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Current maintenance

Maintenance instructions

Maintenance activities and inspections must be carried out carefully according to the instructions below. It is intended to ensure that the capacity of the mobile pre-container under the given conditions of use is maintained or restored to a state where it can function as needed in the most cost-effective manner possible.

Maintenance activities are of major importance especially at the beginning of the program.

Otherwise, the guarantee will lose its validity.

If appropriate specialists are not available, please contact the service department.

The persons operating the machine must have read and understood the instructions for use, especially the safety regulations.

Turn off the main switch (OFF, 0) and disconnect the pre-locker from the power supply before starting maintenance!

All work on electrical equipment must only be performed by a qualified, experienced electrician, in accordance with safety regulations.

It is forbidden to use the steam jet to clean the electrical system.

Inspection and service personnel

The personnel have been trained in the relevant activity and are informed about the specific dangers of hydraulic devices. They must be familiar with the functioning of the hydraulic systems as a whole and their interaction in the operation of this machine, as a whole.

The personnel must be familiar with the hydraulic diagrams and understand the operation and construction of the hydraulic elements of the machine.

Safety regulations must be observed (chapter …).

Cleanliness is very important.

There is a table of the necessary activities to be carried out. It covers work in a single turn; If the machine is used more often, you need to perform the activities more frequently.

Every time you start working The EMERGENCY STOP buttons and the EMERGENCY STOP button (optional) must be checked.

When malfunctions occur, turn off the pre-container and secure it.

Problems should be eliminated before work begins.

The operator must react to any defects and anomalies in the use of mechanical and electrical equipment.

Every time after he was emptied The pre-container must be checked for signs of deterioration
After the first 10-20 working hours All threaded and hydraulic connections must be checked and, if necessary, tightened.
Once a day

 

The pre-container must be visually and acoustically checked for signs of deterioration.

The entire hydraulic system must be checked for leaks.

Pressurized oil can cause injury and fire

Bi-monthly The space behind the ram should be cleaned. It depends on the pressed material, but the interval should not be longer than one month (access through the inspection hatch). Remove the hard objects from the piston surface.
Once a month. All threaded and hydraulic connections must be checked and, if necessary, tightened.

All electrical connections must be checked and, if necessary, replaced.

The control cabinet must be checked for condensation.

Check and clean the air filter cover

Every three months or after 500 hours of operation

 

 

 

 

Check the oil level.

If the level is too low, it may cause the hydraulic units to be destroyed.

The following lubrication points should be lubricated with a common lubricant:

– door hinges (using a lubrication pump)

– container roller bearings (using a lubrication pump)

– moving parts of the ratchet (using a brush)

– the ram’s guide (using a brush)

– the pins (bolts) of the pre-container cylinders (using a lubrication pump)

– the bearings of the lid hinges (using a lubrication pump)

– cap cylinder bolts (using a lubrication pump)

The lubrication interval depends effectively on the working conditions and only the experience will show you the right times.

Clean the electric motor.

Every 6 months Although the rams’ guides are made from scratch-resistant (maintenance-free) polyamide, they should be checked and readjusted if necessary. Screws with lock nuts are provided for this purpose.

All electrical equipment must be checked

 

Annual

 

 

 

 

 

Hydraulic hoses must be carefully checked (cracks, scratches, cuts, detachments, signs of wear, any deformation under pressure and depressurization).

The oil must be changed (tank capacity is about 55 l).

Swap while the compaction chamber is open.

Drain the oil at operating temperature

Used oil and filters in accordance with local laws.

The return filter cartridge must be changed

The air filter cartridge must be changed after 500 working hours
At least once a year.

It will check that the mains power supply connections are tight

Test – the waste compactor must be checked

Every 6 years Hydraulic hoses need to be replaced

 

After the maintenance is complete, check all the SAFETY buttons again.

 Hydraulic oil used in the system: Hydrol L-HV22

However, the following oils are also permitted in the system (according to DIN 51524-T3 / ISO HVLP 22).

 

DEA

 

ESSO

 

SHELL

 

ARAL

 

BP

 

MOBIL

ASTRON

HLP 22

NUTO

H 22

TELLUS Öl

22

ARAL VITAM

GF 22

ENERGOL

HLP 22

MOBIL

DTE 22

Maintenance

General information

All controls and maintenance measures are valid for one-way operation. When the system operates on several shifts, the checks and maintenance will be carried out rigorously

 

WARNING!

During the maintenance and cleaning of the press:

The central panel will be closed and secured before restarting.

The switch will be unplugged

Cleaning the press when it is dirty.

–  Before starting each operating mode all pipes, hoses and screws will be checked.

 

 

WARNING!

Any damage will be remedied immediately!

The burnt oil that is removed could cause burns and fires!

Maintenance and repairs to the electrical system or control panel of the unit will be performed exclusively by persons, professionally qualified, or by our maintenance team.

Hydraulic oil level / air filter

The hydraulic oil level will be checked at least once a quarter. Too low oil level could cause system damage.

