personal injury.

FACTORY SETTINGS

Pressure Switch – 2800 PSI

Pump Compensator – 3000 PSI

Relief Valve – 3200 PSI

Regen Pressure – 600 PSI

��PRESSURE SWITCH ADJUSTMENT

The pressure switch is factory set at 2800 PSI and in not adjustable. This switch controls the maximum baling

pressure.

��PUMP COMPENSATOR AND RELIEF VALVE ADJUSTMENT

The pump compensator is set to reduce the pump flow to zero at 3000 PSI. It may be necessary to adjust the

compensator if the pump is rebuilt or replaced. A set screw and lock nut are located on the pump compensator

control for this purpose. The relief valve is provided on this system as a backup pressure control should the pump

compensator fail.

To set compensator and relief valve pressures, follow these instructions.

1. Place the selector switch on HAND and extend the ram completely.

2. Have an assistant continue to hold the FORWARD button to sustain maximum pressure while you turn the

compensator bolt clockwise to increase pressure to 3200 PSI on the pressure gauge. See Diagram O on the

next page for correct location of compensator adjusting bolt.

If this pressure cannot be attained, then the relief valve is bypassing.

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3. Turn the relief valve adjustment clockwise 1 or 2 turns and then continue adjusting the compensator screw to

reach 3200 PSI on the pressure gauge.

4. Turn the relief valve adjustment counterclockwise until the pressure on the gauge drops just slightly below

3200 PSI. Lock relief valve jam nut.

5. Turn the compensator adjustment counter-clockwise until pressure drops to 3000 PSI. Tighten the

compensator lock nut.

Diagram O. Pump Compensator

��PHOTO EYE ADJUSTMENT

Perform this adjustment with the baler in hand position and photo eye off.

1. Fully retract the platen

Observe Lock Out/Tag Out Procedure when making Photo Eye adjustments.

2 Remove the guard covering the Photo Eye.

��HORIZONTAL ADJUSTMENT

3 Loosen the screws on the bottom of the mounting bracket. Slightly move the eye left and right to sweep the

beam across the reflector. As the beam falls off each edge of the reflector, the red indicator light on top of

the Photo Eye lights up. Retighten the screws so that the beam is held steady halfway between each indicated

edge.

��VERTICAL ADJUSTMENT

4 Loosen the screws on the side of the mounting bracket and adjust the beam as done in the previous

procedure, sweeping the beam up and down.

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PAGE BLANK

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12�� DETAILED PART IDENTIFICATION

