35 Years of Hydraulic Expertise · Old-School Communication. New-School Service.
35 Years of Hydraulic Expertise · Old-School Communication. New-School Service.
Before anything is opened, four things are worth confirming from outside the cabinet: the main disconnect is on, no emergency stop is latched in, the chute or access door is fully closed, and the machine is not simply still locked out from the last service call. Everything past that point requires a qualified technician.
Unlike the compactor pages, every symptom on this page is drafted from T&T Weber job records and stocked parts rather than lifted from existing written material. Causes, checks and tier assignments need bench review before this page goes live.
Show
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-1 | Bale falls apart after ejection, or ties let go›Full guide | Ties too loose, wrong tie material or gauge, T-hooks worn or bent, bale over-filled past the tie channels, ties routed outside a channel | Whether the ties are seated in every tie channel and how much slack was in them before ejection. Keep a failed tie — it usually shows whether it broke or slipped | Tier 1 | Supply correct ties and T-hooks, replace worn hooks, retrain on tie routing, check chamber geometry |
| B-2 | Ties will not reach around the bale, or the hook will not pass | Bale over-filled, tie channels packed with cardboard, channels distorted, ties too short for the bale size | Tie channels clear and undistorted, and whether the operator is filling past the fill line | Tier 1 | Clear and straighten tie channels, correct tie length, fill-line marking and operator guidance |
| B-3 | Bales are light — weight per bale has dropped›Full guide | Platen not reaching full stroke, lost hydraulic force, operator ejecting early, cardboard not spread evenly in the chamber, current limit tripping early | Bale weight against what that machine used to produce, and where the platen stops on a full stroke | Tier 1 | Pressure and stroke check, current limit test and reset, cylinder or pump work, loading practice |
| B-4 | Bale will not eject from the chamber›Full guide | Bale over-dense or over-height, ejector or tip-out mechanism fault, chamber sides bulged and gripping the bale, door not fully open | Whether the door is fully open and latched back, and whether the bale is taller than the chamber opening | Tier 2 | Clear the bale safely, straighten chamber sides, repair ejection mechanism, reset bale height stop |
| B-5 | Bale wedged and the platen will not return | Bale jammed against a bulged chamber wall, hydraulic fault on the retract side, mechanical bind in the platen guides | Nothing from inside the machine. A wedged platen with a loaded bale is stored energy in two directions at once | Tier 3 | Controlled release of the jam, chamber repair, retract circuit diagnosis |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-6 | Door will not latch, so the machine will not start | Door interlock switch out of adjustment or failed, latch or hinge worn, door frame racked, cardboard trapped at the seal face | Whether the door is mechanically closing fully or the interlock is not making. Look for debris at the latch | Tier 2 | Interlock switch replacement and alignment, latch and hinge rebuild, door straightening |
| B-7 | Door will not open with a bale in the chamber | Bale pressing against the door, latch mechanism binding under load, door distorted by repeated over-filling | Whether the bale is over-height. Do not force a door that a bale is pushing against | Tier 3 | Controlled relief of bale pressure, latch repair, door straightening, bale height correction |
| B-8 | Chamber sides bulging or scored | Years of over-dense bales, wear from abrasive material, a previous jam that deformed the wall | Bulge measured against the original chamber width, and whether bales have started sticking on ejection | Tier 2 | Chamber wall repair or replacement panels, wear liner installation |
| B-9 | Cardboard spilling out around the platen | Platen to chamber clearance opened up from wear, platen wear strips gone, chamber sides bulged, over-filling | Wear strips on the platen edges and whether the gap is even all the way around | Tier 2 | Wear strip replacement, platen repair, chamber wall correction |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-10 | Platen drifts down on its own›Full guide | Piston seal bypassing in the cylinder, directional valve spool leakage, failed load-holding check | Whether it drifts with the power off and locked out. Mark the platen and time it — but keep everyone clear of the chamber | Tier 3 | Cylinder rebuild or replacement, valve rebuild, check valve replacement |