– The oil level can be checked using the oil dipstick under the air filter cover

– The oil level must be between the two notches / marks of the rod.

– If the oil level is low it will be completed by opening the air filter cover.

– The oil will change annually, to prolong the life of the hydraulic system components.

– The air filter cover will be cleaned monthly and checked for leaks.

– The lid will then be screwed again.

 

Hydraulic oil exchange

It will be changed annually:

– The combustion plate will be brought to the high position of the final operating mode.

– The central control panel will be disconnected.

– An oil collecting device or an oil suction pump should be placed under the oil release valve.

Hydraulic oil tank capacity is ~ 60 l

– With a hexagon wrench, the screw from the oil tank will be opened and the oil will be allowed to flow into the pre-set vessel.

– If the hydraulic oil tank is dirty it will be cleaned.

– The oil drain valve screw will be screwed back in place. (The gasket will be replaced!)

– The missing oil will be filled.

Oil type: multifunctional cf DIN 51524-T3 / ISO viscosity class HVLP 22

ISO viscosity class  

DEA

 

ESSO

 

SHELL

 

ARAL

 

BP

 

MOBIL

 

Ulei mineral

 

ISO VG 22

HLP

 

Astron

HLP 22

 

NUTO

H 22

 

Tellus Oil

22

 

Aral Vitam

GF 22

 

Energol

HLP 22

 

Mobil

DTE 22

 

– Turn off the main switch.

– The combustion plate will be moved several times from top to bottom and the oil level will be measured once again when the plate is in the highest position after the above process.

– If necessary fill with oil.

– The oil filter cover will be sealed again.

 

Note

When using detergents and degreasers, the dangers they may bring to users will be taken into consideration!

The burnt oil will be disposed of according to the law in force for environmental protection!

Never mix hydraulic oil with a mixture of detergents and degreasers and used oil! These substances will be collected in different vessels and will be disposed of according to environmental protection regulations!

 

Cleaning the hydraulic oil tank

– The oil will be removed from the tank through the drain valve.

– With a straight wrench the hexagon screws from the tank cover will be unscrewed, the lid will be lifted and its tightness checked. The gasket will be removed.

– The inside of the hydraulic tank and the deposits on it will be cleaned.

– Screw back the drain valve, renew the cover gasket.

 

Greasing

– The center button will be closed.

– If necessary, all movable parts and hinges, especially the doors, as well as the door support points will be lubricated.

The baler must be turned off from the switch before carrying out the following tasks. The upper doors and housings are locked, but you can still stop the baling press before you start operating these machine management measures as an extra measure.

To make sure the baler works efficiently, perform the following task, starting with the front of the press. Cleaning of residual debris must be done daily. Lubrication should be done weekly.

Ballot paper Maintenance interval Estimated completion time
Daily Weekly Monthly Annual
Checked the general condition of the press and conveyor belt
OP TA
15 minutes
Check for oil leaks, electric cables, high operating noises, oil temperature, press release reports
OP TA
5 minutes
Cleaning of small particles penetrated into the binding system, the channels of the ram and the guides of the ram.
OP TA
15 minutes
Cleaning the side guide holes of the wire.
OP TA
15 minutes
Examine the safety function of the business doors
OP TA
5 minutes
Cleaning the autostart and auto stop sensors (cat eye, laser reciver)
OP TA
5 minutes
Examination of the anti-lock system
OP TA
5 minutes
Examination of the vaults, examination of the retention pins of the material operated with springs.
TA
20 minutes
Unscrew the protective flap and clean all the dirt accumulated next to the counting sensor at the link
TA
20 minutes
Control of the ventilation blades of the heat exchanger
TA
5 minutes
Cutting blade clearance. The distance between the blade fixed to the press and the blade fixed to the pressing ram must be between 1 and 3 mm. If necessary, adjust the knives
OP TA
15 minutes
Examination of the main pressing pistons. If necessary, change the gaskets and or spherical joints.
TA
30 minutes – 4 hours
The casings of the lances should be opened and cleaned of debris.
TA
20 minutes
Examination of cutting blades for sharpness
OP TA
5 minutes
Check the position of all safety switches and connections. Examine the proximity switch actuators for mechanical damage and replace damaged devices if necessary
TA
30 minutes – 4 hours
Check hydraulic oil level
TA
5 minutes
Lubrication lubrication points
TA
5 minutes
Examination of the mechanism of actuation of the binding system, the movable sled for moving the binding system, the alignment of the laces of the binding system.
TA
30 minutes – 4 hours
Manually check the operation of each parameter of the baler in manual mode.
TA
30 minutes
Changing the filter for hydraulic oil: Every 500 operating hours
TA
15 minutes
Checking the hydraulic and electrical equipment
TA
30 minutes
Check the fuses and replace them if necessary
TA
10 minutes
Check the condition of the polyamide rails
TA
20 minutes
Check the correct positioning of the hydraulic joints
TA
20 minutes
Changing the pressing ram guidesCheck the correct positioning of the other joints, respectively, if there are missing parts
TA
15 minutes
Changing the baler ram guides
TA
8 – 16 hours
Changing hydraulic oil: 1. Change after 2000 hours of operation
TA
2 – 4 hours
Staff training
TA
1 hour
Personnel tracking in the operation of the baler and granting the qualifications to acquire the skills
TA
1 hour

 

OP – The operator of the balers

TA – Authorized technician.