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MAIN BALER

NO. PART NO. QTY DESCRIPTION

1 P-1035 3 Nylock Nut

2 M-1050 3 Dog

M-5689 3 Dog – Foam Baler

3 P-1029 3 Bolt – Dog

4 P-1037 5 Bolt – Shear Bar -- Torque to 212 ft. lbs.

5 P-1038 5 Flat Washer – Shear Bar

6 M-1056 1 Shear Edge

M-6007 VAR Shim - Shear Edge EX62/63

7 A-1806 1 Scraper

8 P-1394 2 Shoulder Screw – Scraper

9 P-1024 2 Flat Washer – Rear Cover

10 P-1025 2 Lock Washer – Rear Cover

11 P-1016 2 Bolt – Rear Cover

12 A-1475 1 Rear Cover

13 M-2978 1 Door Hinge Pin

14 A-1148 1 Hinge Limit Cam

15 P-1128 1 Flat Washer – Hinge Pin

16 P-1035 3 Nylock Nut –Door

17 P-1031 3 Bolt – Door

18 A-2201 1 Door (service includes 2 ea – M-3808)

19 A-1797 1 Door Latch

20 A-1147 1 Latch Limit Cam

21 M-3009 1 Latch Pin

22 M-3046 1 Extended Latch Pin

23 A-1008 6 Wire Guide

24 P-1016 12 Bolt – Wire Guide - Up to Serial Number

P-1023 12 Nylock Nut

25 P-1025 12 Lock Washer – Wire Guide

26 P-1024 12 Flat Washer – Wire Guide

27 HP-1593 1 Door Cylinder

28 P-1043 2 Nylock Nut – Door Cylinder

29 P-1042 2 Bolt – Door Cylinder

30 EP-1502 2 Proximity Switch

31 A-1014 1 Clean Out Tool

32 P-1052 10 Grease Zerk

44 | P a g e

33 M-1614 2 Wear Plate

M-5704 1 Wear Plate EX63 Foam Baler

34 A-1721 1 Chassis Weldment- LH

A-1693 1 Chassis Weldment- RH

A-2605 1 Chassis Weldment- LH Foam Baler

A-2606 1 Chassis Weldment- RH Foam Baler

35 EM-1015 1 Photo Eye Cover - see page 66 for exploded view.

36 EM-1013 1 Reflector Mounting Bracket

37 P-1555 4 Set Screw

45 | P a g e

PAGE BLANK

46 | P a g e

�� PLATEN

47 | P a g e

��PLATEN


1 M-2046 VAR Side Platen Shim

2 A-1406 1 Platen

A-2601 1 Platen Foam Baler

3 M-2025 6 Bearing Rear/Bottom/Side

M-2025 8 Bearing Rear/Bottom/Side (Foam Baler)

4 M-2023 2 Lower Bearing

5 M-2039 VAR Shim – Lower Bearing

6 S-1010 2 Glide Retainer

7 P-1033 4 Lock Washer – Glide Retainer

8 P-1672 4 Flat Washer – Glide Retainer

9 M-2034 2 Top Side Bearing

10 P-1029 4 Bolt – Glide Retainer

11 M-5852 VAR Shim - Rear Platen

12 A-2924 2 Horizontal Stiffener

48 | P a g e

�� CYLINDERS – HOSES

49 | P a g e

�� CYLINDERS – HOSES


1 HP-1906-00 2 Hose

2 HP-1266 2 O-Ring

3 HM-1132 1 Splitter Manifold

4 P-1025 2 Lock Washer – Splitter Manifold

5 P-1016 2 Bolt– Splitter Manifold

6 HP-1024 4 Adapter


8 M-1054 4 Cylinder Pin

9 P-1031 4 Bolt

10 HP-1253 2 Hydraulic Cylinder

HP-2151 ea Packing Kit for HP-1253

11 HP-1040 4 O-Ring

12 HP-1034 4 Hose – Pressure

13 HP-1263 4 O-Ring

14 HP-1039 4 O-Ring

15 HP-1059 4 Fitting – Zerk

Please include model and serial number information when ordering parts

50 | P a g e

�� CYLINDERS – HOSES – FOAM

51 | P a g e

�� CYLINDERS – HOSES – FOAM


1 HP-1906-00 2 Hose

2 HP-1266 2 O-Ring

3 HM-1132 1 Splitter Manifold

4 P-1025 2 Lock Washer

5 P-1016 2 Bolt

6 HP-1024 4 Adapter


8 M-1054 4 Cylinder Pin

9 P-1031 4 Bolt

10 HP-2491 2 CYL. 6B/4R/124S/ EX63F EX3160<

HP-2600 2 CYL. 6B/4.5R/124S-EX63F EX3170>

11 HP-1040 4 O-Ring

12 HP-1034 4 Hose – Pressure

13 HP-1263 4 O-Ring

14 HP-1039 4 O-Ring

15 HP-1059 4 Fitting - Zerk

Please include model and serial number information when ordering parts.

