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ORKEL DENS-X Hi-X Compactor User Manual

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User Manual
Hi-X Compactor
Rev.Hi-X.UM.2A.EN
Original version. Published 2020.
According to Directive 2006/42/EC, Annex | 1.7.4.1
Orkel AS
Valid from serial number: 20427005
Johan Gjønnes' veg 25
Orkel part number: 16776
7320 Fannrem, Norway
orkel.no/qr/hi-x

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Summary of Contents for ORKEL DENS-X Hi-X Compactor

  • Page 1: Io Block

    User Manual Hi-X Compactor Rev.Hi-X.UM.2A.EN Original version. Published 2020. According to Directive 2006/42/EC, Annex | 1.7.4.1 Orkel AS Valid from serial number: 20427005 Johan Gjønnes' veg 25 Orkel part number: 16776 7320 Fannrem, Norway orkel.no/qr/hi-x...

  • Page 2: Table Of Contents

    Table of contents 1 General 1.1 Introduction 1.1.1 Foreword 1.1.2 Disclaimer 1.1.3 Range of use 1.2 Control before delivery 1.2.1 Preparation at customer location 1.3 Identification of the machine 1.4 The operators manual 1.4.1 How to use this manual 1.5 Warranty 1.6 Declaration of conformity 2 Safety 2.1 Introduction...

  • Page 3: Io Block

    2.6 Break-in period 3 Settings and hydraulic adjustments 3.1 Main parts 3.1.1 Principle of operation 3.2 Hydraulics 3.2.1 Guidelines for hydraulic adjustments 3.2.2 Tank valves Hi-X 3.3 Feed hopper 3.3.1 Control panels 3.3.2 Settings 3.4 Elevator and sub conveyor 3.4.1 Settings 3.5 Chamber 3.5.1 Opening speed settings 3.5.2 Chamber pressure settings...
  • Page 4 4.1.1 Safe work routine 4.1.2 Operator safety 4.1.3 Other people's safety 4.1.4 Assembly on site 4.1.5 Elements of hazard during operation 4.1.6 Danger zones during operation 4.1.7 Risk of overturning 4.1.8 Leaving the machine 4.2 Connection and setting up the machine 4.2.1 Rig up 4.2.2 Telescopic drawbar and feed hopper F10 4.2.3 Lever/Controls overview...

  • Page 5: Io Block

    4.8 Parking brake 4.9 Operators platform 4.10 Compressed air cleaner system 4.10.1 Mode of operation 4.10.2 Recommendations 5 Transport 5.1 Transport safety 5.1.1 Speed limit 5.1.2 On road preparation 5.1.3 Lifting points 5.1.4 Strapping and tie down 5.1.5 Dismantling the machine 5.2 Highway use 5.2.1 Transport preparation, Telescopic drawbar and feed hopper F10...

  • Page 6: Io Block

    6.1.16 Software 6.1.17 Settings and explanations 7 Maintenance and mechanical adjustments 7.1 Safety 7.1.1 Before maintenance 7.1.2 Safety precautions during maintenance and mechanical adjustments 7.1.3 Elements of hazard during maintenance 7.1.4 Control after repair or maintenance 7.2 Electrics 7.2.1 Fuses 7.3 Wheels 7.4 Chains 7.4.1 Chain tensioner A...

  • Page 7: Io Block

    7.8.4 Adjusting the chamber belt tensioner 7.8.5 Replacing chamber belt 7.9 Plastic tying unit 7.9.1 Control and maintenance 7.10 Wrapping table 7.10.1 Inspection 7.10.2 Adjusting the wrapping table belt 7.11 Frame, drawbar, attachments 7.11.1 Frame 7.11.2 Main components, fastening points 7.12 Chamber roller bushings 7.12.1 Wear inspection 7.12.2 Permissible wear...
  • Page 8 8.2.1 Refilling the oil reservoir 8.2.2 Adjusting the amount of grease 8.2.3 Bleeding the grease system 8.3 Electric pump and main distributor 8.4 Troubleshooting for Beka max 8.5 Oil temperature 8.6 Approved lubricants 8.6.1 Hydraulics 8.6.2 Chain lubrication 8.6.3 Greasing 8.6.4 Gearbox and gears for hydraulic motors 8.7 Manual lubrication charts 8.7.1 The compactor...
  • Page 9 10.5.3 IO block 3 10.5.4 IO block 5 10.5.5 IO block 6 10.5.6 IO block 7 10.6 Power supply 10.6.1 Supply block 1 10.6.2 Supply block 2 10.7 Inputs and outputs sorted by number 10.7.1 IO list 1 10.7.2 IO list 2 10.7.3 IO list 3 10.8 Inputs and outputs sorted by type 10.8.1 Inductive sensors...
  • Page 10 11.2.2 Valve list for Hi-X 12 Specifications 12.1 Electrical system 12.2 Power take off 12.3 Lubrication system beka-max 12.4 Hydraulic system 12.5 Wheels and tyres 12.6 Dimensions and weight 12.6.1 Measurements 12.6.2 Power requirements 12.6.3 Dimensional sketch F10, operating mode 12.6.4 Dimensional sketch F10, transport mode Glossary Index...