Maintenance manual

The tasks of repairs and inspections must be carried out with due care, according to the recommendations defined below. You have to make sure that under the given conditions of use, the pre-container is in a state that allows the tasks to be carried out in the most economical way possible.

During maintenance and repair, make sure that all the company’s security requirements are met and the blocking / labeling procedure is followed. The owner / employer must apply the blocking / prohibition procedure with labeling for hazardous energy control. The procedure must isolate all energy sources (electrical, mechanical, hydraulic, gravitational and kinetic energy, etc.). This is very important, as the unexpected start-up of the machine or the release of stored energy could be a danger to the employees.

You can start the machine only for tests, seconded by a person.

The performance of the service tasks is of particular importance during the initial period of use of the equipment. Otherwise, the warranty will be canceled.

If the user does not have appropriate specialists, contact the service department.

Employees using the machine should be familiar with the user manual and especially with the safety provisions.

The main switch must be switched off before starting the service tasks (OFF, 0) and the press must be disconnected from the power supply!

All work involving electrical equipment can only be used by qualified, experienced electricians who comply with safety rules. It is forbidden to use steam operated air blower to clean the electrical circuits.

Personnel carrying out service work and inspections

The personnel must be trained for the purpose of carrying out the specific operations and must be informed about the risks related to the hydraulic system. Employees should be aware of the use of hydraulic systems in general and their impact on the operation of the entire machine.

The personnel must be familiar with the hydraulic diagrams and understand the operation and construction of the hydraulic elements of the machine.

Safety regulations must be observed (chapter …).

Maintaining cleanliness and order in the work environment is very important.

A table has been prepared specifying the tasks required. The table refers to operations in a single job exchange; if the equipment is used more intensively, individual tasks should be directed more often.

Each time, before using the machine Check the EMERGENCY STOP buttons – and the optional EMERGENCY release button.

In case of an error, the press must be stopped and secured against restart.

Any problems must be eliminated before working with the machine.

The operator must respond to any defects and anomalies in the use of mechanical and electrical equipment.

After each drain Check that the container has not been damaged.
After the first 10-20 working hours Check all joints with screws and hydraulic couplings. Tighten loose parts if necessary.
Daily Check for visible damage and suspicious noise from the pre-container.

Check the entire hydraulic system for potential leaks.

Oil under pressure

it can be a cause of personal injury or fire.

Bi-monthly Clean the space under the plunger. The frequency of cleaning depends on the pressed materials; however, it will be done at least once a month (access through the service hatch). Remove the hard objects from the piston surface.
Once a month. Check all joints with screws and hydraulic couplings. Tighten loose parts if necessary.

Check all electrical connections. Change what is needed. Check for condensation in the control box.

Check and clean the air filter cover.

Every three months or after 500 hours of operation Check the oil level.

Too low level can cause the hydraulic elements to break down.

Normal grease lubrication at the following points:

– the door hinges (with a lubrication pump),

– the roller bearings of the container (with a lubrication pump),

– movable parts of the ratchet (with a brush),

– the piston guides (with a brush),

– the bolts of the press actuators (with a lubrication pump),

– the bearings of the cover (with a lubrication pump),

– the bolts of the actuators of the lid (with a lubrication pump).

The lubrication frequency depends largely on the conditions of use. The appropriate intervals can only be determined by practice.

Clean the electric motor.

Every 6 months Although the guides are made of durable polyamide (which does not require maintenance), they must be checked and adjusted, if necessary. For this purpose, screws with fastening nuts are used.

Check all electrical devices.

Annual Check in all respects all hydraulic pipes (cracks, bends, crossings, signs of wear and deformation under pressure or without pressure).

Change the oil (tank capacity, approx. 55 l).

This task must be performed with the pressing chamber open. The oil must be drained at operating temperature.

Used oil and filters must be handled in accordance with local regulations.

Replace the return filter cartridge.

Change the air filter cartridge after 500 working hours, at least once a year.

Check the pressure transducer connection.

Test – perform the balerrun test.

Every 6 months Change hydraulic pipes.

 

Check all the SAFETY buttons once the maintenance work is completed.

Hydraulic oil used in the system: Hydrol L-HV22

However, the following oils can still be used in the system (ISO HLP 22 viscosity class):

 

DEA

 

ESSO

 

SHELL

 

ARAL

 

BP

 

MOBIL

 

ASTRON HLP 22

 

NUTO H 22

 

TELLUS Öl 22

 

ARAL VITAM GF 22

 

ENERGOL HLP 22

 

MOBIL DTE 22

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