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PTR Vertical Baler User Manual

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1. TX Jx 330388 CONNECTION LINK 40 xT xX x 500113 EECTORCONNECTINGLINK460 j J l x 330025 SHACKLE 1 4 1 0 x X x x X j x EJECT HOOK ee Jj J j J x eee Se EJECT RECESSED T HOOK x xX X x EJECT SPROCKET HOOOK L Jj J j ee 500056 _ SIDEWHEELTURNBUCKLE8 x x x x X xX x 0 __ WHEEL TURNBUCKLE M NYLON GUIDE 1 2 X 2 X 36 LG ee C x NYLON GUIDE 1 2 X 2 X 42 LG 1 1 x jx x x NYLON GUIDE 1 2 X 2 X 23 LG C Jj J Sx NYLON GUIDE 3 8 X 2 X 42 LG Jj J j J x NYLON GUIDE 3 8 X 2 X 36 LG 1 1 xjx x x NYLON GUIDE 3 4 X 1 X 4 LG LX x J 1 NYLON GUIDE 3 4 X 1 X 23 LG x x x xx J NYLON GUIDE 3 4 X 1 X 24 LG NYLON GUIDE 3 4 X 1 X 33 LG x x x x j j J 500042 PowRUNT3HP 3A 3 4JX XJ XJ Xx x x j 500077 POWERUNIT 5H P G2oViPH x xj x x 1 1 1 1 1 1 50095 POWERUNT 10H P j x
2. 500986 UNIT 15 To To p l 1 50095 UNIT 20 1 S l T S T l1 lx x LV Low Voltage 208 240 HV High Voltage 460 480
3. _ Set Auto Man Switch at door open ____ Set Up Down Switch at Down Press Down Button ____ Ram Travels down Hold Down Button until Cylinder bottoms Continue to press down button until motor and pump stop Run unit up and down several times Note any unusual occurrences During down time travel lift gate up while continuing to hold the down button Ram and motor should stop Run Ram to Up position Ram and Pump should stop at the top Set Auto Man Switch at Auto Main door closed Press Start Button or Down Selector _ __ Ram lowers automatically reverses at bottom of stroke then rises and automatically stops at the top of the stroke unless equipped with interlock boxes ___ Check gate safety Start Machine and during down travel lift gate Ram should stop Check Push Pull Gate Up amp Down to check for gate movement WHITE SERVICE DEPT YELLOW INVOICE PINK CUSTOMER GOLDENROD QUOTE PTR Baler and Compactor 2207 E Ontario Street BALER Commactor 215 533 5100 Philadelphia PA 19134 Fax No 215 537 8536 Branch Office Locations Baltimore e Bayshore LI e Harrisburg PA e Paterson NJ Philadelphia PA MFG MOD NO SER NO ELECTRICAL Comp 1 Control Box A Fuse Clips tight 8 All term tight C Magnetic starter contacts for pitting amp wear D Breakers not sticking 2 All wire and cab
4. 4 9 j J Jj 1 500235 223048 X DX x 11110 602823 MOTOR 5 220 SINGLE PHASE x X X x 6020001 MOTOR 10H P 208 23 84 602002 MOTOR 15H P 208 230 463 0 60200 MOTOR 20H P 208 230 464 11 xX LV Low Voltage 208 240 HV High Voltage 460 480 EFFECTIVE 10 2006 1800 1800 2300 3400 3600 3400 5000 7230 7200 o o we 600175 j j 605200 STARTER 14 14 l l Lt S dof 03106 STARTER 40A j x H 603988 STARTER 22A X X X x XI x 1 60397 40 j x 60301 804 o 0 j 603109 J vERLOAb 200 0 0 XI x 500088 LEAFEJECTONCHAN BL534 j l xf 500645 LEAF EJECTONCHAINHDBL634 j j x 330387 LINKEJECTORCHAIN 40 Jx 320086 h ANCHORCHAN 0 0 X X X X xj x x 50040
5. Back of baler place ejector T Hooks on ram lugs Turn start switch to UP position press START button and hold Keeping clear of the ejecting bale Close bale chamber door Turn start switch to DOWN position press START button Open bale chamber door place a flat piece of cardboard on floor Close and latch bale chamber door BALER MODES There are three basic modes of operation a downstroke vertical baler will perform loading compression and ejection LOADING Material is evenly loaded into the baler chamber while the safety charging gate and ram are in the UP position The baler chamber door is closed and locked COMPRESSION With the safety gate down the ram pushes the material down into the bottom of the baler chamber area Retainer Dogs located on baler chamber door help hold the compressed material down while the ram travels up to the loading position opening the baler safety charging gate as it travels up EJECTION When full bale indicator arrows on the ram face and baler frame match the bale is the proper size Lift gate unlatch and open chamber door at least 110 degrees slide baling wire through slots and tie off all wires Close feed gate by pulling it down completely Attach the ejector hooks at back of baler to ram ejector lugs set the UP DOWN switch located on baler electrical box to the UP position press and hold button in until the bale ejects Keep clear of ejecting bale Safe B
6. CYLINDER 330525 6 3 1 2 X 48 POWER UNIT NO 500985 RESERVOIR SYSTEM IS DESIGNED FOR USE WITH INLET STRAINER DRYDEN ISO GRADE 46 HYDRAULIC PUMP 10 5 G P M FLUID OR EQUAL MOTOR APPROX 10 5 RELIEF VALVE DIRECTIONAL VALVE 4 WAY PRESSURE SWITCH PRESSURE GAUGE COUPLER HOLLOW SHAFT DIRECT TO MOTOR 2 3 4 5 6 7 8 9 TITLE 10HP HYDRAULIC DWG 1800HD 2300HD 2318 3400HD 7250 DWG NO AB400296 BALER AND CYLINDER HOSES E DO Lc RESERVOIR SYSTEM IS DESIGNED FOR USE WITH INLET STRAINER DRYDEN ISO GRADE 46 HYDRAULIC PUMP FLUID OR EQUAL MOTOR RELIEF VALVE DIRECTIONAL VALVE PRESSURE SWITCH PRESSURE GAUGE TITLE BALER HYDRAULIC SCHEMATIC GENERIC FOR ALL BALERS DWG NO AB401756 MAINTENANCE INSTRUCTIONS INCLUDING PERIODIC MAINTENANCE ITEMS FLUID Check the level of hydraulic oil in the reservoir The oil level should be mid way between high and low marks on the gauge when cylinder is in the maximum UP position The oil level should be approximately at the low mark when the cylinder is all the way down This check should be made every six months If oil must be added or replaced it should be transferred through a 100 mesh strainer If oil replacement is required clean the reservoir and suction strainer before refilling We recommend Dryden ISO 46 or equal
7. Contractors should not be permitted to operate in house baling equipment unless they have been properly trained and authorized C Asa leading baler manufacture we recommend that your company utilizes the following baler safety training outline and baler safety video which cover the following 1 Pre start up 2 Operation operation procedures are also posted on front of control box 3 Safe bale ejection 4 Inspection maintenance see baler safety inspection checklist included in this manual 5 Operator Safety Prohibited practices 6 Training requirements necessary training as identified from hazard assessment and use of baler safety video 7 Record keeping see Attachment D Your company safety official should periodically review their company specific program to ensure the effectiveness of your safety program and make revisions as necessary Heed amp Obey Warning Signs Signs such as Danger Caution Warning and Attention are on the machine for your protection Warning signs must remain in place and be kept in readable condition Report and replace all damaged or missing warning signs Operational carelessness and safety shortcuts can cause serious injury or death Follow safety Guidelines and be safety conscious Every operator should read operators manual and the operating instructions posted on the front of the control box The operating key should not be left in the machine when the machine is left unattended
8. Hose Connections 9 Grease Fittings C 5 Security Hinges 10 Main Door Hinge 6 Safety gate 11 Cylinder Crown Bolts 1 7 Container wheels 3 12 Pressure Gauge Condition 8 Cylinder pins C 3 Bale Ejector A Hooks B Cables C Welded eye D Retainers E Chains 4 Loose Parts A Lock nuts on gate arms B Safety on door handle 5 Door Linkage A Pin bracket engagement B Tighten if necessary 6 Ratchet Binders 7 Hooks Adjusted _ _ OK 0 Replacement Required Replaced 6 2 Does WHITE COPY SERVICE DEPT ORIGINAL CANARY COPY INVOICE COPY PINK COPY CUSTOMER COPY a gee p ee MAINTENANCE INSTRUCTIONS Continued CAUTION DO NOT UNLOCK OR OPEN chamber door while ram is advancing under pressure Even though safety switches are incorporated keep clear of moving parts at all times This baler is equipped with safety switches to prevent operation when protective gate is open IMMEDIATELY replace switches that are not in proper working order DO NOT ATTEMPT TO DEFEAT THE PURPOSE OF ANY SAFETY SWITCH In case of emergency 1 Push Emergency Stop button 2 Pull wall safety
9. Turn the machine off and remove key from control panel On Off switch 2 Place a large piece of flat cardboard over the completed bale 3 Turn the machine back on run the ram down 4 Stop machine with ram at lowest point of travel against completed bale by hitting the e stop immediately after the ram reversed direction 5 Turn the machine off and remove key from control panel On Off switch 6 Open bale eject door beyond 90 degrees Break plane of side of baler with door Warning If door is not open beyond 90 degrees while ejecting bale eject chains may break and bale may not properly eject 7 Use poker rod as necessary to clear a path for the baling wire both under and over the bale Attention The remainder of the following steps involve handling baling wire Before proceeding any further it is recommended that you consult your supervisor or company safety professional for required personal protective equipment when handling baling wire It is strongly recommended that safety glasses and forearm length leather gloves be worn when handling baling wire at any time 8 From the front of the machine manually feed the first baling wire loop end first under the bale through the available wire slots on the bale chamber floor until the wire protrudes slightly through the rear of the machine The wire can actually be fed either end first either over or under the bale This loop end first was chosen only because customer feedba
10. Prior to Start Up 1 Wear proper safety equipment as recommended by your company safety official 2 Never allow yourself or anyone involved with the baling system to be under the influence intoxicants or narcotics while the baler is operating 3 Walk around the baling system to check for proper equipment condition Open hopper door and check inside the baler 4 Be positive no one is working on the baler or adjoining equipment With ram in up position lift gate and look inside main chamber area to be sure no one is inside 5 The following operational check should be conducted prior to each shift e With the gate raised press all buttons in any order or combination No motion should occur e Close gate and start machine open gate during downward motion Machine should immediately stop e Close gate and start machine Gate will automatically open with upward ram travel During this time raise the gate off the ram Machine should immediately stop e Demonstrate that the machine will not operate in automatic if the main bale door is open Operator should do this by having the ram in the up position and with the gate closed set the selector switch to down and push Release the button and the ram should stop If anything does not function as indicated immediately report problems to supervisor remove Key lockout machine and call for service Operator Safety Always Use Lockout Tagout Power must always be disconnected and loc