| B-11 | Platen binds or runs crooked in the chamber | Worn or missing guides and wear strips, debris packed in the guide track, bent platen from a jam, uneven loading | Guide tracks clear, wear strips present, and whether the platen sits square at the top of the stroke | Tier 2 | Guide and wear strip replacement, platen straightening, realignment |
| B-12 | Baler chain worn, stretched, or broken | Normal wear, shock loading from jams, misalignment, poor lubrication | Chain stretch against its original length, and any elongated or cracked links | Tier 2 | Chain replacement, sprocket inspection, alignment and lubrication |
| B-13 | Platen does not reach full down stroke | Lost hydraulic force, cylinder not achieving full stroke, mechanical obstruction, current limit stopping the cycle early | Where the platen stops compared to where it used to, with a full chamber | Tier 2 | Pressure and stroke test, cylinder work, current limit adjustment |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-14 | Foot switch does nothing | Failed switch, damaged cord from being run over or crushed, wiring at the strain relief, blown control fuse | Whether the machine responds to any other control. Foot switch cords live on the floor and fail there | Tier 2 | Foot switch replacement, cord and strain relief repair, control circuit check |
| B-15 | Machine dead at the key switch | Key switch failed or in the wrong position, control transformer fuse, main disconnect, contactor not pulling in | Key position, disconnect position, and whether anything else on that circuit has power | Tier 2 | Key switch replacement, fuse and transformer work, contactor replacement |
| B-16 | Baler will not stop at bale-full | Current limit device failed or set too high, sensing circuit fault, latch relay not dropping out | Whether the machine has ever stopped on its own recently, or whether operators have been stopping it manually | Tier 3 | Current limit test, reset or replacement, sensing and latch circuit repair |
| B-17 | Baler stops before the bale is full | Current limit set too low or failed closed, pressure not reaching the device, relay dropping out early | Whether bale weight has dropped at the same time. Light bales plus early stopping points at the same device | Tier 2 | Current limit test and reset or replacement |
| B-18 | Machine only runs while the foot switch is held | On most vertical balers this is the designed behaviour, not a fault | Whether it has always done this. A machine that used to latch and now does not is a fault; a machine that never latched is working as built | Tier 1 | Confirm against the machine’s design. Repair the holding circuit only where one was fitted |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-19 | Cardboard dust building up on and around the machine | Normal by-product of baling dry cardboard, no cleaning schedule, no extraction | Dust on the motor, in the control enclosure and on hot surfaces. This is a fire load in a back room | Tier 1 | Cleaning schedule, enclosure sealing, guidance on what may and may not be blown down |
| B-20 | Interlock taped, wired back, or bypassed | Someone defeated it to work around a nuisance fault, and the nuisance fault is still there | Any tape, wire or wedge at a door switch. This is a stop-work finding, not a maintenance item | Tier 1 | Stop the machine. Restore the interlock and fix the original fault that caused someone to defeat it |
| B-21 | Uncertainty about who is allowed to operate the baler | Staff turnover, seasonal hiring, no written policy at the machine | This is a policy and compliance question, not a mechanical one — and the answer is set by federal and state rules, not by us | Tier 1 | We can point you at the applicable standards. The determination is yours and your insurer’s |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-1 | Bale falls apart after ejection, or ties let go›Full guide | Ties too loose, wrong tie material or gauge, T-hooks worn or bent, bale over-filled past the tie channels, ties routed outside a channel | Whether the ties are seated in every tie channel and how much slack was in them before ejection. Keep a failed tie — it usually shows whether it broke or slipped | Tier 1 | Supply correct ties and T-hooks, replace worn hooks, retrain on tie routing, check chamber geometry |
| B-2 | Ties will not reach around the bale, or the hook will not pass | Bale over-filled, tie channels packed with cardboard, channels distorted, ties too short for the bale size | Tie channels clear and undistorted, and whether the operator is filling past the fill line | Tier 1 | Clear and straighten tie channels, correct tie length, fill-line marking and operator guidance |