52 | P a g e

�� RESERVOIR - FILTER

53 | P a g e

�� RESERVOIR - FILTER


1 A-1636 1 Reservoir Weldment

2 A-1009 1 Reservoir Cover Assembly

3 P-1271 10 Bolt

4 P-1007 10 Flat Washer

5 HP-1922 1 Clamp 1" T-Bolt

6 HP-1912-01 1 Tank Hose Assembly

7 HP-1039 1 O-Ring

8 HP-1006 1 Oil Filter Housing

8A HP-2454 1 O-Ring F/Filter Housing / Cover

9 HP-1049 1 Oil Filter Replacement

10 HP-1891 1 Gasket – Filter ASM to Cover


12 P-1174 4 Bolt


14 HP-1128 1 Adapter

15 HP-1244 1 O-Ring

16 HP-1047 1 Hose Clamp

17 HP-1428 1 Plug

18 HP-1015 1 Breather Filter

19 HP-1906-00 2 Hose

20 HP-1908-00 1 Hose

21 Not Used

22 HP-1018 1 Clamp

23 HP-1594 1 Hose Suction

24 HP-1125 1 Split Flange Kit

25 HP-1248 1 O-Ring

26 HP-1014 1 Sight Gauge

27 HP-1016 1 Drain Plug

28 HP-1052 1 Tank Heater

28A HP-1050 20 Gasket

29 HP-1907-00 1 Hose-EX63 Pump To Manifold

30 HP-1917-01 1 Hose – Manifold To Pump Compensator

HP-1918-00 2 Hose – Manifold To Door Cylinder

54 | P a g e

�� PUMP -MOTOR

55 | P a g e

�� PUMP - MOTOR


1 P-1028 8 Bolt


3 P-1672 4 Flat Washer

4 HP-1000 1 Hydraulic Pump* – up to S/N EX3221

HP-2062 1 Pump Compensator*

HP-2426 1 Gasket-Compensator To Pump*

HP-2626 1 Hydraulic Pump** – EX3222 and after

HP-2628 1 Pump Compensator ** F/HP-2626

5 P-1256 1 Keystock

6 HP-1004 1 Pump to Motor Adapter

HP-2513 1 Gasket- Base Plat to Adapter: HP-1000 & HP-1893

7 HP-1001 1 Pump Coupler - Torque to 135 in lbs.

8 HP-1003 1 Coupler Insert

9 HP-1002 1 Motor Coupler - Torque to 135 in lbs.

10 M-4807 1 Keyway

11 EP-1000 1 Motor 230/460V

EP-1531 1 Motor 380/415V

HP-1520 1 Motor 575V


13 HP-1243 1 O-Ring


15 HP-1040 1 O-Ring

16 HP-1030 1 Hose Swivel


18 HP-1262 1 O-Ring

19 P-1036 2 Bolt


21 HP-1912 1 Hose – Case Drain

22 HP-1917-00 1 Hose Pump Control

23 HP-1907-01 1 Hose Pump Pressure Control

56 | P a g e

�� VALVES - FITTINGS

57 | P a g e

�� VALVES - FITTINGS


1 HP-1848 2 Adapter

2 HP-1558 2 Adapter

3 HP-1873 2 Adapter

4 HP-1585 1 Adapter

5 HP-1920 1 Adapter

6 HP-1587 1 Adapter

7 HP-1022 1 Adapter

8 HP-2333 1 Manifold Assy. w/ Valves F/EX63/66/77

HP-2472 1 Manifold Block w/Plugs F/EX63-77

9 HP-2134 1 Counter Balance Valve

HP-1367 O-Ring Kit

10 HP-1767 1 Counter Balance Valve

HP-1368 O-Ring Kit

11 HP-2142 1 Check Valve

HP-1367 O-Ring Kit

12 HP-1456 1 Relief Valve

HP-1368 O-Ring Kit

13 HP-2136 1 Sterling Valve

HP-2009 O-Ring Kit

14 HP-1231 1 Pressure Switch

15 HP-2007 1 Orifice Disk

16 P-1589 3 Bolt

17 HP-1863 2 Directional Valve (VICKERS) Through Serial # EX3074

HP-2010 O-Ring Kit – Directional Control (VICKERS)

OR HP-2335 2 Directional Valve (NACHI) Beginning with Serial # EX3075

HP-2337 O-Ring Kit – Directional Control (NACHI)

18 P-1145 12 Bolts


20 HP-1039 3 O-Ring

21 HP-1266 3 O-Ring

22 HP-1261 2 O-Ring

23 HP-1262 1 O-Ring

24 HP-1264 2 O-Ring

58 | P a g e

�� CONTROLS -To Late 2008

59 | P a g e

�� CONTROLS -To Late 2008

REF. NO. PART NO. DESCRIPTION QTY.