11. T6 T9 T4 TF 1 que T L2 13 12 WIRE DELTA THREE PHASE FOR 10HP 15HP 20 415 440 VOLT 580 16 TS 14 Lh T11 T10 T12 TO MOTOR STARTER HYDROLEC 10 MOTOR STARTER MOTORS 7 17 00 TITLE MOTOR WIRING GUIDE FOR INTERNATIONAL VOLTAGES DWG AB401376 BALER AND 20 120 250 CONTROL LINE 460V STOP OFF ON 20 KEY SWITCH START DOWN 5 UP RAM SP 3 BALE DOOR 6 THERMOSTAT X2 WHT 8 BLUE 1 gt YELLOW 9 3 ORANGE 9 MARK 4 MARK 12 BROWN 5 RED 13 BLACK HEATER 6 15 PURPLE RED 208V 250V 19 GRAY R3 7212 5 J REMOVE IF FULL LIGHT OPTION INSTALLED TITLE NO MAX STANDARD BALER CIRCURT DP DT DWG NO AB4005883 BALER amp CO WHT YELLOW 9 ORANGE MARK 208 230 460 3 60 RED 360 BALER STOP OFF ON 20 FUSE Bp ss KEY SWITCH START DOWN 5 UP RAM STOP 3 BALE DOOR GATE PROX RAM GATE 9 5 F B S START UP R1 6 10 05 9 4 97 TITLE NO MAX STANDARD CIRCUIT WITH DP DT SWITCH DWG NO AB4006801 BALER AND 208 230 460 VOLT 3 PHASE 60 _ NP qe 588 9A Mis 9 9 STOP N 0 RAM GATE SW REV 5 8 27 05 OPTIONAL CIRCURT TITLE GATE LOCK LOCKED GATE HORN DP DT ANN IE BALER AND COMPACTOR CO
12. and cleaning procedures p Keeping all surrounding walking areas and floors free from obstructions and accumulations of waste matter grease oil and water slipping and tripping hazards q Maintaining records or employee reports of malfunctions r Specifically inspecting safety interlocks switches and other protective devices to ensure that these devices are not disabled or bypassed and not to permit the baler to be operated unless these devices are fully functional These inspections shall be in accordance with g s Ensuring that containers supplied are capable of withstanding the maximum forces generated by the baling system Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC t Ensuring that loaders are aware of hazards and safety requirements u Ensuring that only authorized employees 18 years old or older operate inspect or maintain balers v Ensuring that only authorized employees 16 years old or older load but do not operate balers and w Incorporating balers into the employer s safety program see Section 8 7 2 Operator and employee responsibilities Operators who work on and around the baler shall be responsible for the items listed below a Using all applicable safety features provide
13. be exercised when handling any potentially sharp objects such as bailing wire Follow appropriate precautions and procedures Always stand clear of ejecting bale Baling wire recommendation is based on industry standard and past history of success with this wire in a wide variety of customer environments and usages of balers and other vertical balers with comparable compression yielding bales of comparable size and weight 0 WASTE EQUIPMENT ENVIRONMENTAL INDUSTRY TECHNOLOGY ASSOCIATION arer areni BALER amp CO WALL BRACKET KIT MATERIAL LIST WALL BRACKETS WALL TOGGLE BOLTS 3 8 X 6 Lg 6 1 0 PVC PIPE 5 0 LG WITH PIPE SLEEVE amp 6 10 PVC PIPE 5 0 LG WITHOUT PIPE SLEEVE 4 3 8 X 5 4 SELF DRILLING SCREWS INSTALLATION GUIDE MARK A LEVEL LINE ON WALL MARK LENGTH OF WIRE ON LEVEL LINE SPACE BRACKETS EQUAL DISTANCE INSIDE WIRE LENGTH TO BALANCE WIRE MARK BRACKET HOLES ON WALL USING EACH BRACKET AS ITS OWN TEMPLET USING A 1 MASIONARY DRILL DRILL EACH HOLE INSERT TOGGLE BOLT INTO EACH HOLE MOUNT THE WALL BRACKETS TO THE BOLTS TIGHTEN ALL BOLTS IN PLACE ASSEMBLE PIPE TOGETHER AND SECURE BOTH HALF S AT THE PIPE S SLEEVE SEE BELOW 10 INSTALL THE THREE 8 X 3 4 SELF TAPPING SCREWS INTO THE PIPE SLEEVE 90 APART SEE BELOW 11 MOUNT PVC PIPE ONTO 7 7 WALL BRACKETS SEE BELOW REF
14. disconnect switch handle to end all electrical power HYDRAULICS Hydraulic fluid operates at high temperatures and high pressures Avoid contact with hoses cylinder and hydraulic fluid leaks to prevent the possibility of burns and severe injury In event of such injury seek medical attention immediately WARNING DECALS AND INSTRUCTION PLATES Read and follow the warning instructions of each decal it is for the operator safety that each decal is in place Make certain that each decal is obeyed at all times Notify proper authority of any missing decal Replacements can be ordered from PTR Baler and Compactor Company 2207 E Ontario Street Philadelphia PA 19134 800 523 3654 800 523 1155 or 215 533 5100 215 537 8536 FAX BALER amp CO No aw DANGER CLOSE GATE BEFORE OPERATING BALER CAUTION 330229 6 1 DANGER HIGH VOLTAGE ENG amp SPAN 500644 MAINTENANCE AND IS THE RESPONSIBILITY OF THE OWNER 8 1 CAUTION KEEP CLEAR OF GATE WHILE EJECTING BALE ENG amp SPAN 50007 9 1 DANGER DO NOT PUT HANDS IN MACHINE WHILE IN OPERATION ENG amp SPAN 500137 ee gt i 2 24 HOUR SERVICE PTR BALER AND COMPACTOR 311658 h FV gi 7 2207 ONTARIO ST PHILA 19134 INSIDE PA 215 5335100 OUTSIDE PA 1 800 523 3654 VOLTAGE AMP PSI INFORMATION LABEL 154377 15 11 TH
15. the manufacturer The employer will maintain records as to the names of employees and the dates of training c Providing instructions for addressing abnormal situations e g bridging of the loading chamber or feeding chute jam of materials d Assigning only trained employees to work on which includes operating loading cleaning servicing maintaining or repairing the baler e Monitoring the employee s operation of the baler and taking appropriate action to ensure proper use including adherence to safe practices and the employee requirements of this standard and monitoring the employee s operation of balers and taking appropriate action to ensure proper use of equipment including adherence to safe practice f Repairing prior to placing the baler into service any mechanical malfunctions or breakdowns that affect the safe operations of the baler g Establishing and following a program of periodic and regular inspections of all balers to ensure that all parts component equipment and safeguards are in safe operating condition and adjusted in accordance with the manufacturer s recommended procedures This shall include keeping all malfunction reports and records of inspections and maintenance work performed h Implementing a program for the maintenance of the baler which will incorporate the following elements 1 Requirements for trained competent maintenance employees or contractors to perform inspection and repair wo
16. the power is disconnected and locked out If work on or in the baler is required disconnect the power to the baler and lockout Never assume that you are protected by another employee s safety lock Before restarting repeat the Prior to Start Up procedures Anytime the baler is shut down the Prior to Start up procedures should be repeated Never bale aerosol cans or containers filled with liquid Use of safety glasses and forearm length leather gloves are strongly recommended when handling baling wire Attachment A TRAINING RECORD Employee Name Description of Training and other Notes Date of Training Seen Video Yes No Employee Signature Store name and location Store _ Store Manager Name Signature and Date Training Video Present at Store Manual present at Store Name or Trainer Signature of Trainer DIMENSIONS AND MINIMUM CLEARANCES a OF INSTALLED BALERS Dimension Clearance MODEL 360 420 1800HD 2300HD 3400HD 3600HDLP 5000HD 7200HD A 7 111 2 7 111 2 11 6 12 8 12 7 7 115 12 6 12 6 B 4 2 4 10 5 7 6 3 6 5 69 7 3 2 10 2 10 3 7 3 9 3 10 5 4 5 3 11 4 10 D 5 3 5 4 ee 88
17. 215 533 8907 PTR Baler and Compactor Company Baler Installation Information Check List Baler Information Model No Serial No Installed By Date Signature of Installer Customer Information Customer and Store No Address Phone No Operation and Maintenance Manual Received By Name amp Signature Individuals Instructed In Safety Procedures And Operation Of Machine Names amp Signatures Keys Received By Name amp Signature Operation Video Tape Received By Name amp Signature Verify The Following ELECTRICAL HYDRAULIC 1 All connections made 1 Oil Level 2 All terminals tight 2 All 4 hose fittings re tightened 3 Fuse clips tight after unit was set in place 4 Limit switches tight door and gate 3 Motor pump coupling tight 5 Proximity switch tight 4 Directional valve shifting 6 All switch buttons selectors smoothly and quietly tight and properly aligned 5 Pressure settings 7 Seal the control box with the High Voltage Sticker 8 Push relay tight to relay base PHYSICAL OPERATIONAL 1 Anchored to floor 1 Power to machine 2 Ejector chain assys In place 2 Run to check proper operation properly aligned 3 Demonstrate proper operation 3 Cylinder bolts tight to customer See baler safety checklist in manual 4 All gate hardware tight 5 Touch up
18. 2207 E ONTARIO AVE 800 599 1 215 533 5100 PHILA PA 19134 1 800 523 3554 STARTER OVERLOAD DETUR SEHING 75 120 06 80 25 80 56 50 20 CGC 40A 120 CGE 40 2P 40A 25 75 120 06 80 25 80 42 38 15 40 120 CGE 40 2P 40A 18 CGC 40A 120 40 2 40 128 25 21113110 CGC 40A 120 06 40 2 40 13 5113 1 40 120 CGE 40 2P 40A 16 14 65153 060 22 120 40 2 20 756 19 5 22 120 CGE 40 2P 20A 19 8 14 33 22 120 06 40 2 20 4 5 Ee 2 _ ELECTRICAL CONNECTION REQUIREMENTS ADDITIONAL CURRENT DRAW MAXIMUM DUE TO HEATER OPTION IF PRESENT LOW VOLTAGE HEATER OPTION 2 08 AMPS AT 240VAC HIGH VOLTAGE HEATER OPTION 1 04 AMPS AT 480VAC CONNECT TO CIRCUIT WITH DUAL ELEMENT TIME DELAY FUSES RATED TO AT LEAST 125 OF THE MOTOR F L A PLUS THE OPTIONAL HEATER LOAD AND NO MORE THAN 175 OF THE MOTOR F L A PLUS THE OPTIONAL HEATER LOAD IF PRESENT SUPPLY WIRE AMPACITY FROM THE FUSES TO THE MACHINE CONNECTION POINT MUST BE AT LEAST THAT OF THE DUAL ELEMENT TIME DELAY FUSES PROTECTING THE WIRES MOTOR HP VOLTAGE VAC HEATER YES NO CONNECT TO CIRCUIT WITH DUAL ELEMENT TIME DELAY FUSES RATED AMP MAX USE SUPPLY WIRE WITH A MINIMUM AMPACITY OF AT LEAST AMP PSI Pol RELIEF Pol PSI PSI SEG CYCLES SCHEMATIC
19. 5 9 eS QX 5 5 5 55 gt XS 7 BS 55 RS ete 55 55 2 255525 NN 52 22 555525 555 25 22 N OD OG 5 50 xX 25 2260 5 x 5 eX v b 2 v RAM ASSEMBLY SEE NOTE 1 FRONT VIEW OF BALER FRONT VIEW OF BALER DOOR POWER UNIT amp GATE WITH SPROCKET ASSEMBLY HAS BEEN REMOVED FOR CLARITY NOTE 1 ALL PARTS TO BE ORDERED FROM PTR BALER amp COMPACTOR CO FOR PROMPT SERVICE IT IS IMPORTANT FOR CUSTOMER TO GIVE BALER MODEL NUMBER amp SERIAL NUMBER LISTED ON MANUAL COVER SHEET OR ON ELECTRICAL BOX DOOR AS SHOWN ON MECHANICAL PARTS INFORMATION GATE PROX SWITCH EXCEPT OTHERWISE SPECIFIED ee BALER CROWN BROKEN SEE NOTE 1 SEE NOTE 1 FOR CLARITY 811 IF GATE PROX SWITCH FOR BALER MODELS 360 3600 1 500010 7200 0 amp 7200HDLP SEE NOTE 1 DOOR SWITCH SEE NOTE 1 RAM SWITCH Wi SEE NOTE 1 QQS 5 55 FULL LIGHT SWITCH OPTIONAL SEE NOTE 1 LA DLL 8 66 1 T L LF FRONT VIEW OF BALER BACK VIEW OF BALER FRONT VIEW OF BALER DOOR POWER UNIT amp GATE WITH SPROCKET ASSEMBLY HAS BEEN REMOVED FOR CLARITY NOTE 1 ALL PARTS TO BE ORDERED FROM PTR BALER amp COMPACTOR CO FOR PROMPT SERVICE IT IS IMPORTANT FOR CUSTOMER TO GIVE BALER MODEL NUMBER amp SERIAL NUMBER LISTED ON MANUAL COVER S
