Excel EX62 User manual

1
HORIZONTAL BALER
EXCEL MODEL EX62
Owners Manual
FOR:
CUSTOMER _________________
SN: EX2_____
CUSTOMER SUPPORT
1-800-475-8812
 January 15th, 2012

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3


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 TORQUE LIMITER 40
6

INSTALLATION INSTRUCTIONS 15 PUMP 40
ELECTRICAL REQUIREMENTS 15 PHOTO EYE 40
CHANGING VOLTAGE 15 12 

DETAILED PART IDENTIFICATION 42
INITIALSET UP 16 MAIN BALER 42
INSTALLATION SITE 16 PLATEN 46
BREATHER CAP INSTALLATION 16 CYLINDERS AND HOSES 48
HYDRAULICS 16 VALVES AND FITTINGS 50
CONNECTING BALER TO POWER SOURCE PUMP AND MOTOR 52
REMOVE ATTATCHED PARTS 18 ELECTRICAL ENCLOSURE 62
WIRE GUIDE INSTALLATION 18 LIMIT SWITCH RAIL 66
FINAL INSPECTION 19 PHOTO EYE 68
7

START UP AND TESTING 20
DECALS 70
8

OPERATING INSTRUCTIONS 22 HOPPER BOLT PATTERN DIAGRAM 72
OPERATING CONTROLS PREVENTATIVE MAINTENANCE
CHECK LIST 73
SEMI AUTOMATIC BALER CYCLE 24 WARRANTY 74
BALE TIEING 25 APPENDIX A 76
BALE EJECTION 27 ELECTRICAL SCHEMATICS 77
9

CARE AND MAINTENANCE 29 HYDRAULIC SCHEMATIC 87
CLEANING PLATEN AND REAR COVER 29 NOTES 89
FILLING OIL RESERVOIR 29
WEEKLY CARE REQUIREMENTS 30
SEMIANNUAL CARE REQUIREMENTS 32
YEARLY CARE REQUIREMENTS 32

4


INTRODUCTION
THANK YOU FOR CHOOSING AN EXCEL BALER.
You have selected a precision-engineered product designed with advanced features for modern recycling center baling. 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 weanticipate 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 [phone].
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 EX62 bales all plastic, 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 tieing 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
Tieing 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. Tieing 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 latch
while the baler is in operation, the motor stops then the platen decompresses and backs off the bale. The door also must be
completely open before the platen will extend to eject thebale.

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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 17
seconds cycle time, allowing material such as corrugated cardboard to be baled at higher production rates.
INTEGRATED CONVEYOR CONTROLS W/CONVEYOR MOTOR STARTER (optional)
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 anytime.

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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”
WIDTH - 77”
CHAMBER - 47”L x 60”W x 30”H
FEED OPENING - 54”W x 35”L
SHIPPING WEIGHT - 14,000 LBS.
*AREA REQUIRED TO OPERATE - 10’ x 20’
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 - D06 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 - 46 SEC. - 30 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 1700 Lbs.
Newspaper - Up to 1600 Lbs.
Corrugated Cardboard - Up to 1250 Lbs.
Tin Cans - Up to 1300 Lbs.
Aluminum Cans - Up to 650 Lbs.
HDPE - Up to 1100 Lbs.
*See diagram on next page.

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DiagramA. EXCEL Model EX62 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'senclosure that may be of sufficient magnitude to constitute
a risk of electric shock to persons.
The exclamationpoint within anequilateral triangle is intended toalert the user to the presence of important
safety reminders, and operating and maintenance (servicing) instructionsin the literature accompanying the
equipment.
The key andlock 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 ofthe unit, and to understand and adheretoall safetyprecautions in this manual. It is important to keep watch for any
condition or situation which may affect the safe performance of the equipment. Ifunsafe conditions arepresent 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 safetyand operating instructions before operating thebaler.
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) Onlyproperlytrained 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 safetyglasses 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
Everyunit manufactured by EXCEL has a RED extended head emergency stop button. All personnel should be aware that
depressing this button at anytime 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. Theymust not be overridden or removed in anymanner
which prevents them from functioning properly.
8. ACCESS COVERS
Access covers must beproperlymaintained and in placeat all times.
9. PINCH POINTS
All moving machinery has pinch points. EXCEL has provided guards on them where possible. Some, because ofthe operating
characteristics, cannot be guarded. Operators must use caution when closing doors, etc.

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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 onlyattachments and accessories approved by EXCEL.
13. CLEANING BALE CHAMBER OR BALER
The power must be shut offto the machine at the MAIN disconnect, and locked out, when entering the baler chamber to remove
debris, or to clean around thepower unit and cylinders. Refer to LOCK OUT/TAG OUT PROCEDURE section ofthis 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. Toprevent unauthorized use, turn off and lock out theBALER
disconnect. SeeDiagram G located in Connecting Baler to Power Sourceunder INSTALLATION INSTRUCTIONS. Also
refer tothe 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 ofany 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. Obtain newSafety Decals at no charge, by contacting Excel
Manufacturing.