1 P-1048 Lock Washer 4

2 P-1226 Bolt 4

3 EP-1407 Bushing 1

4 EP-1208 Gasket 1

5 EP-1243 Cord Grip 1

6 EP-1446 Cord Grip 1

7 EP-1248 Connector Gasket 1

8 EP-1119 Bushing 1

9 EP-1863 Control Box 1

10 EP-1077 Contact Block 11

11 EP-1233 Switch 3 Position 1

EP-1532 Key F/ EP-1233 1

12 EP-1068 2 Position Selector Switch 4

EP-1452 Knob, BLK F/ 2 Position Switch 1

13 EP-1066 Green Push Button 3

14 EP-1065 Yellow Push Button 2

15 P-1730 Overlay – RH 1

P-1831 Overlay – LH 1

D-1114 Overlay – 2 ¼” switch spacing (built 2004 and up) 1

16 EP-1064 Emergency Stop Push Button 1

EP-1448 Cap- Red E-STOP 1

17 EP-1076 Contact Block 1

18 EP-1204 Lighted 2 Position Switch 1

19 EP-1849 Nut 1

20 EP-1678 Nut 1

Include model number and serial number information when ordering parts.

60 | P a g e

�� CONTROLS Late 2008- Current

61 | P a g e

�� CONTROLS Late 2008- Current

PART NO. QTY DESCRIPTION


2 P-1226 4 Bolt

3 EP-1407 1 Bushing

4 EP-1208 1 Gasket

5 EP-1243 1 Cord Grip


7 EP-1248 1 Gasket

8 EP-1119 1 Bushing

9 EP-1863 1 Control Box

10 EP-2322 11 Contact Block NO

11 EP-2318 1 3 Position Keyed Selector Switch

EP-2298 1 Replacement Key

12 EP-2317 4 2 Position Selector Switch

13 EP-2254 3 Green Push Button

14 EP-2257 2 Yellow Push Button

15 D-1114 1 Overlay

16 EP-2259 1 Emergency Stop Push Button

17 EP-2321 2 Contact Block NC

18 EP-2323 11 Latch Mounting

19 EP-2326 1 Lighted 2 Position Switch

20 EP-1849 1 Nut

21 EP-1678 1 Nut

Include model number and serial number information when ordering parts.