20. 5 533 8907 Branch Office Locations Baltimore MD Bayshore LI Harrisburg PA Paterson NJ Philadelphia BALER SAFETY CHECKLIST The following is a SAFETY CHECKLIST for the purpose of keeping the Baler in a Safe Operating Condition A Check that all signs and warnings are in place and in good condition Name Plates and all Decals installed Signs missing A WARNING No one under 18 is permitted to operate this machine CAUTION Stand clear while bale is ejecting B C OPERATING INSTRUCTIONS D DANGER HIGH VOLTAGE E CAUTION CLOSE GATE F CAUTION KEEP CLEAR G WATCH FINGERS H DO NOT CLIMB B Check the following control functions On Off Keyswitch __ Man Auto Selector Switch Start Button Up Down Pushbutton Selector Switch Emergency Stop Button Full Light Others Check Door Safety with main door open machine should not operate in auto Check all wiring for frayed or loose connections Check condition of expanded metal on gate Check entire structural including ram for welding and structural failure Check ejector chains or cables for bent or broken parts Serviceman s Signature Customer s Signature Hinge Side Cylinder Size Voltage PIN Size Serial No Model Manuf C Check Operation of Baler Manual Pull Down Gates amp Auto Gates Press all buttons with gate up no motion should occur 4 Pull Gate down and check the following
21. ALER UNLESS GATE IS FULLY CLOSED KEEP CLEAR OF THE BALER WHILE EJECTING A BALE THE BALER SHOULD NEVER BE ENTERED OR SERVICED WITHOUT FOLLOWING THE LOCK OUT TAG OUT PROCEDURE The baler should not be restarted until all workers have exited the baler and moved out of the way of all moving components Lock out procedure is listed on the following page ONLY AUTHORIZED PERSONNEL SHOULD BE ALLOWED TO OPEN THE PANEL BOX Baler operates with high voltage and should not be serviced by people who are High voltage Authorized not certified to do so ock out procedure must be used before opening panel box BEWARE OF MOVING COMPONENTS The gate and door should not be opened at anytime while the ram is a advancing under pressure The user should stand away from baler while in operation and should never reach into the machine in any way DO NOT CLIMB THE BALER UNDER ANY CIRCUMSTANCE User should also be familiar with applicable safety codes including those issued by ANSI OSHA UL NFPA etc NOTICE WHEN CHANGING CYLINDER PERFORMING HYDRAULIC SERVICE OR PERFORMING STRUCTURAL REPAIRS Be absolutely sure to fully support the ram Suggested method shown on drawing AB340367 in the user manual Balers that are found not to be operating safely must be IMMIEDIATELY reported to PTR Baler and Compactor AT 800 523 3654 pu LOCK OUT PROCEDURE IS LOCATED ON THE FOLLOWING PAGE
22. C D E 1 4 K L M TROUBLE SHOOTING GUIDE RAM WILL NOT TRAVEL UP POSSIBLE CAUSE Hydraulic Fluid Level Low Pump Taking Air Directional Valve Malfunction Electrical Malfunction Material Jamming Ram Incorrect Pump Rotation Relief Valve Pump Not Building Pressure Hydraulic System Pressure Is Low Pressure Switch Cylinder Up Stop Limit Switch Gate N N N POSSIBLE REMEDY Check hydraulic fluid level gauge on reservoir add hydraulic fluid Check fittings to see if they are tight Check valve solenoid Push in manual override pins are on each end of solenoid Perform electrical continuity check Remove all jamming material from ram Check fan rotation on motor fan should turn clockwise Check setting Replace valve Replace pump Check pressure setting Check relief valve for malfunction Worn pump Improper pressure setting Bad electrical contact Check for internal external cylinder leakage Check arm is free and not activated Make sure gate is down Check switch A B C D A A B C D E TROUBLE SHOOTING GUIDE RAM DRIFTS DOWN POSSIBLE CAUSE POSSIBLE REMEDY Directional Valve 1 Spool may be jammed Cylinder 1 Seals may be damaged Replace seals or replace cylinder optional Regenerative Hydraulic Valve 1 Hoses may be reversed Ver ify to extend and B to retract Hydr
23. ER TO MOTOR STARTER HYDROLEC 4 2 9 WIRE STAR THREE PHASE WEG 208 230 VOLT 460 VOLT 15 16 7 T8 T9 15 MOTOR STARTER 12 WIRE DELTA THREE PHASE 460 VOLT he 15 14 19 18 T7 T11 T10 T12 15 12 11 WARFEL MOTOR STARTER L TO MOTOR STARTER HYDROLEC 9 WIRE STAR IHREE PHASE MOTORS 208 230 VOLT aE BALDOR 14 15 16 15 16 eo T7 18 19 18 T1 M TH 12 13 MOTOR STARTER TO MOTOR STARTER NOTE VERIFY AGAINST MOTOR NAME PLATE WHEN POSSIBLE MM REV 2 9 7 06 4 15 98 REV 1 7 10 02 TITLE MOTOR WIRING GUIDE DWG 5405482 BALER AND SINGLE PHRASE EE GIC AL INFORMATION clement ruses Minimum Motor Hp Voltage 1 VAC Roope Circuit Ampacity 20 500 70 80 80 18 00 5 120 CGE 80 2S 80 150 5 128 40 120 40 2 40 28 r CGC 22A 20 40 2 20 117 15 20 22 40 2 20 20 minimum fuse size 122 Motor F L A plus optional heater current maximum fuse size 175 Motor F L A plus optional heater current Heater at 220V draws 1 91 amps INCOMING POWER DRAWN MUM DATE 8 15 06 SINGLE PHASE ELECTRICAL INFORMATION DWG NO AC4032431 L1 1 Electrical Information For 50117 power GROUNDING INSTRUCTIONS The compactor must be connected to a grounded metal permanent wiring syste
24. FLUID CLEANLINESS We recommend that oil be changed every two 2 years If for any reason dirt or water gets into the fluid or if the baler is operating in an extremely dirty or dusty area then the fluid should changed more frequently OPERATING TEMPERATURE Fluid temperature should not exceed 180 degrees F high temperatures may cause fluid and seal deterioration Use sight temperature gauge located on back of tank to check the temperature ELECTRICAL SYSTEM MAINTENANCE For electrical system to function properly components must be clean and dry limit switches must be clean of foreign material and properly adjusted All maintenance service to the electrical system must be performed only by trained authorized personnel WEAR PADS The nylatron wear pads attached to the ram should be checked every six months for wear and should be replaced if they are worn 1 8 or more YEARLY INSPECTIONS Perform a full safety inspection at least once per year as per the Baler Safety Checklist At this time also perform the necessary preventative maintenance as per the Preventative Maintenance Checklist Both checklists are contained in this manual i PTR Baler and Compactor Company strongly recommends that current and applicable ANSI and OSHA standards be available to operators at all times Barer ComeacTor 2207 Ontario Street PTR Baler and Compactor Philadelphia PA 19134 1 800 523 1155 215 533 5100 Fax 21
25. HEET OR ON ELECTRICAL BOX DOOR AS SHOWN ON THE BALER PARTS DESCRIPTION amp NUMBERS SECTION LIMIT SWITCH INFORMATION EFFECTIVE 10 2006 1800 1800 2300 3400 3600 3400 5000 7230 7200 s 7 T o o 500459 JPUMPt3GPM x j j 500480 3 7 6 x 500126 PUMPtO5GPM PX X X x x x x 0027 pPuUMP1e1GP M 0 0 j x x 1500063 WAY VALVE S GO1 C7Y FR E11S X X X x x x 155529 SWAY VALVE SS G03 C7Y FR E115 xX 500461 5 000 x x x x 500461 SUMP SCREEN LH50950_ j x xT x SUME SCREEN t _ 3 X 1 3 4 X 32 CYLINDER 6 X 3 1 2 X 48 CYLINDER 6 X 3 1 2 X 38 CYLINDER 6 X 3 1 2 X 27 CYLINDER 7 X 4 X 48 CYLINDER 4 X 2 E X e 230174 HVDRAULIG HOSE AER Gm 1 1 181 18 1818 18 1 1 500591 HYDRAULIC HOSE BALER 32 12 x x 500592 HYDRAULIC HOSE BALER 40 12 00148 32 081 1 4 54 4 4 4 14 4 14 4 4 HYDRAULIC HOSE BALER
26. IS BALER MEETS ALL ANSI 7 245 5 1997 SAFETY 500270 O O AND PERFORMANCE STANDARDS FRONT VIEW 16 IMPORTANT BALE DOOR MUST BE OPEN BEYOND 90 FOR 500272 PROPER EJECTION 17 1 CAUTION GATE LOCK SYSTEM IN USE DO NOT FORCE 500504 8 1 CAUTION LOAD BALE CHAMBER AS EVENLY AS POSSIBLE 900505 WARNING NO ONE UNDER 18 IS ALLOWED TO OPERATE 500639 THIS BALER WARNING ENG amp SPAN 20 1 DANGER BEFORE AND DURING ANY MAINTENANCE TESTING 500576 AND OR ELECTRICAL CONNECTING MOVE DISCONNECT SWITCH OFF POSITION AND PADLOCK PLACE A WARNING TAG ON THE DISCONNECT SWITCH AS FOLLOWS WARNING DO NOT ENERGIZE WITH THE PERMISSION 2111 CAUTION SAFETY GATE LOCK IN USE ON THIS BALER DO NOT 500553 FORCE GATE OPEN OR OVERRIDE SYSTEM RM a 22 CAUTION WITH CONTROL PANEL DOOR OPEN 500651 INCOMING POWER SIDE OF DISCONNECT IS STILL ELECTRIFIED 2300HDLP UNITS ONLY 2 PTR BALER AND COMPACTOR FOR BALING WIRE CALL CONFINED 5 USE LOCKOUT TAG OUT WARNING KEEP BALER CLEAN amp FREE OF DIRT DANGER HIGH VOLTAGE AUTHORIZED PERSON CONTROL BOX ETC 500448 FUSE 2 0 AMP KEEP CLEAR OF GATE TYPE 1 ENCLOSURE GROUNDS ATTENTION WHEN ELECTRIC IS FIRST CONNECTED RUN BALER TO SIDE VIEW MAKE SURE THAT MOTOR ROTATES IN INDICATED DIRECTION x si VOLTAGE BEFORE EACH SHIFT CHECK THE FOLLOWING PSA T AED 5 7 15 04 4 9 30 03
27. LOCKOUT TAGOUT PROCEDURE DEVELOPMENT INFORMATION Warning Before performing maintenance or service work on the baler the OSHA Occupational Safety and Health Administration 29 CFR Code of Federal Regulations 1910 147 requires that each company develop maintain and follow a lock out tag out procedure for employees and equipment standard should be referenced for definitions to various terms such as isolation affected and authorized This procedure must be followed prior to performing maintenance or service work or entering any hazard area that may exist The following is merely a guideline for creating a company equipment specific lock out tag out procedure and is not intended to supplant either the specific company procedure or OSHA standard 29 CFR 1910 147 and 29 CFR 1910 147 appendix A 1 2 All affected employees shall be notified that equipment is being shut down and locked out prior to performing service or maintenance The equipment if operating shall be shut down by normal means and the energy isolating device shall be de activated to isolate the equipment from the energy source by an authorized employee Isolation shall include a Removing the key from the key lock ON OFF switch on the baler control box b turning off disconnect and affixing a lock securing disconnect in the off position Affixing tag to the lock clearly identifying the individual who locked out the machine warn against hazardo
28. NUMBER c o m Cd No gt PIR BALER AND CUMPACTUR CU FLECTRICAL INFORMATION Minimum 3Hp 106 ee __ Joe e 112 51 05 1 8 08 0 96 ves 118 143 3H 48616 9 3Hp 44 40 48 7 9 9 3Hp 5 55 39 5 9 9 7 105 990 579 1611 176 dei 10Hp 29 28 1308 No 40 60 60 10 Hp 80 28 308 40 60 460 o 50020 981 i 50 44 40 4 175 25 25 10 6 49 14 ves 20 25 25 10 Hp 55 55 11 No 15 Hp 15 Hp 200 208 15 Hp 20 244 48 N 15 Hp 2020 48 460 60 60 15 Hp 44 400 21 30 40 40 00208 524 80 80 80 20 20 08 597 980 80 80 80 Hp 2 2 54 70 80 80 80 Hp 20240 54 70 80 80 1054 Motor F L A plus optional heater current minimum fuse size 1754 Motor F L A plus optional heater current maximum fuse size Heater at 208 draws 1 80 amps Heater at 240 draws 2 08 amps Heater at 480V draws 1 04 amps TITLE ELECTRICAL INFORMATION AND FUSING REQUIREMENTS DWG AC403147 PIR BALER COMPACIOR MOTOR WIRING GUIDE 12 WIRE DELTA THREE PHASE 460 VOLT 208 230 VOLT 1 14 14 19 18 T7 T11 T10 T12 15 12 11 TO MOTOR START