| B-3 | Bales are light — weight per bale has dropped›Full guide | Platen not reaching full stroke, lost hydraulic force, operator ejecting early, cardboard not spread evenly in the chamber, current limit tripping early | Bale weight against what that machine used to produce, and where the platen stops on a full stroke | Tier 1 | Pressure and stroke check, current limit test and reset, cylinder or pump work, loading practice |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-18 | Machine only runs while the foot switch is held | On most vertical balers this is the designed behaviour, not a fault | Whether it has always done this. A machine that used to latch and now does not is a fault; a machine that never latched is working as built | Tier 1 | Confirm against the machine’s design. Repair the holding circuit only where one was fitted |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-19 | Cardboard dust building up on and around the machine | Normal by-product of baling dry cardboard, no cleaning schedule, no extraction | Dust on the motor, in the control enclosure and on hot surfaces. This is a fire load in a back room | Tier 1 | Cleaning schedule, enclosure sealing, guidance on what may and may not be blown down |
| B-20 | Interlock taped, wired back, or bypassed | Someone defeated it to work around a nuisance fault, and the nuisance fault is still there | Any tape, wire or wedge at a door switch. This is a stop-work finding, not a maintenance item | Tier 1 | Stop the machine. Restore the interlock and fix the original fault that caused someone to defeat it |
| B-21 | Uncertainty about who is allowed to operate the baler | Staff turnover, seasonal hiring, no written policy at the machine | This is a policy and compliance question, not a mechanical one — and the answer is set by federal and state rules, not by us | Tier 1 | We can point you at the applicable standards. The determination is yours and your insurer’s |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-4 | Bale will not eject from the chamber›Full guide | Bale over-dense or over-height, ejector or tip-out mechanism fault, chamber sides bulged and gripping the bale, door not fully open | Whether the door is fully open and latched back, and whether the bale is taller than the chamber opening | Tier 2 | Clear the bale safely, straighten chamber sides, repair ejection mechanism, reset bale height stop |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-6 | Door will not latch, so the machine will not start | Door interlock switch out of adjustment or failed, latch or hinge worn, door frame racked, cardboard trapped at the seal face | Whether the door is mechanically closing fully or the interlock is not making. Look for debris at the latch | Tier 2 | Interlock switch replacement and alignment, latch and hinge rebuild, door straightening |
| B-8 | Chamber sides bulging or scored | Years of over-dense bales, wear from abrasive material, a previous jam that deformed the wall | Bulge measured against the original chamber width, and whether bales have started sticking on ejection | Tier 2 | Chamber wall repair or replacement panels, wear liner installation |
| B-9 | Cardboard spilling out around the platen | Platen to chamber clearance opened up from wear, platen wear strips gone, chamber sides bulged, over-filling | Wear strips on the platen edges and whether the gap is even all the way around | Tier 2 | Wear strip replacement, platen repair, chamber wall correction |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-11 | Platen binds or runs crooked in the chamber | Worn or missing guides and wear strips, debris packed in the guide track, bent platen from a jam, uneven loading | Guide tracks clear, wear strips present, and whether the platen sits square at the top of the stroke | Tier 2 | Guide and wear strip replacement, platen straightening, realignment |
| B-12 | Baler chain worn, stretched, or broken | Normal wear, shock loading from jams, misalignment, poor lubrication | Chain stretch against its original length, and any elongated or cracked links | Tier 2 | Chain replacement, sprocket inspection, alignment and lubrication |