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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 stronglyrecommended that
current OSHA and ANSI standards publications be available and
reviewed with operators at all times.
SAVETHESE 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 energysources. A
comprehensive publication of this standard can be obtained from OSHA. The purpose ofthis procedure is to ensure that the equipment
is isolated from its energysources 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 standardrequires employers to establish an energyprogram 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 ofthe 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 toisolate power (see diagram F).
3. Tag Out all other controls or energysources not capable of being locked out. Everyperson affected
should knowand understand all Lock Out Tags.
4. Verify that all energysources have been accounted for prior to service or maintenance work.
5. Torestart 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
The parts diagram on the following 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.
BASIC PART IDENTIFICATION
1. Bale Chamber 25. HOPPER OVER FILL LIMIT LOWER-UPPER - 2
Position Selector Switch
2. Retractable Dogs 26. BALER PHOTO EYE OFF-ON - 2 Position
Selector Switch
3. Removable Shear Blade With 4 Cutting Edges 27. REVERSE Button - Yellow
4. Feed Opening 28. Pilot Valve
5. Platen 29. Relief Valve
6. Wiper 30. Oil Reservoir
7. Access Panel (Rear of Baler) 31. Pump
8. Cylinders (Inside) 32. Motor
9. Bale Tie Light 33. Drain Plug (Optional Heater)
10. Six Wire Tie Slots 34. Temperature/Sight Gauge
11. Door 35. Breather Cap
12. Door Latch 36. Oil Filter
13. Turnbuckle - Ratchet 37. Clean Out Tool
14. 6 Wire Guides (Under Baler)
15. Control Panel
16. Photo Eye
17. Electrical Enclosure
18. BALER Power Disconnect Switch
NOTE: This is not the MAIN Disconnect Switch
19. EMERGENCY STOP - Red
20. FORWARD Button - Green
21. SYSTEM - 3 Position Key Switch and KeyHAND-
OFF-AUTO
22. SHORT STROKE OFF-ON - 2 Position Selector
Switch
23. CONVEYOR OFF-0N - 2 Position Selector Switch
24. CONVEYOR ON OVERRIDE - Push Button

14
DiagramB. EXCEL Model EX62 Basic Parts Identification Diagram.

15
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 offis 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.
Ifnot, a qualified electrician must take whatever steps are necessaryto 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 aremissing or appear damaged, contact your EXCEL
Manufacturing representative immediately.


INSTALLATION SITE
Careful consideration should be given to the site selected for the baler. Refer to Diagram A on page 3 to determine the amount of room
required to operate the baler. Ample room must beprovided to load the baler feed opening, remove a bale from the baler, and obtain
access to theback and sides of the baler for maintenance work and servicing.
Use extreme cautionwhen moving the baler into position. Watch for all persons whomay be in the path of the
baler and moving equipment.


BREATHER CAP INSTALLATION
Remove the Breather Cap from the baler’s electrical enclosure (Refer to Diagram B, Item 17). Remove the shipping plug from the oil
reservoir and install the Breather Cap. For the Breather Cap installation location see Item 35, Diagram B.

16


HYDRAULICS DiagramE. 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 tothe baler. Make sure
that the MAIN disconnect switch is padlocked in the OFFposition. 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 theAPPENDIX section of this manual for the wiring diagram and electrical schematic. A copy ofthe wiring diagram and electrical
schematic mayalso 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.

17
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 blow
them out 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 lineas shown in Diagram G on the next page.

18
DiagramG. 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 attatched to inside of bale
door.


WIRE GUIDE INSTALLATION (INSTALLED AT FACTORY)
Parts Required: EX2001-2424
6 - Wire Guides 12 – P-1016 Bolts
12 – P-1025 Flat Washers
12 – P-1024 Lock Washers
OR
EX 2425 & above
Studs 12 – P-1023 Nylock Nut
12 - P-1024 Flat Washer

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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 ofthe wire guide to the front ofthe 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.
DiagramH. Wire Guide Installation.
4. Use 2 – P-1016 bolts, 2 – P-1024flat washers, and 2 – P-1025 split lock washers to securethe guide. If your baler has
the factory installed studs, please use2 – 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, andloose
or missing bolts and nuts.

20
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 withthis test, make sure that all persons are clear of the baler.
1. With theMAIN 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 MAINsupply
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 ofthe arrow located on the motor housing when viewed
from thefan end. Ifthe direction arrow is missing, the motor must turn in same direction as indicating arrow on pump.
5. Insert the key into the key switch located on the control panel.
6. Turn the key counterclockwise to the HAND position.
7. Depress the green FORWARD button momentarily. The motor will start and the platen will move forward while the button is
being depressed.
8. Ifthe observer indicates that motor rotation is incorrect, depress the EMERGENCY STOP button IMMEDIATELY and go on
to step 9. If motor rotation is correct, skip to step 11.
9. 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.
10. To change motor rotation for 3 phase motors, switch anytwo 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 wasnecessary to switch them tocorrect
motor rotation.
Return tostep 4 and repeat the rotation testing procedure to assure proper motor rotation.
11. Turn the key switch toOFF and then toAUTO.