29. ONLY 1 2 3 4 5 6 7 8 9 REF ONLY REF ONLY EXAMPLE 3 PIPE SLEEVE REF ONLY 8 SCREW 90 APART BALING WIRE 14 0 2300HD 3400HD 5000HD 16 0 7200HD BALING WIRE 5 12 06 WALL BRACKET KIT DWG 4006371 BALER MODELS SEE MANUAL CONTROL LAYOUT SECTION FOR ELECTRICAL BOX INFORMATION WHEEL LOCK ASSEMBLY SEE NOTE 1 LINK amp LEAF CHAIN ASSEMBLY SEE NOTE 1 SIDE VIEW BALER MODEL BALER SERIAL SEE NOTE 1 1800 669 3400 3400 0 5000 0 7200IHD SEE MANUAL BALER PARTS DESCRIPTION SECTION SEE MANUAL BALER PARTS amp DESCRIPTION SECTION FOR POWER UNIT INFORMATION FOR CYLINDER INFORMATION SPROCKET ASSEMBLY SEE NOTE 1 M 5 e 2 5 5 22 5 2002 SX s 5 5 52 26 9 529 QS 22 QS 5250 Q 2 25 KKK 25262565 525006 52559 55255596 5550595 55255062 22 5250 Q 5250 QS Q lil 1 4 NUMBER DOOR LATCH ASSEMBLY SEE NOTE 1 DOOR ASSEMBLY SEE NOTE 1 c I ii OS 5 22 22 50 x 22 Sx 7 22 22 2002 o 55 2 22 NUMBER 55 2009 5 SX 55 SX et gt 5 5
30. PIE BALER amp 2207 EAST ONTARIO STREET PHILADELPHIA PA 19134 1 800 325 5654 HYDRAULIC BALERS FOR DEPENDABLE COST SAVING RECYCLING ENGINEERED FOR SUPERIOR DURABILITY amp MAXIMUM SAFETY OUR EMPHASIS MODEL No IS ON SAFETY SERIAL No TABLE OF CONTENTS INTRODUCTION GENERAL ANSI REFERENCE LOCKOUT PROCEDURES CHANGING BALER CYLINDER SAFETY TRAINING INFORMATION BALER MINIMUM CLEARANCE CHART INSTALLATION INFORMATION PRESSURE SETTING PROCEDURES CONTROL LAYOUT BALER OPERATING INSTRUCTIONS TROUBLE SHOOTING GUIDE ELECTRICAL INFORMATION ELECTRICAL CIRCUITS HYDRAULIC SCHEMATIC MAINTENANCE INSTRUCTIONS DECAL amp INSTRUCTION PLATES PLACEMENT WARRANTY PARTS amp SERVICE BALING WIRE IMFORMATION WALL BRACKET KIT MECHANICAL PARTS INFORMATION LIMIT SWITCH INFORMATION BALER PARTS DESCRIPTION amp NUMBERS Revised 10 2006 5 11 12 14 14 15 19 20 21 23 24 25 26 31 32 36 37 44 45 47 48 49 50 53 54 55 56 57 58 59 60 61 62 Congratulations on your purchase of a PTR Baler PTR is known for producing balers with the highest safety and quality standards in the industry e All PTR Balers are factory tested and receive a vigorous quality assurance inspection to insure top performance and safety in the field e Many of the advanced design features on our balers make operation easy without sacrificing safety e At PTR Baler and Compactor operator safety is ou
31. RTER OVERLOAD TERMINAL STRIP 155441 RELAY C H 155392 BASE C H 155393 1 CONTACT BLOCKS 155399 2 CONTACT BLOCKS 155400 3 CONTACT BLOCKS 155401 CONTACT COIL 500065 TRANSFORMER SECONDARY FUSE 320209 TRANSFORMER PRIMARY FUSE BLOCK 500529 TRANSFORMER PRIMARY FUSE 603320 OVERLOAD RESET ACTUATOR 602437 gt HW a CONTROL COVER LAYOUT DWG NO AB4002982 BALER OPERATING INSTRUCTIONS WARNING This unit is to be operated by authorized personnel only By law no one under 18 years old is permitted to operate this machine A Preparing the baler to make a new bale of cardboard L 5 Insure power key switch is in the OFF position Insure baler ram is in the UP position With gate in the UP position open bale chamber door Lay a flat piece of cardboard on the bottom of the bale chamber over top of the ejector straps or chains Close and latch the bale chamber door To make a bale 1 Fill the chamber with cardboard boxes need not be broken down the material to be baled should be loaded evenly in the chamber Pull the gate down to the top of the chamber door Turn power key switch to the ON Position Set the UP DOWN switch to the DOWN position which is also the AUTO setting Press the DOWN button and release the ram will travel down and automatically reverse when reaching full down stroke Repeat above steps until full bale
32. TLE BALER amp CO D 1 LOCATE CENTER LINE OF TOOL TO CENTER LINE OF RAM CUP 1 ha E RAM CUP RAM SUPPORT TOOL SUPPORT FOR CHANGING BALER CYLINDER 1 2 X 18 X 18 PLATE TOP amp BOTTOM 8 SCH 60 PIPE 31719 OPTIONAL RAM SUPPORT TOOL BALER CYLINDER CHANGING PROCEDURE 1 APPLY THE LOCKOUT PROCEDURES DESCRIBED IN THE MANUAL TO DE ENERGIZE THE BALER WHILE THE RAM IS IN IT S UP POSITION SEE LOCKOUT PROCEDURES IN TABLE OF CONTENTS 2 OPEN THE CHAMBER DOOR AND POSITION THE RAM SUPPORT ALIGNED WITH THE CENTERLINE OF CYLINDER AS SHOWN IN THIS DRAWING 3 AT THE POWER UNIT RELIEVE PRESSURE OF THE SOLENOID VALVE BY PUSHING THE SPOOL END BUTTONS IN THIS WILL ALLOW THE RAM TO DRIFT SLOWLY DOWN UNTIL IT SITS ON TOP OF THE RAM SUPPORT 4 PROCEED WITH THE CYLINDER MAINTENANCE AS REQUIRED NOTE WHEN CHANGING CYLINDERS NEW LOCKNUTS MUST BE USED DWG NO AB340367 Baler Safety and Training Outline I Scope Employers should designate a Safety Risk Manager or equivalent person that has qualifications necessary to evaluate and manage safety and operational training issues related to the operation of baling equipment as part of their operator safety and training program Each individual baler owner should develop their own training program specific to their equipment personnel processes environment and unique site application A Your company safety offici
33. al should conducted a hazard assessment of the various baling equipment utilized at your facility and use the information from the hazard assessment to develop a company specific baler safety training program The hazard assessment should include at a minimum the following 1 Identification of material being baled clean cardboard only 2 Hazards associated with the baling equipment and material baled 3 An initial and then periodic review of the capabilities qualifications and training of any person who may potentially encounter the identified hazards B Your company safety official should evaluated the means and methods of controlling the hazards identified in the hazard assessment including information such as industry and regulatory requirements instructions for the operation inspection and maintenance of balers and other information appropriate to the identified hazards 1 Your company safety official should ensure compliance with applicable OSHA Code of Federal Regulations under 29 CFR 1910 and applicable ANSI baling equipment standards under ANSI Z245 5 and 7245 51 2 Your company safety official should ensure that all employees including supervisors engaged in the operation cleaning maintenance service or repair of the baling equipment are properly trained according to their assigned jobs or tasks The Baler Safety Video supplied by PTR should be shown to all potential operators and the manual should be read thoroughly 3
34. ale Ejection Recommended Bale Tie Off and Eject Procedure for PTR Baler and Compactor Company s standard built 2300HD baler producing bales of ordinary corrugated cardboard Please consult PTR Baler and Compactor Company for recommendations specific to your model and application Show how to tie off a bale Include adding a piece of flat cardboard over the top of the finished bale prior to the last compression cycle Use only properly sized baling wire Visibly inspect wire for damage nicks sharp kinks etc immediately before use Do not use damaged baling wire Baling wire should not be re used Use the maximum number baling wires allowed by the number of available slots on the back of the machine This will be five wires on standard 2300HD machines and will never be less than four Care should be taken when handling any potentially sharp objects such as baling wire Follow appropriate procedures and precautions Removal of the bale from the area in front of the machine after it is ejected is not covered in this procedure due to the wide variety of methods and procedures in use A bale cart pallet etc may be placed in front of the baler before the bale is ejected to catch the bale and to better facilitate bale removal and transportation This procedure starts once a full bale is determined to be in the baling chamber and assumes the machine stops the previous cycle in the normal way with the ram fully raised and the feed gate open 1
35. aulic Leak 1 Check all connections for leaks MOTOR DOES NOT STOP WHEN RAM RETURNS TO THE UP POSITION POSSIBLE CAUSE POSSIBLE REMEDY Limit Switch 1 Check for broken limit switch arm 2 Improper switch adjustment 3 Bad contacts in motor starter HYDRAULIC PRESSURE NOT OBTAINABLE Worn Pump Cylinder bypass Relief valve malfunction Improper pressure setup Loose fitting A B A B C D TROUBLE SHOOTING GUIDE BALER IS NOISY POSSIBLE CAUSE POSSIBLE REMEDY Ram Rubbing Cylinder and ram may not be centered Noise at Directional Valve in chamber Cylinder rod may be bent Directional valve worn Check for broken springs inside valve PUMP NOISE POSSIBLE CAUSE Oil Reservoir Level Low Worn Pump Restricted Inlet Strainer Air Leakage in Oil POSSIBLE REMEDY Check oil level gauge on reservoir add oil if necessary Check hydraulic system pressure Replace strainer Check for foamy hydraulic fluid in reservoir oil level gauge ELECTRICAL INFORMATION The unit as shipped is pre wired to a specific voltage as shown on the cover of its control panel The standard baler is intended for indoor installations only Please contact PTR Baler and Compactor Co if a baler is required for an outdoor application CAUTION If your power supply voltage does not agree with the voltage stated on the Compactor control panel cover DO NOT CONNECT THEM damage may occur Have an authorized electrician reset
36. cessories requiring repair or replacement within the warranty period shall be returned PREPAID to the PTR BALER AND COMPACTOR COMPANY at the expense of the buyer lessee or consignee The PTR BALER AND COMPACTOR COMPANY will return at its expense replacement parts components or accessories found to be defective Shipment of parts under warranty shall be made via United Parcel Service or Parcel Post Cost of any other means or transportation shall be paid by the equipment user PTR BALER AND COMPACTOR COMPANY does not assume any responsibility of liability for improper use of the equipment or improper installation of any unit part or accessory which may cause damage to the unit The installation of parts or accessories manufactured or sold by any other supplier shall be deemed to void all warranties Warranty claims for equipment will not be proceeded unless a properly completed and signed warranty card attached to the installation checklist has been received NON WARRANTABLE REPAIRS Routine adjustments limit switches pressure switch or relief valve Tightening of hydraulic fittings and terminal connections Electrical fuses tripped over loads or breakers Power to the unit phase change motor rotation change facility electrical problems or damage by customer from improper electrical hook up to unit Addition of hydraulic oil Ejector system parts such as chains t hooks and shackles 7 Repairs necessitated by improper use s