| B-13 | Platen does not reach full down stroke | Lost hydraulic force, cylinder not achieving full stroke, mechanical obstruction, current limit stopping the cycle early | Where the platen stops compared to where it used to, with a full chamber | Tier 2 | Pressure and stroke test, cylinder work, current limit adjustment |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-14 | Foot switch does nothing | Failed switch, damaged cord from being run over or crushed, wiring at the strain relief, blown control fuse | Whether the machine responds to any other control. Foot switch cords live on the floor and fail there | Tier 2 | Foot switch replacement, cord and strain relief repair, control circuit check |
| B-15 | Machine dead at the key switch | Key switch failed or in the wrong position, control transformer fuse, main disconnect, contactor not pulling in | Key position, disconnect position, and whether anything else on that circuit has power | Tier 2 | Key switch replacement, fuse and transformer work, contactor replacement |
| B-17 | Baler stops before the bale is full | Current limit set too low or failed closed, pressure not reaching the device, relay dropping out early | Whether bale weight has dropped at the same time. Light bales plus early stopping points at the same device | Tier 2 | Current limit test and reset or replacement |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-5 | Bale wedged and the platen will not return | Bale jammed against a bulged chamber wall, hydraulic fault on the retract side, mechanical bind in the platen guides | Nothing from inside the machine. A wedged platen with a loaded bale is stored energy in two directions at once | Tier 3 | Controlled release of the jam, chamber repair, retract circuit diagnosis |
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-7 | Door will not open with a bale in the chamber | Bale pressing against the door, latch mechanism binding under load, door distorted by repeated over-filling | Whether the bale is over-height. Do not force a door that a bale is pushing against | Tier 3 | Controlled relief of bale pressure, latch repair, door straightening, bale height correction |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-10 | Platen drifts down on its own›Full guide | Piston seal bypassing in the cylinder, directional valve spool leakage, failed load-holding check | Whether it drifts with the power off and locked out. Mark the platen and time it — but keep everyone clear of the chamber | Tier 3 | Cylinder rebuild or replacement, valve rebuild, check valve replacement |
Scroll sideways for every column. On a phone each symptom becomes its own card.
| # | Symptom | Likely causes | What to check | Who Checks | What we do |
|---|---|---|---|---|---|
| B-16 | Baler will not stop at bale-full | Current limit device failed or set too high, sensing circuit fault, latch relay not dropping out | Whether the machine has ever stopped on its own recently, or whether operators have been stopping it manually | Tier 3 | Current limit test, reset or replacement, sensing and latch circuit repair |
Scroll sideways for every column. On a phone each symptom becomes its own card.
Every symptom on this page carries one of three labels. The label tells you where your own checking safely stops. This is not a liability disclaimer — it is the honest answer to a question facility managers ask us constantly: how much of this can my own people handle?
Tier 1 · Site Check
Tier 2 · Qualified Maintenance
Tier 3 · Service Technician
480 volts, three phase. An arc flash inside a compactor control cabinet is a burn injury, not a shock. The control components inside that cabinet run on 120V or 24VDC — which is exactly why people open the door and get hurt. The 480V line side is right there beside them.
Stored hydraulic energy. A compactor parked with the ram out has a loaded cylinder and pressurized lines even with the motor off and locked out. Cracking a fitting “to see if there’s pressure still in it” is how people get injection injuries. Pressure is relieved deliberately and confirmed at the gauge before anything is opened.
The safety framework behind these tiers comes from ANSI Z245.2 (Stationary Compactors — Safety Requirements for Installation, Maintenance and Operation), OSHA 29 CFR 1910.147 (Control of Hazardous Energy), and NFPA 70E (Electrical Safety in the Workplace). Welding and cutting on a building in Massachusetts falls under 527 CMR 1.00, Chapter 41.
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T&T Weber Hydraulic Inc.
184 Stone St, Unit 5
Clinton, MA 01510
Onsite compactor and baler service throughout New England — Massachusetts, Connecticut, Rhode Island, New Hampshire, Vermont and Maine. Hydraulic, electrical, controls and PLC, and full mechanical repair, plus installations, relocations and preventative maintenance contracts.