  • Page 11: General

    1 General 1.1 Introduction 1.1.1 Foreword 1.1.2 Disclaimer 1.1.3 Range of use 1.2 Control before delivery 1.2.1 Preparation at customer location 1.3 Identification of the machine 1.4 The operators manual 1.4.1 How to use this manual 1.5 Warranty 1.6 Declaration of conformity 1.1 INTRODUCTION 1.1.1 Foreword The products from Orkel AS are well known for their high quality, reliability and strength.

  • Page 12: Range Of Use

    1.1.3 Range of use The Hi-X compactor is designed for compressing fine waste material as compost, RDF or bin waste to bales wrapped in plastic film for storage or transport. The compactor must only be used for this purpose. NOTE: Other materials can also be compressed, but have to be confirmed by Orkel AS in each case. This due to warranty legislations.

  • Page 13: The Operators Manual

    1.4 THE OPERATORS MANUAL 1.4.1 How to use this manual This manual is organized after the «see—think—use»-principle. The content and explanations are arranged in smaller sequential operations, and the main chapters are arranged according to the normal use of the machine (Example: Setup —> Operation —> Maintenance). Chapter overview: 1.

  • Page 14: Declaration Of Conformity

    1.6 DECLARATION OF CONFORMITY 1 GENERAL...

  • Page 15: Safety

    2 Safety 2.1 Introduction 2.2 Symbols 2.2.1 Warning, danger and caution 2.3 Emergency stop 2.4 To the operator 2.4.1 Exercise of security 2.4.2 Personal protection 2.4.3 Personal safety 2.4.4 Safe operation 2.4.5 Important issues 2.4.6 Danger zones 2.5 Precautions 2.5.1 Know your machine 2.5.2 Equipment control 2.5.3 Cleaning 2.5.4 Environmental protection...
  • Page 16 The symbol and the word DANGER, The symbol and the word WARNING, indic- state a direct or immediate dan- ates a potentially hazardous situation. If gerous situation that will cause you fail to comply with instructions given it DEATH OR SERIOUS INJURY if not could result in personal injury or loss of life.

  • Page 17: Emergency Stop

    Stairway. Access only for operators or Noise zone. Use ear protection. mechanics. Make sure the transmission is run- ning with the correct speed and direction. Wrong speed and/or direction can damage machinery and Stay clear, rotating machinery. may cause great danger to persons nearby.

  • Page 18: To The Operator

    Figure 2.1 : Red circles indicates emergency stop locations. Two more buttons are located on the opposite side, ground level. When an emergency stop button has been triggered, the emergency stop button has to be reset so that the machine can be started from the control panel. Figure 2.2 : Mushroom head type emergency stop button.

  • Page 19: Personal Protection

    2.4.2 Personal protection The Compactor might generate a lot of dust and noise, depending on which material being com- pressed. For your own health, we recommend that operators use personal protective equip- ment, such as safety goggles, dust/filter mask, and ear-protection during operation. 2.4.3 Personal safety Use all available protective and safety equipment.

  • Page 20: Precautions

    2.5 PRECAUTIONS 2.5.1 Know your machine Know your machine. Learn all the functions and actuating mechanisms, and familiarize where the emer- gency stop switches are located. Learn the machines capacity and limitations, to avoid unnecessary down- time and mechanical brake-down. IMPORTANT: If any dangerous situations occur, shut down the power take off (PTO) right away.
  • Page 21 Check Check points All bearings have a visible grease collar. Figure 2.3 No visible grease on the relief valve on the grease pump. Precautions: A new compactor must go through a break-in in period. It shouldn’t be run at maximum capa- city at the first 25 hours of operation.