37. ck indicated it is generally easier to feed the wire this way as opposed to the alternatives 9 Repeat with a wire in each of the available wire slots feeding each one loop end first Do not cross the wires each wire should pass though corresponding wire slots on the chamber floor and on the ram face Do not put baling wire through the two slots occupied by the bale eject chains Do not allow baling wire to tangle with bale eject chains or other baling wire 10 From behind the baler take each wire and pass the loop end over the bale through the available wire slots in the ram face until the loop end of wire protrudes slightly beyond the ram toward the front of the machine Pull additional wire from under the bale as required to continue feeding wire over the bale 11 Walk back to the front of the machine 12 Pull each loop end of the wire until there is sufficient slack to pull loop end down to the bottom corner of the bale where the wire was originally fed under the bale 13 Carefully pass the non loop end of the wire through the baling wire loop 14 Manually pull the wire snuggly around the bale 15 Carefully wrap the section of wire that protrudes through the loop around the rest of the wire several times to tie off the bale 16 Move behind the baler and engage the ejector chain tee hooks onto the ram ejector brackets 17 Turn the machine back on 18 Itis importance to allow the machine to au
38. d on the baler b Using the baler only after receiving instruction c Reporting any damage to or malfunction of the baler by submitting a report to the employer or responsible authority when the damage or malfunction occurs d Ensuring that access doors and service opening covers are in place secure and or locked before operations begin e Ensuring that the area of operation around container cart lifting systems and the container will be clear of persons during all phases of the lifting operation prior to energizing the dumping system f Ensuring that all persons are clear of the baler point of operation before actuating any compaction cycle controls or container cart lifting system controls and being prepared to stop the compaction cycle or container dumping operation if necessary g Ensuring that all persons are clear of the tailgate on baler container combinations so equipped before the tailgate is opened or shut The operator shall warn all persons not to cross behind or under an open tailgate h Using the baler in accordance the manufacturer s instructions including ensuring the proper position of all locks doors guards etc i Ensuring that no one disables or bypasses safety interlocks switches or other protective devices and that the baler is not operated unless these devices are fully functional j Locking out the unit when inspecting malfunctions jams or other problems arising from daily operations servicin
39. eavier wire Line must be fused with time delay fuses Once the power has been properly connected press the Down Up button and observe direction of the rotation of the motor Look at the motor fan proper rotation is clockwise As indicated by the arrow on the motor If the fan rotation is not clockwise follow the lock out tag out procedures and interchange any two and only two of the three power connecters and re check for proper rotation This should correct the problem Affix the provided seal across the control box opening This sticker must then be ripped to access the control box after the initial install The sticker reads Danger High Voltage Danger Do Not Open This Control Box Can Only Be Serviced Authorized Personnel Any scrap material should be picked up and discarded after the completion of the installation All scratches and exposed metal on the baler must be touched up out the Operating and Safety Checklist the Preventative Maintenance Checklist and the Baler Installation Information sheet Supply the customer with the operation manual and video Also get them to sign them the two checklists and the Baler Installation Information sheet which must be completed and mailed or faxed to PTR TO BE COMPLETED BY INSTALLER 2207 E Ontario St Please complete and mail fax this form along with the Philadelphia PA 10134 completed Baler Safety Checklist immediately after installation Fax
40. ejector chains Close and latch the bale chamber door d Ready for a new bale of cardboard 1 Follow steps A B amp C NOTE a Occasionally paper will be wedged in the ram area 1 Turn off the power at the disconnect box and remove any excess paper if left to build up it could affect the operation of the baler b Sometimes an operator will try to run the baler and it does not operate 1 Be sure the power key switch is ON 2 Be sure gate is pulled down completely 3 Be sure chamber door is completely closed 4 Be sure not to lift the gate while ram is moving baler will shut down and not start until gate is pulled down to the top of the chamber door 5 Other checks are discussed in the trouble shooting section See Table of Contents OPERATING INSTRUCTIONS FOR BALERS WITH THE GATE SECUR LOCKING SYSTEM TO COMPRESS MATERIAL POWER KEY 1 2 3 4 Turn selector switch to UP position press START button Load material evenly in the chamber Pull gate down Turn selector switch to DOWN position press START button TO EJECT FINISHED BALE POWER KEY ON bD 10 11 12 Turn start switch to UP position press START button Place a flat piece of cardboard on top of bale Pull gate down Turn start switch to DOWN position press START button When ram stops open bale chamber door wide so ejecting bale will clear Insert and tie 4 bale wires
41. ergy control procedures are provided such as Warning Follow lockout tagout procedures before entering b These instructions shall include the requirement to affix a sign to the baler at or near the entrances to those confined spaces for which hazardous energy control procedures are provided such as Danger Confined Space 8 Safety and training program 8 1 General 8 1 1 Employers shall evaluate and manage safety issues related to the operation of baling equipment as part of their safety program Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC 8 2 Safety program 8 2 1 The employer s program shall include at a minimum the following elements a A hazard assessment in which the employer conducts a review of the various types of baling equipment that the employer utilizes and the hazards associated with them and review and assess the capabilities qualifications and training of any person who may potentially encounter these hazards b An evaluation of the means and methods of controlling the hazards identified in the hazard assessment including information such as industry and regulatory requirements instructions for the operation inspection and maintenance of balers and other information a
42. ermal or other potential energy sources 0 gravity kinetic etc It shall be used to ensure that the baler is stopped isolated from all potentially hazardous energy sources and locked out before employees perform any servicing or maintenance where the unexpected energization or start up of the baler or release of stored energy could cause injury 7 3 3 The lockout tagout procedure shall include but is not limited to the following a Shutting down all power sources b Removing keys or other devices that enable the baler c Using a lock to secure the power supply or if that is not feasible installing a tag on an appropriate location using a non reusable fastener or installing a similar warning device d Placing operating components in such a position so as not to be subject to possible free fall and or installation of additional blocking devices to prevent such free fall of any raised or elevated component and e Relieving stored hydraulic or pneumatic pressure after blocking devices are installed if maintenance is to be done to the hydraulic or pneumatic system 7 3 4 The procedure shall address the following a Sequence of lockout for the baler 1 Notify all affected employees that servicing or maintenance is required on a baler and that the baler must be shut down and locked out to perform the servicing or maintenance 2 The authorized employee shall refer to the company procedure to identify the type and magnitude o
43. f the energy that the baler utilizes shall understand the hazards of the energy and shall know the methods to control the energy 3 If the baler is operating it must be shut down by the normal stopping procedure depress stop button open switch close valve etc 4 De activate the energy isolating device s so that baler is isolated from the energy source s 5 Lock out the energy isolating device s with assigned individual lock s 6 Stored or residual energy must be dissipated or restrained by methods such as grounding repositioning blocking bleeding down etc Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC 7 Ensure that the baler is disconnected from the energy source s by first checking that no personnel are exposed then verify the isolation of the equipment by operating the push button or other normal operating control s or by testing to make certain the equipment will not operate Caution Return operating control s to neutral or position only after verifying the isolation of the equipment NOTE The machine or equipment is now locked out b Restoring the baler to service When the servicing or maintenance is completed and the baler is ready to return to normal operating condition
44. g or performing maintenance except maintenance testing The affected employee shall identify the type and magnitude of the energy that the baler uses shall understand the hazards and know the methods to control the energy see 7 3 k Coupling and securing a compatible container to a baler frame as specified by the baler and container manufacturer s Operating inspecting and maintaining the baler only if 18 years old or older and after being properly instructed and trained and m Loading but not operating the baler only if 16 years old or older Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC 7 3 Procedures for the control of hazardous energy sources lockout tagout 7 3 1 The owner employer shall have a hazardous energy control lockout tagout procedure to follow when performing servicing and maintenance on balers where the unexpected energization or start up of equipment or release of stored energy could cause injury to employees 7 3 2 The owner employer shall utilize the instructions provided by the manufacturer for the control of hazardous energy sources The lockout tagout procedure shall isolate and render safe all energy sources including electrical mechanical hydraulic pneumatic chemical th