62 | P a g e

�� CONTROL OVERLAY

63 | P a g e

PAGE BLANK

64 | P a g e

�� LIMIT SWITCH RAIL

65 | P a g e

�� LIMIT SWITCH RAIL


1 EM-1010 2 Slide Nut

EM-1627 1 Slide Nut – Foam Baler


3 P-1003 2 Bolt

4 EM-1008 1 Cam

5 EP-1501 1 Slide

EP-2294 1 Slide – Foam Baler

6 P-1271 2 Bolt

7 EM-1009 1 Driver

EM-1626 1 Driver – Foam Baler

8 P-1045 8 Bolt


10 EP-1021 4 Limit Switch Arm

11 EP-1019 2 Limit Switch


13 P-1012 2 Bolt

14 P-1011 2 Bolt

15 EM-1006 2 Top Rail Clamp

16 EM-1007 2 Bottom Rail Clamp

17 EM-1005 4 Limit Switch Bracket


19 P-1631 10 Bolt

20 EP-1024 1 Bell Box Cover


22 EM-1069 1 Bell Box w/ Mounting Holes & 1 Side Hole

23 EP-1500 1 Mount Rail

EP-2292 1 Mount Rail – Foam Baler

24 EP-1020 2 Limit Switch


26 EP-1208 1 Gasket

27 EP-1849 1 Locking Nut Steel

28 EP-1407 1 Insulated Bushing

66 | P a g e

�� PHOTO EYE -LOWER

67 | P a g e

�� PHOTO EYE - LOWER


1 EM-1013 1 Reflector Mounting Bracket

2 EP-1062 1 Reflector

3 P-1004 2 Bolt


5 EP-1058 1 Photo Eye Head

6 EP-1157 1 Photo Eye Base

7 EP-1159 1 Relay


9 EP-1411 7 Cord

10 EP-1063 1 Photo Eye Mounting Bracket

11 P-1101 4 Bolt

12 EM-1015 1 Photo Eye Cover

13 EP-1583 1 Cable Clamp

68 | P a g e

�� ELECTRICAL ENCLOSURE

69 | P a g e

�� ELECTRICAL ENCLOSURE


1 EM-1067 1 EX 63 MAIN ELECT BOX

2 EM-1068 1 PANEL, EX63

3 EP-1144 1 DISCONNECT KIT (200V-230)

EP-1327 1 HANDLE DISCNCT 230V

EP-1004 1 DISCONNECT KIT (415V-575V)

EP-1085 1 HANDLE,DISCNCT 460V

4 EP-1443 3 FUSE 100A JTD (200V)

EP-1827 3 FUSE 90A JTD (208V)

EP-1146 3 FUSE 80A JTD (230V)

EP-1149 3 FUSE 50A JTD (415/ 460V)

EP-1489 3 FUSE 40A JTD (575)

5 EP-2277 1 POWER SUPPLY

6 EP-1439 1 PLC MICROLOGIX

7 EP-1145 1 TRANSFORMER

EP-2226 1 TRANSFORMER ( 208/415/575V

8 EP-1316 1 FUSE BLOCK (415V ONLY)

9 EP-1467 2 FUSE 4A KLDR (200/208V)

EP-1666 2 FUSE 3.5A KLDR (230V)

EP-1631 2 FUSE 6.25A KLDR (415V)

EP-1313 2 FUSE 5.6A KLDR (460V)

EP-1868 2 FUSE 4.5A KLDR (575V)

10 EP-1751 1 FUSE HOLDER/ SLO-BLO (415V ONLY)

11 EP-2036 1 FUSE 2.8A SLO-BLO

12 EP-1936 1 CONTACTOR (200/208V)

EP-1935 1 CONTACTOR (230V)

EP-1932 1 CONTACTOR (415-575V)

13 EP-1948 1 OVERLOAD (200-230V)

EP-2028 1 OVERLOAD (415-575V)