  • Page 22: Settings And Hydraulic Adjustments

    3 Settings and hydraulic adjustments 3.1 Main parts 3.1.1 Principle of operation 3.2 Hydraulics 3.2.1 Guidelines for hydraulic adjustments 3.2.2 Tank valves Hi-X 3.3 Feed hopper 3.3.1 Control panels 3.3.2 Settings 3.4 Elevator and sub conveyor 3.4.1 Settings 3.5 Chamber 3.5.1 Opening speed settings 3.5.2 Chamber pressure settings 3.6 Plastic tying unit...

  • Page 23: Main Parts

    3.1 MAIN PARTS The compactor main parts Figure 3.1 : 3.1.1 Principle of operation The material is loaded into the feed hopper using a wheel loader, or directly by a conveyor belt. The mater- ial is then transported by the elevator into the chamber. The amount and speed is controlled by an ultra- sonic sensor as well as settings in the display unit.

  • Page 24: Guidelines For Hydraulic Adjustments

    3.2.1 Guidelines for hydraulic adjustments Specific instructions regarding hydraulic settings are listed and explained for each individual component chapter. NOTE: All references to valves found in this sub chapter can be found in the hydraulic schematic and valve over- view in chapter 11 "Hydraulics"...

  • Page 25: Elevator And Sub Conveyor

    Figure 3.2 : The red box indicates the M1 valve 3.4 ELEVATOR AND SUB CONVEYOR 3.4.1 Settings The speed of the elevator belt and the sub conveyor may be changed from the display unit, on the machine settings page. 3.5 CHAMBER The bale chamber can handle high loads, but the set chamber pressure and the resulting bale density must be considered and possibly limited according to type of material.

  • Page 26: Plastic Tying Unit

    When the chamber pressure sensor registers a pressure of 135 bar (75 % of 180 bar) , the elevator speed is reduced. The elevator will maintain the low speed until a chamber pressure of 180 bar is reached. Then the plastic tying starts automatically. IMPORTANT: The chamber pressure must never exceed 280 bar! 3.6 PLASTIC TYING UNIT 3.6.1 Principle of operation...

  • Page 27: Settings

    high density bale. The brake force should be set when net/film is pulled during the automatic net/film sequence. The brake force is shown on the brake pressure gauge. The valve for the brake pressure is adjus- ted consecutively until the appropriate brake force is reached. Start the adjustment with a low brake force, and increase it.

  • Page 28: Remote Control

    3.6.4 Remote control The plastic tying unit may be operated from the platform using the remote control. Each button activates a programmed sequence, including several functions running in order: Press and hold red and blue buttons until the sequence is finished (knife and feed Open film system: rollers open).

  • Page 29: Film Cutter Settings

    NOTE: The wrapping arms low speed needs to be set correctly in order to ensure the correct orientation to the film cutters. The wrapping arm speed may increase when the oil is warm. Therefore, closely monitor the wrap- ping arm slow speed and readjust if needed. The position of sensor S5 may also need to be readjusted. 3.7.2 Film cutter settings The opening and closing speed of the film cutters must be set correctly.

  • Page 30: Wrapping Table Tilt Speed

    Figure 3.7 : Film cutter rollers 3.7.3 Wrapping table tilt speed Adjusting the wrapping table tilt speed may affect the speed of the bale when rolling off the wrapping table during bale drop. Adjusting the wrapping table tilt speed is done by turning valve P3. Clockwise decreases the speed.

  • Page 31: Drawbar

    4. When the desired distance is set, press both buttons simultaneously two more times and make sure the output mode is set to “Normally closed” (symbol shown below). If not, press up or down to change. 5. Then press both buttons simultaneously one more time until the LCD blinks ”End”. 6.

  • Page 32: Operation

    4 Operation 4.1 Safety 4.1.1 Safe work routine 4.1.2 Operator safety 4.1.3 Other people's safety 4.1.4 Assembly on site 4.1.5 Elements of hazard during operation 4.1.6 Danger zones during operation 4.1.7 Risk of overturning 4.1.8 Leaving the machine 4.2 Connection and setting up the machine 4.2.1 Rig up 4.2.2 Telescopic drawbar and feed hopper F10 4.2.3 Lever/Controls overview...