45. gly recommends that current completed applicable ANSI and OSHA standards are available to operators at all times PTR Baler and Compactor Company strongly recommends Keep the baler clean and free of contaminant Failure may cause illness or death Bale clean Cardboard only Note The information contained herein is subject to change without notice We reserve the right to make changes and alterations to the equipment and information contained herein at anytime Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC 7 Operational requirements 7 1 Owner employer responsibilities for balers The owner employer shall provide properly maintained balers that meet all applicable regulatory safety requirements and the requirements of this standard and shall be responsible for all of the following a Ensuring that the installation of the baler conforms to local codes ordinances and manufacturer s recommendations If installing into a system examine prevailing safety standards of associated equipment b Providing to employees instruction and training in safe work methods before assigning them to operate clean service maintain modify or repair the baler Such instruction and training shall include procedures provided by
46. he equipment grounding terminal or lead on the baler A qualified electrician should be consulted if there is any doubt as to whether an outlet box or the machine is properly grounded 3 HP MOTOR 3 PHASE 60 CYCLE Voltage F L A Fuse Wire Size Disconnect Switch 200 208 10 amp Time Delay 14 30 amp 220V 230V 9 amp Time Delay 14 30 amp 440V 460V 5 amp Time Delay 14 20 amp 550 575 4 amp Time Delay 14 20 amp 5 HP MOTOR 3 PHASE 60 CYCLE 200 208 16 Time Delay 12 30 amp 220V 230V Time Dela 12 440V 460V Time Delay 14 550V 575V 6 amp Time Delay 14 30 amp 10 HP MOTOR 3 PHASE 60 CYCLE 200V 208V 29 Time Delay 8 60 amp 220V 230V 26 Time Delay 8 60 amp 440V 460V 14 amp Time Delay 12 30 amp 550V 575V Time Dela 30 amp 15 HP MOTOR 3 PHASE 60 CYCLE 200 208 43 amp Time Delay 6 60 amp 220V 230V 39 amp Time Delay 6 60 amp 440V 460V 20 Time Delay 8 60 amp 550V 575V 16 amp Time Delay 10 30 amp 20 HP MOTOR 3 PHASE 60 CYCLE 200V 208V 57 Time Delay 4 100 220V 230V 51 Time Delay 4 100 440 460 30 Time Delay 8 60 amp 550 575 21 Time Delay 8 60 amp PTR BALER AND COMPACTOR FOR SERVICE PTR BALER AND COMPACTOR CO FOR SERVICE 215 533
47. hiladelphia PA 19134 800 523 3654 800 523 1155 215 533 5100 THANKS AGAIN FOR YOUR PATRONAGE OF PTR BALER AND COMPACTOR COMPANY PTR Baler amp Compactor Co 2207 E Ontario St Philadelphia PA 19134 PHONE 215 533 5100 FAX 215 533 8907 Baling wire recommendation for PTR Baler and Compactor Company s standard built balers producing bales of ordinary cardboard Consult PTR Baler and Compactor for wire recommendations for non cardboard applications MODELS 1800HD 2318 2300HD 3400HD 3600HD 7230 Minimum of 14 Ga galvanized steel wire approximately 14 long with one end looped for bale tie off Wire is to have a tensile strength of approximately 70 000 to 85 000 psi or more and a break strength of approximately 380 to 420 pounds or more MODELS 360 420 Minimum of 15 Ga galvanized steel wire approximately 9 long with one end looped for bale tie off Wire is to have a tensile strength of approximately 75 000 to 80 952 psi or more and a break strength of approximately 300 to 340 pounds or more MODELS 5000HD 7200HD Minimum of 12 Ga galvanized steel wire approximately 16 long with one end looped for bale tie off Wire is to have a tensile strength of approximately 70 588 to 76 136 psi or more and a break strength of approximately 600 to 670 pounds or more Additional Information At least four baling wires must be used per bale Slots are available for five or more bailing wires to be used Care should
48. indicator arrows on the ram face and wall match as ram reverses To tie off and eject a bale Load Evenly 1 SN u P With ram in the UP position Insert a flat piece of cardboard on top of the bale this will provide a flat surface for tying Pull gate down Turn power key switch to ON position Set the UP DOWN switch to DOWN Press the DOWN button When the ram cannot compress the cardboard any further press the STOP button BALER OPERATING INSTRUCTIONS Continued 11 12 13 14 15 16 17 18 19 20 21 Lift gate unlatch and open chamber door at least 110 degrees Do not stand in front of the door Slide baling wire through slots in floor and back through slots in ram Tie off all wires Position a pallet hand truck forklift in front of baler opening to receive the bale when it s ejecting Place ejector hooks onto the ejector ram lugs in the back of the baler Set the UP DOWN switch to the UP position Pull gate down as far as it will go Press and hold the UP switch until the bale ejects Pull gate down as far as it will go Turn the UP DOWN switch to the DOWN position Press the DOWN button and hold ejector chains and hooks will automatically disengage during downward travel Turn the UP DOWN switch to the UP position Press the UP DOWN button and hold down until the ram is in the UP position Lay a flat piece of cardboard on the bottom of the bale chamber over top of the
49. is closed Upper Limit Switch malfunction Upper Limit Switch needs adjustment Reset overload on motor starter 2 Check current Load Amps Replace fuses Turn power off at wall disconnect switch Perform electrical system continuity check BALER WILL NOT OPERATE IN AUTO All the above can be applied to the Auto Mode POSSIBLE CAUSE Door Switch Pressure Switch Relay Plug In POSSIBLE REMEDY Main door may not be closed properly against switch Door Switch loose Door Switch malfunction Improper pressure setting Bad electrical contact Loose on base in control enclosure A B C D E TROUBLE SHOOTING GUIDE RAM WILL NOT TRAVEL DOWN POSSIBLE CAUSE Directional Valve Malfunction Relay Electrical Malfunction Material Jamming Ram Ram Switch Pressure Switch Solenoid Proximity Switch Ne POSSIBLE REMEDY Check valve solenoid Push in manual override pins are on each end of solenoid May be loose in base Perform electrical system continuity check Remove all jamming material from ram Ram Switch not in proper position Limit Switch malfunction Adjust Limit Switch Pedal Switch jammed in down position Improper pressure setting Bad electrical contact Check for shifting of solenoid check light Proximity switch must detect plate mounted on gate counter weight Proximity switch malfunction A B
50. ked out before working within or performing maintenance on the baler or associated equipment Standard Lockout Tagout procedures should be followed in accordance with the OSHA standard 1910 147 The control of hazardous energy A group safety lock should be used when multiple employees are working on the machine at one time so that all locks need to be removed in order to be able to re energize the baler Every employee who works on or with the baler should have his own lock and key Never assume you are protected by another employee s safety lock Keep Safety Guards in Place Safety guards must be kept in place and secure at all times Keep the guards in good repair with periodic maintenance Keep limit switches free of debris or obstructions Do not override of bypass safety switches or features If feed gate becomes difficult to open or close maintenance should be informed Operators should be instructed on how to conduct a brief visual safety inspection that includes areas door hinges and latch Also how to conduct a visual inspection of the ejector chains t hooks and shackles Operator should know that maintenance should be called if there is any evidence of damage or if anything looks different as opposed to prior inspections Practice Fire Prevention 1 Keep fire extinguishers accessible at all times Use the extinguisher recommended for the material being baled It should be rated safe for use of electrical fires 2 Ne
51. le free from breaks amp wear on insul amp properly secured 3 Check all relays for proper position and continuity 4 All switch buttons selectors tight and properly aligned 5 Check amp Inspect A Reset button on starter B Up stop Limit C Main door limit D Safety door limit E Pressure switch F Check auto size timer G Security door switch H Gate interlock box I Ram safety limit switch COMMENTS Serviceman s Signature Store Manager s Signature Date PREVENTATIVE MAINTENANCE CHECKLIST BALER AND COMPACTORS DATE JOB NO STORE NO LOC CUSTOMER HYDRAULIC amp MECHANICAL STRUCTURAL Comp Baler Comp 1 Oil Level 1 Physical Appearance 2 Condition of Oil Paint 3 Cylinder Connections B Rubber Filler around chute A Directional Valve C Area clear of foreign B Top Valve 7 material 4 C Valve Connections 2 Frictional Parts 4 Pressure Setting A Excessive wear Pressure settings 1 Bailing Chamber b B Relief settings 2 Ram Guides C 5 Line or hose clamps y 3 Lift Gate Tracks C 6 Motor pump coupling 4 Slide Cover 7 Cylinder Seals B Lubricate Gland Leaky cs 1 Gate Track B Gland Loose T x lt 8
52. m or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the compactor A qualified electrician should be consulted if there is any doubt as to whether an outlet box or the machine is properly grounded 3 HP MOTOR 3 PHASE 50 CYCLE Voltage F L A Type Fuse Wire Size Disconnect Switch 380V 5 4 Time Delay 14 30 amp 415V 5 2 Time Delay 14 30 amp 440V 5 0 Time Delay 14 30 amp 5 HP MOTOR 3 PHASE 50 CYCLE 380V 8 7 Time Delay 12 30 amp 415V 8 0 Time Delay 12 30 amp 440V 7 8 amp Time Delay 14 30 amp 10 HP MOTOR 3 PHASE 50 CYCLE 380V 17 amp Time Delay 8 30 amp 415V 16 1 amp Time Delay 8 30 amp 440V 15 amp Time Delay 12 30 amp 15 HP MOTOR 3 PHASE 50 CYCLE 380V 23 1 amp Time Delay 8 60 amp 415V 22 amp Time Delay 8 60 amp 440V 21 5 amp Time Delay 8 60 amp 20 HP MOTOR 3 PHASE 50 CYCLE 380V 29 2 amp Time Delay 8 60 amp 415V 28 amp Time Delay 8 60 amp 440V 27 5 Time Delay 8 60 amp Wire Size denotes minimum wire size required to be used from power supply to disconnect switch Use a heavier wire if distance is more than 25 feet PIR BALER COMPACIOR MOTOR WIRING GUIDE 9 WIRE DELTA THREE PHASE FOR 3HP SHP 208 230 VOLT 380 460 VOLT