14 EP-1404 61" PANDUIT DUCT

15 EP-1403 61" PANDUIT COVER

16 EP-1397 33" DIN RAIL, STEEL

17 EP-1011 6" MINIDIN RAIL

18 EP-1380 2 END ANCHOR

19 EP-1391 1 END SECTION

20 EP-1688 2 TERMINAL BLOCK GREEN/YELLOW

21 EP-1383 3 TERMINAL BLOCK BLACK

22 EP-1381 4 TERMINAL BLOCK WHITE

23 EP-1387 7 TERMINAL BLOCK RED

24 EP-1385 3 TERMINAL BLOCK GREY

70 | P a g e

25 EP-1382 20 TERMINAL BLOCK BLUE

26 EP-1389 12 TERMINAL BLOCK YELLOW

27 EP-1790 2 TERMINAL CIRCUIT SEPARATOR

28 EM-1263 1 TERMINAL JUMPER BAR 2 HOLE




32 EP-1835 14 TERMINAL JUMPER SCREW/ WASHER

33 EP-1806 1 VERTICAL MARKER 1-10





38 EP-1372 1 LUG, GROUND 1/0

39 EP-2018 1 LIGHT, STROBE RED 120V

39A EP-2145 REPLACEMENT BULB – EP-2018 & 2019

40 EP-2019 1 LIGHT, STROBE BLUE 120V

41 EP-1249 1 HORN 120V

42 EP-1422 1 BUSHING, SNAP

43 EP-2531 1 HOUR METER 120V

44 EP-2532 1 GASKET, HOUR METER

45 EP-1208 4 GASKET

46 EP-1849 3 LOCK NUT, STEEL

47 EP-1407 3 BUSHING

48 EP-1244 1 CORD GRIP

49 EP-1329 1 CORD GRIP

50 EP-1044 1 CONDUIT CONNECTOR

51 EP-1209 1 GASKET

52 EP-1040 1 CONDUIT CONNETOR

53 EP-1045 80" CONDUIT/ POLYFLEX

54 EP-1210 30" CONDUIT LIQUATITE

55 P-1395 2 4-4OUNC X 1/4" RSMS

56 P-1585 2 INTERLOCK WASHER

57 P-1785 2 FLAT WASHER

58 P-1048 38 INTERLOCK WASHER

59 P-1140 6 FLAT WASHER

60 P-1226 32 10-24 X 1/4" RSMS

61 P-1138 6 10-24 X 1/2" RSMS

62 P-1001 1 1/4-20 X 1/2"

63 EP-1216 4 HOLE SEAL KIT (W/O CONVEYOR)

64 D-1020 3 DECAL REPLACEMENT FUSE

65 D-1044 1 DECAL CERTIFIED U/L

66 P-1081 1 PADLOCK

71 | P a g e

67 D-1015 1 DECAL BALE TIE LIGHT

68 D-1024 1 DECAL LOCKOUT/TAGOUT

69 D-1021 1 DECAL,VOLTAGE RATING

70 D-1082 1 DECAL 200V

D-1040 1 DECAL 208V

D-1002 1 DECAL 230V

D-1085 1 DECAL 415V

D-1003 1 DECAL 460V

D-1038 1 DECAL 575V

71 EM-1419 1 EX63 PRESSURE SWITCH ASSY

72 EP-1248 1 GASKET

73 EP-1678 1 LOCK NUT, STEEL

74 EP-1119 1 BUSHING

75 EP-1446 1 CORD GRIP LEFT HAND)

75 EP-1409 1 CORD GRIP (RIGHT HAND)

OPTIONAL COMPONENTS

AA EM-1484 1 EX63 CONV COMP (CONN/GRIPS)

BB EM-1425 1 CONV COMP (200-208V 2HP)

EM-1426 1 CONV COMP (230V 2HP)




EM-1430 1 CONV COMP (200-208V 3HP)






EM-1436 1 CONV COMP (208-230V 5HP)




EM-1440 1 CONV COMP (200-208V 7.5HP)

EM-1441 1 CONV COMP (230V 7.5HP)

EM-1442 1 CONV COMP (415-460V 7.5HP)

EM-1443 1 CONV COMP (575V 7.5HP)

72 | P a g e

�� FOAM BALER – DIAGRAM

PART NO. QTY DESCRIPTION

HP-2491 2 CYLINDER EX63F S/N EX3160<

HP-2600 2 CYLINDER EX63F SN EX3170>

A-2606 1 CHASSIS- FOAM

A-2630 3 DOG- COVER

A-2728 1 FOAM HOPPER

S-1442 1 LIMIT SWITCH ASSY

M-5689 3 DOG- FOAM BALER

A-2600 1 PLATEN- FOAM BALER

73 | P a g e

PAGE BLANK

74 | P a g e

�� DECALS

75 | P a g e

�� DECALS


1 D-1009 1 MOTOR ROTATION ARROW

2 D-1001 1 SMALL EXCEL LOGO

3 D-1008 1 WARNING- ACCESS PANEL

4 D-1015 1 BALE TIE LIGHT

5 D-1024 2 LOCK OUT/ TAG OUT

6 D-1082 1 200V

D-1040 1 208V

D-1002 1 230V

D-1083 1 230V

D-1085 1 415V

D-1003 1 460V

D-1038 1 575V

7 D-1029 2 PERIODIC MAINTENANCE

8 D-1000 2 LARGE EXCEL LOGO

9 D-1007 1 MODEL #, SERIAL # INFORMATION

10 D-1016 2 MADE IN USA FLAGS

11 D-1020 1 REPLACEMENT FUSE (INSIDE ELEC BOX)

D-1121 1 DECAL, ANSI INSTALLATION (Inside Electrical Box)