53. paint if required 6 All safety signs in place 7 Gate moves up down easily See sticker location drawing in manual INSTALLER S CHECKLIST PRIOR TO INSTALLATION A main electrical disconnect providing over current protection must be furnished by the user of this equipment Refer to electrical section for setup information See Table of Contents Determine if the available electrical current agrees with the voltage marked on the front of the panel door and the wiring of the motor starter AFTER INSTALLATION The unit is shipped with oil in the hydraulic system and reservoir IMPORTANT Before operating baler remove the pipe plug at the fill opening in the reservoir and install the breather cap located in the blue box in the zip lock bag in the control panel OIL LEVEL With the ram in the full UP position oil in the sight glass on the reservoir should be at the high mark on the gauge DOOR Open and close the door to make sure that it is free and easy to move ELECTRICAL If an electrician is available advise them about proper motor fan rotation If the rotation is not correct follow lock out tag out procedures and interchange any two of the three power conductors IMPORTANT If an electrician is not available advise the store manager about the motor fan rotation GATE Pull gate up and down to make sure that it is free and easy to move If the gate is hard to move check the roller chains to make s
54. ppropriate to the hazards that are identified C A written program based upon the hazard assessment and evaluation to include procedures for the operation inspection and maintenance of balers prohibited practices record keeping training requirements and normative references to documents such as operating manuals that are relied upon and may be required as part of that program d A program conforming to 8 3 for the implementation of the written program and e Periodic review and program revisions as necessary to ensure the effectiveness of the safety program 8 3 General training 8 3 1 Employers shall ensure all employees including supervisors contract laborers and all other persons engaged in the operation cleaning maintenance service or repair of baling equipment are properly trained appropriate for their assigned jobs and tasks Contractors who may be engaged to operate or maintain the employer s balers shall be advised of the unique hazards related to the equipment that may affect the activities in which the contractor s employees will engage 8 3 2 Training frequency 8 3 2 1 Training shall be provided upon initial assignment to a job or task with periodic refresher training to maintain the required level of competence Retraining shall be provided for employees whenever their job assignments change or an equipment change occurs that presents a new hazard Additional retraining shall be provided whenever the employer has
55. r number one priority We ask that all operators read and fully understand this manual and view provided safety operational video All baler operators must be at least 18 years old e UL Approved and CUL Approved IMPORTANT A The operating keys are located inside of the control panel A tool is required to open the control box and only trained and authorized service personnel should enter following proper lockout tagout procedures B When power has been properly connected press the Down Up button and observe the direction of the rotation of the motor Look at the motor fan proper rotation is clockwise As indicated by arrow on motor If fan rotation is not clockwise follow lock out tag out procedures and interchange any two of the three power conductors re check for proper rotation This should correct the problem GENERAL PTR s vertical downstroke baler is designed with the operator s safety in mind However as with most industrial equipment the ultimate responsibility for safety rests with the operator It is the operator s duty to be thoroughly familiar with this manual and video before operating the baler Additional operator responsibilities are to insure that the units operation is in accordance with safety requirements and codes especially all applicable Occupational Safety and Health Administration O S H A standards and American National Standard Institute A N S I Regulations PTR stron
56. reason to believe or periodic inspections reveal that employee deviations from procedures have occurred or inadequacies in the employee s knowledge of procedures become evident 8 3 3 Instructional information 8 3 3 1 Employers are required to refer employees to and have readily available the manufacturer s instructions to ensure correct operating and maintenance procedures and work practices are understood and followed Employers are required to ensure employees possess knowledge and skills to safely operate the baler 8 3 4 Contract labor Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC 8 3 4 1 Employers shall ensure for each job or task performed that training is provided either by the contract laborer s parent employer or by the employer 8 3 5 Training records 8 3 5 1 Employers are required to maintain training records to include the date s of the training and the type of training received Records are required to be maintained as required by applicable regulations Contractors and contract laborers are required to provide the employer with appropriate training records upon demand 8 3 6 Equipment specific training 8 3 6 1 Training shall be tailored for individual operations and the type of equipment utili
57. rev 3 3 10 03 2 1 8 03 rev 1 3 13 02 9 4 01 TITLE LOT WARNING DECALS amp INSTRUCTION PLATES DWG NO AB4004554 WARRANTY PTR BALER AND COMPACTOR COMPANY warrants all equipment when operated maintained and installed and used in normal service for a period of three hundred sixty five 365 days after the date of installation to be free from defects in material and workmanship The responsibility of PTR BALER AND COMPACTOR COMPANY under this warranty to the purchaser except as to title shall not in any case exceed the cost of correcting defects in the equipment Warranty repair or replacements shall not extend the initial warranty period PTR BALER AND COMPACTOR COMPANY shall under no circumstances be responsible for any loss of business or profit to the purchaser or any other consequential damages in connection with the sale of such equipment or any obligation under this warranty The foregoing shall constitute the sole remedy of the purchaser and the responsibility of PTR BALER AND COMPACTOR COMPANY Warranty repairs and or replacements at our option will be made for both parts and labor The authorized service center must use PTR BALER AND COMPACTOR COMPANY authorized parts Labor will be allowed at a maximum of 40 hourly rate Premium rates will be at the customer s accountability All warranty calls must be called into PTR BALER AND COMPACTOR COMPANY for dispatch 1 800 523 3645 All parts components or ac
58. rk 2 Providing for the cleaning inspection and repair of the baler in accordance with the manufacturer s recommendations including periodic maintenance 3 Ensuring that all required safety features are operational and functioning and repairing prior to placing into service any reported malfunction or defect that affects the safe operation of the baler and 4 Ensuring that all caution warning and danger markings required by 5 14 are installed and legible or are replaced if damaged defaced or missing i Utilizing the manufacturer s recommended procedures for the control of hazardous energy sources lockout tagout in a program complying with Part 1910 147 of Title 29 of the Code of Federal Regulations OSHA see 7 3 Compaction Equipment Reference Excerpts from American National Standard Z245 5 2004 Copyright 2004 by the Environmental Industry Associations and has been reprinted and reproduced with the permission of the publisher The Waste Equipment Technology Association WASTEC j Utilizing the manufacturer s recommended procedures for access control for permit required confined spaces as part of the employer s program see 7 4 k Protecting any person by one of the methods in 5 8 1 or by other means as effective as those means of protection 1 For balers fed by means of a loading pit conveyor reciprocating floor or push pit that is flush with or below the facility floor providing 1 Protection for employee
59. s 8 7 6 2 8 7 8 7 E 6 8 7 2 9 75 10 9 5 10 8 7 12 11 10 11 F 11 4 2 5 1 5 55 5 10 5 11 5 11 6 9 G 2 2 2 465 3 5 3 5 3 5 3 5 3 5 H 2 8 2 8 3 7 4 88 4 6 2 9 1 5 4 5 1 7 Per 2 1 2 3 2 4 7 2 2 2 2 J 5 6 7 2 Hus 8 9 9 4 9 4 10 8 K 3 2 3 8 4 11 5 10 5 10 5 10 6 6 L 0 5 8 o 5 gv o r 0 7 0 7 0 7 M 1 6 1 6 1 6 1 6 45 85 r e 1 6 1 6 1 6 1 6 tee 1 6 4 the BALER INSTALLATION GUIDE Place the Baler in the location desired by the customer While doing so be sure to maintain the minimum clearances listed in dimension table otherwise the baler will not be able to function properly After the baler has been placed it must then be anchored to the floor using the 4 supplied anchors through the mounting holes on the bottom of the baler Run power to the control panel from the customer supplied wall disconnect NOTE The disconnect must adhere to local state and federal electrical and safety codes and must be located within line of sight of the Baler start controls The manual electrical section can be referred to for minimum wire size amperage requirements and fuse specifications Wire sizes given are for runs of under 25 ft longer runs require h
60. s by means of i Limiting access within 6 feet 183 cm of the edge of the pit to authorized employees ii Training authorized employees to recognize and avoid the hazards associated with the pit area iii Requiring that others whose employees use the pit area provide assurance of such training and iv Limiting access by unauthorized persons by installing signs such as RESTRICTED AREA AUTHORIZED EMPLOYEES ONLY 2 Providing a device to the extent practicable which prevents trucks or other motor vehicles that unload directly into the loading pit from rolling into the pit m When balers equipped with automatic start cycling controls are provided allowing their use only in locations where a startup alarm is utilized or it is demonstrated that automatic starting does not result ina risk of injury to persons NOTE Achieving acceptably low risk of injury would include demonstrating that lockout procedures are strictly adhered to when bridging in feed chutes occurs or jammed material must be cleared from the loading chamber n Providing guard railings for dock ramps that meet U S Occupational Safety and Health Administration requirements These shall be located around the loading chamber opening if walk on ramps are used to deposit refuse into the loading chamber Guard railings and toe boards shall be provided on the sides of docks and ramps Providing for an adequate work area around the baler for safe maintenance servicing
61. the following steps shall be taken 1 Check the machine or equipment and the immediate area around the machine or equipment to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact 2 Check the work area to ensure that all employees have been safely positioned or removed from the area 3 Verify that the controls are in neutral 4 Remove the lockout devices and reenergize the machine or equipment NOTE The removal of some forms of blocking may require re energizing of the machine before safe removal 5 Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use 7 4 Procedures for work in confined spaces 7 4 1 The owner employer shall have a written procedure for work in confined spaces meeting the criteria of permit required confined spaces such as integrated power units The procedure shall utilize the manufacturer s instructions for the hazardous energy control lockout tagout procedure which shall isolate and render safe all energy sources including electrical mechanical hydraulic pneumatic chemical thermal or other potential energy sources e g gravity kinetic etc which may create a hazard during entry into each of those confined spaces a These instructions shall include the requirement to affix a sign to the baler at or near the entrances to those confined spaces for which hazardous en
62. the unit to match your power supply voltage By code the control panel wire harness must be connected to a properly sized fused disconnect switch The disconnect switch should be time delay fuse type and must be located less than 15 feet and adjacent to the compactor while always within clear view of its operator MINIMUM SIZING REQUIRED Wire size denotes wire to be used from power supply to disconnect switch use heavier wire if distance is more than 25 feet CONVERSION VOLTAGE In order to convert the compactor from high to low voltage or vise versa the following components must be changed Motor connection as indicated by diagram on motor Transformer connection as indicated by diagram on transformer Overload size as indicated by voltage requirements IMPORTANT MOTOR ROTATION When power has been properly connected press the START button momentarily and observe the direction of the rotation of the motor Look at the motor fan proper rotation is clockwise If fan rotation is not clockwise interchange any two of the three power conductors This should correct the rotation CHECK OPERATION Check by following the operating instructions listed on the cover plate of the unit s control panel ELECTRICAL INFORMATION GROUNDING INSTRUCTIONS The baler must be connected to a grounded metal permanent wiring system or an equipment grounding conductor must be run with the circuit conductors and connected to t
63. tomatically lift the gate during bale ejection Verify that the loading gate is fully lowered to the top of the ram Do not lower the gate below the ram Warning Ejecting a bale with the feed gate below the ram will cause gate damage 19 Ensure that the area in front of the baler is clear of all personnel and that baler door is still open beyond 90 degrees of the side of baler 20 Raise the ram and eject the bale Do not attempt to attempt to attach the ejector chains while the ram is in motion Do not allow anyone to walk behind baler while it is in motion 2 Remove the bale from in front of the machine 22 Close the main bale dump door and lower the feed gate 23 Run the ram down to automatically disengage the ejector chain tee hooks from the ejector brackets 24 Turn the key back off and remove it from the control panel 25 Place a large piece of flat cardboard on the floor of the baler before starting new bale Cardboard should be long and wide enough to cover all slots on bale chamber floor A B C D E A B C TROUBLE SHOOTING GUIDE BALER WILL NOT OPERATE POSSIBLE CAUSE No Power Limit Switch Ram Motor Overload Tripped Blown Fuses Electrical Malfunction ON d WN POSSIBLE REMEDY Check main power source Check if power key switch is on Reset Overloads Check motor starter contacts for extreme wear Check if gate is down Check bale chamber door
64. uch as failure to follow instructions and abuse of equipment 8 Operator error example chamber door not closed tight enough or gate not pulled down flush to top of chamber door 9 Damage or install errors from customer supplied installer NOTE Always have Serial and Model Number of unit ready when calling for service EUM QM PARTS AND SERVICE PTR Baler and Compactor Company has carefully chosen the components in your vertical downstroke baler to be the best available for you particular model We strongly recommend that all replacement parts be identical to the original components PTR Baler and Compactor Company will not be responsible for equipment failures resulting from use of incorrect replacement parts or unauthorized modification to the baler PTR Baler and Compactor will gladly supply replacement parts for your vertical downstroke baler Main components are identified in Parts Description Section See Table of Contents for page numbers When ordering please include the Model and serial Number of the unit This is located on the baler electrical panel box door shown in Control Cover Layout See Table of Contents for page numbers When ordering parts for a cylinder please include the Cylinder Number which is shown in Parts Description Section See Table of Contents for page numbers To order replacement parts please call the parts and service department PTR BALER AND COMPACTOR COMPANY 2207 E Ontario Street P
65. ure that they are on the sprockets Counter balance tubes are bolted on for ease of adjustment Not on all models PRESSURES Start machine and check to see if pressure switch setting and the relief valve setting are at the recommended settings If either is incorrect see pressure setting procedures See Table of Contents 10 11 12 13 PRESSURE SETTING PROCEDURES Disconnect 8 wires from bottom of terminal strip Adjust pressure switch setting to a very high point Press Down button Extend ram allow pressure to read consistently on the gauge Back relief valve off until the pressure gauge reads working P S I desired Lock relief valve there Shut off baler reconnect 8 wires Restart baler Adjust pressure switch DOWN until the solenoid valve shifts and the ram starts UP Lock pressure switch at that point and disconnect 8 wires from electrical circuit of the pressure switch Extend ram to allow pressure to read consistently on the gauge Adjust relief valve in until the pressure gauge reads maximum P S I desired Lock relief valve at that point Reconnect 8 wires Your working pressure and maximum pressure are now set BALER AND DESCRIPTION PART NO ENCLOSURE 14X12X6 500147 ON OFF KEY SWITCH 155408 UP DOWN BUTTON 155397 EMERGENCY STOP BUTTON 155398 OVERLOAD RESET BUTTON 602436 DESCRIPTION PART NO ENCLOSURE See above TRANSFORMER 155350 STA
66. us conditions and actions required to avoid hazardous conditions such as Do not operate d Placing operating equipment in such a position as not to be subject to possible free fall and or installing additional blocking devices to prevent freefall See drawing number AB340367 in user manual e Relieving stored hydraulic or pneumatic pressure after blocking devices are installed Equipment isolation shall be verified by activating the normal operating controls ensuring first that no personnel are exposed insure operating controls are returned to the neutral or off position after verifying the isolation of the equipment When the servicing or maintenance is completed only after checking that the equipment is ready to operate ensuring that the surrounding area is clear that employees are safely positioned or removed from the area and verifying that controls are in neutral shall the lockout devices be removed and the equipment be re energized Tags and locks must be removed by the same person who attached them Affected employees shall be notified that the servicing or maintenance has been completed and the equipment is ready for use PTR Baler amp Compactor strongly recommends that current and applicable ANSI and OSHA standards be made available to operators at all times At the time of printing the applicable OSHA Standard 29 1910 147 1910 147 Appendix A applied Also reference ANSI Z245 5 others may also apply TI
67. ver smoke close to combustible material Clean the area before welding or other repair activities that produce sparks or source of ignition Keep tank and motor areas free of oil dust or paper accumulations Keep a Clean Machine gt Bale only clean cardboard Clean motor area monthly 3 Remove any wedged cardboard from sides and back of ram Remove any cardboard on the top of the ram daily 4 Remove any cardboard stuck on retainer dogs and limit switches 5 Keep baler clean and free of dirt and other contaminants Failure to do so may cause illness or death a Remember All possible Dangers cannot be predicted Your own safety attitude and habits are your best protection 10 11 Additional Safety Guidelines for Baler Operation Only authorized personnel 18 years of age or older who are trained in baler operation are permitted to operate the baler The owner and operator are responsible for the safety of the employees and should be familiar with applicable OSHA and ANSI standards Operate in accordance with the owner s manual supplied with your baler Do not set the hydraulic pressure above factory specs Specified pressures are listed inside the control box Severe baler damage and or personal injury could result Bale only the specified material for which the baler was built And also for which the hazard assessment was conducted for Never overload the baler chamber Never enter the main chamber area unless
68. zed including detailed equipment specific training for machine operators as well as maintenance personnel and supervisors who must operate equipment as part of their job duties Training shall include practical demonstration of equipment operation knowledge and skills by the employee as appropriate to the requirements of the employee s job duties 8 4 Training requirements 8 4 1 Training is required to include at a minimum The necessary training as identified in the hazard assessment see 8 2 1 b The training required by laws and regulations such as those of federal and state Occupational Safety and Health Administrations the Departments of Transportation and other applicable regulatory agencies and c Operational instruction on each specific type of equipment used by the employee including the instructions provided with the equipment Baler Operational And Repair Safety Instructions WARNING DO NOT OPERATE BALER WITHOUT THOROUGH UNDERSTANDING OF INSTRUCTIONS DAILY PERFORM SAFETY CHECK TO ENSURE PROPER INTERLOCK FUNCTION ONLY AUTHORIZED PERSONNEL SHOULD BE ALLOWED TO OPERATE THIS BALER Keys to this machine should be removed between uses to prevent unauthorized operation Federal regulation prohibits use of this machine by people under the age of 18 DO NOT ATTEMPT TO DEFEAT THE PURPOSE OF ANY SAFETY SWITCH Immediately replace any switches that are found not to be in proper working condition DO NOT OPERATE B

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