12 D-1021 1 VOLTAGE RATING (INSIDE ELEC BOX)

13 D-1044 1 CUL LABEL

14 D-1019 2 DANGER- MACHINE STARTS AUTOMATICALLY

15 D-1028 3 STAY OFF BALLER

16 D-1041 2 SAFETY GLASSES REQUIRED

17 D-1004 2 DANGER- NEVER ENTER OR REACH INTO…

18 D-1112 2 DANGER- BODY CUTTING HAZZARD

19 D-1033 1 ATTENTION- BALE EJECTION

20 D-1017 2 NO SKID SURFACE

21 D-1046 1 ATTENTION- MACHINE OPERATION

22 D-1104 1 CAUTION- LATCH MUST BE SECURED

23 D-1027 1 REVERSE COMPRESSION RAM

24 D-1023 2 WARNING- STAND CLEAR WHEN BALE IS EJECTED

25 D-1026 2 CAUTION- DOOR UNDER PRESSURE

26 D-1031 1 OIL LEVEL

29 D-1006 3 DECAL- CUTTING HAND HAZARD

30 D-1111 1 SERVICE LABEL

31 D-1037 1 PATENT PENDING

32 D-1035 1 SENSITIVE ELECTRONICS

76 | P a g e

EX63 PREVENTATIVE MAINTENANCE CHECK LIST

WEEKLY PROCEDURES

& Check Baler Disconnect ڤ .1

Padlock

Check Oil Level ڤ .2

Adequate ڤ

Low ڤ

Lubricate Baler ڤ .3

Side Wear Pads ڤ

Latch Hinge ڤ

Door Hinge ڤ

& Inspect for Oil Leaks ڤ .4

Condition

Hoses ڤ

Pump ڤ

Valves ڤ

Cylinders ڤ

Reservoir ڤ

Inspect Cylinder Pins, Pin ڤ .5

Retainer, Bolts

Remove Rear Cover ڤ .6

Clean Out Behind Platen ڤ

Clean Limit Switch Rail ڤ

Check Limit Switches ڤ .7

Front ڤ

Rear ڤ

Tie Off ڤ

Short Stroke ڤ

Test Controls ڤ .8

System Hand-Off-Auto ڤ

Emergency Stop ڤ

Forward ڤ

Reverse ڤ

Short Stroke On-Off ڤ

Baler Photo Eye On-Off ڤ

Conveyor On-Off ڤ

Conveyor On Override ڤ

Hopper Over Fill Limit ڤ

Test Photo Eye ڤ .9

Lower ڤ

Upper ڤ

Test Bale Tie Light ڤ .10

Test Door Safety Interlock ڤ .11

Open ڤ

Closed ڤ

Inspect Turnbuckle ڤ .12

Inspect Door Latch & Pins ڤ .13

.Inspect Door & Hinge Pins 15 ڤ .14

Clean Platen Wire Tie Slots ڤ

Clean Wire Guides ڤ .16

Check Clean Out Tool ڤ .17

Inspect Platen Wiper ڤ .18

Inspect Dogs ڤ .19

Check All Nuts & Bolts ڤ .20

Inspect Overall Condition ڤ .21

Clean, Free of Debris ڤ

Decals ڤ

Structural ڤ

,Access Panels, Covers ڤ .22

Guards in Place

Check Platen to Shear Edge ڤ .8

Clearance

OK ڤ

Shims Required ڤ

Adjustment Made ڤ

Check Platen Bottom ڤ .9

Bearings

OK ڤ

Replaced ڤ

Check Platen Wire Guide ڤ .10

Alignment & Side Bearings

OK ڤ

Shims Required ڤ

Adjustment Made ڤ

Check Pressure Settings ڤ .11

Pressure Switch ڤ

2800 PSI

Pump Compensator ڤ

3000 PSI

Relief Valve ڤ 3200 PSI

CUSTOMER NAME

ADDRESS

SERIAL NUMBER INSPECTION DATE

NOTES

SERVICE PERSON CUSTOMER SIGNATURE

YEARLY PROCEDURES WEEKLY PROCEDURES ڤ .1

SEMIANNUAL ڤ .2

PROCEDURES Check Motor Resistance ڤ .3

Test Oil (Attach Report) ڤ .4

Passed ڤ

Replaced (Provide Oil ڤ

Information Below)

SEMIANNUAL PROCEDURES

WEEKLY PROCEDURES ڤ .1

Change Breather Filter ڤ .2

Change Oil Filter ڤ .3

Lubricate Motor ڤ .4

Inspect Electrical Connections ڤ .5

Check Wear Liner ڤ .6

Adequate ڤ

Replace ڤ

Inspect Shear Edge ڤ .7

Adequate ڤ

Rotated ڤ

77 | P a g e

EXCEL MANUFACTURING LIMITED WARRANTY

Warranty applicable in Continental United States only.

EXCEL Models EX77, HV 9 & HV 10, 2R63, 2R9, 2R10 Signature 100, 150 & Signature

200 balers and appropriate conveyor systems will carry a warranty of: 1 year (2080 hours

operation) parts and labor.

EXCEL Models EX62, EX63 & EX66 balers and appropriate conveyor systems will carry a

warranty of: 1 year on labor (2080 hours operation), 2 years on parts (4160 hours operation),

and 3 years on the chassis structure and the main and eject cylinders (6240 hours operation).

EXCEL retains final judgment on all warranty and service performed and determines the

validity of such claims.

When Equipment is purchased along with an EXCEL conveyor, the warranty applicable to

the equipment applies to the conveyor. Within the time periods prescribed by this Limited

Warranty, the Seller will replace or repair at its discretion any parts supplied by Seller.

During the prescribed period Seller will only pay for standard ground freight for replacement

parts within the continental United States. During the prescribed period Seller shall only pay

for warranted labor within the continental United States. Seller will have no obligations

under this warranty to make repairs or replacements necessitated in whole or in part by

accidents, abuse, or negligence. This warranty does not apply to scheduled maintenance of

Equipment or parts deteriorating from normal wear and tear. Buyer’s or user’s failure to use

EXCEL parts may void the warranty. The Equipment is only warranted for its intended use

as identified in the Owner’s Manual. Seller reserves the right to provide the labor necessary

to install parts during this warranty period. Seller may, at its sole discretion, elect to grant

adjustments in the field through an authorized representative. A new warranty period is not

established for replacement parts. Replacement parts are warranted for the remaining portion

of the original warranty. Service parts replaced after the warranty has expired are warranted

for a period of 30 days.

The warranties set forth above are in lieu of all other warranties, expressed or implied, which

are hereby disclaimed and excluded by the seller, including without limitation, any warranty

or merchantability or fitness for a particular purpose or use. The seller shall not be liable for

any loss or damage caused by delay in furnishing the equipment. Seller shall not be liable for

any environmental contamination to soil or property due to oil leaks or oils spills from the

equipment. The sole and exclusive remedies for breach of any and all warranties and the sole

remedies for the seller’s liability of any kind, including liability for negligence, shall be

limited to the remedies provided in the limited warranty. In no event shall the seller’s

liability of any kind include special, indirect, incidental, or consequential losses or damages,

even if the sells shall have been advised of the possibility of such potential loss or damage.

BUYER:________________________________________

78 | P a g e

Appendix A

COMMON COMPONENTS

ES-1011

ES-1012

SPECIFIC COMPONENTS

208/230v- ES-1010

460V- ES-1013

575V- ES-1016

415V CE VERSION

ES-1208

ES-1209

ES-1210

79 | P a g e

80 | P a g e

81 | P a g e

82 | P a g e

83 | P a g e

84 | P a g e

85 | P a g e

86 | P a g e

87 | P a g e

�� Hydraulic Schematics

88 | P a g e

NOTES

ex63revised 022112sr

Documents

excel baler

electrical requirements

employer requirements

installation instructions

main baler

semiannual care requirements

weekly care requirements

yearly care requirements