  • Page 33: Safety

    4.8 Parking brake 4.9 Operators platform 4.10 Compressed air cleaner system 4.10.1 Mode of operation 4.10.2 Recommendations 4.1 SAFETY IMPORTANT: If any dangerous situations occur, shut down the PTO right away. 4.1.1 Safe work routine This machine must under no circumstances be used for any other purpose than the intended one. Operate in daylight conditions only.

  • Page 34: Elements Of Hazard During Operation

    Take care when assembling/mounting the compactor. Squeezing of body parts and injuries from falling can occur when maneuvering the wrapping table. Max. height in operation position: 3900 mm 4.1.5 Elements of hazard during operation If you fail to comply with instructions given it could result in personal injury or loss of life. Pay attention to the risk of: squeezing/crushing/cutting of fingers or hands near the knife for plastic tying unit.

  • Page 35: Telescopic Drawbar And Feed Hopper F10

    4.2.2 Telescopic drawbar and feed hopper F10 1. Park the compactor on an even and solid surface. 2. Disconnect cables for lighting, hoses for brakes and hydraulics, as well as the drawbar. 3. Move and park the tractor on the left side of the compactor, perpendicular to the compactor’s lon- gitudinal axis, and aligned with the input shaft on the hydraulic pump’s gearbox.

  • Page 36: Lever/Controls Overview

    4.2.3 Lever/Controls overview Figure 4.1 : Lever/Controls overview Hi-X section 3.3.1 "Control panels" for descriptions of the levers/controls regarding the feed hopper. 4.2.4 Lever list Telescopic drawbar and feed hopper F10 Lever no: Valve function Left support leg, rear Up / down Right support leg, rear Up / down Feed hopper...

  • Page 37: Leveling The Machine

    Lever no: Valve function Film storage (right side) In / out Film storage (left side) In / out 4.2.5 Leveling the machine 1. Ensure that the feed hopper is raised clear of the ground when leveling the machine. The feed hop- per may be lowered onto the ground only when the machine is properly leveled.

  • Page 38: Oil Temperature

    Feed hopper lifting cylinders, jack stands, film roller storage, and drawbar. All functions are operated through manual levers on the machine. See section 4.2.3 "Lever/Controls over- view" IMPORTANT: Check that all the valves between the oil tank and hydraulic pumps are opened before the PTO is started.

  • Page 39: Checkpoints While Baling

    No Checkpoint prior to startup Check the tension of chains, carrier belts, and chamber belts. Check wrapping table sensors and table movement. Leave the wrapping table in its middle position. Look for oil leaks. Check the oil temperature. 10 Check the levelling of the machine. 4.3.2 Checkpoints while baling No Checkpoint prior to baling Continuously observe all moving parts and functions.

  • Page 40: Automatic Operation

    Figure 4.2 : Filters IMPORTANT: Orkel recommends that the operator regularly performs visual controls of the compactor as well as act- ive listening for abnormal noises. Perform adjustments as soon as there is a need. A problem that is not immediately rectified may cause further problems, and in worst case lead to mechanical breakdown.

  • Page 41: Film Roller Storage

    overview" When pressing the start icon on the display unit, the following will happen: The chamber starts, the elevator starts, the sub conveyor and hopper start. Material is fed into the bale chamber. The feed amount is controlled by the ultrasonic sensor S29. When set chamber pressure is reached (elevator slow threshold) the elevator slows down in order to reduce the material flow into the chamber until the bale is finished.

  • Page 42: Wrapping Arms

    age. In order to operate the storages the machine must be connected to the tractor’s hydraulic system, with the oil flow activated. The total capacity is 15 film rollers. NOTE: 14 turns/laps of the wrapping arm equals approximately 6 layers of film on the bale. 4.7 WRAPPING ARMS 4.7.1 Wrapping arm emergency stop The compactors wrapping arms are equipped with safety guards that stop the wrappers movement if...
  • Page 43 Figure 4.3 : Film stretcher with tensioner Figure 4.4 : Empty film strecher Threading of the film shall be done as illustrated in the principle drawing Figure 4.5 : Film in the film stretcher seen from above. 4 OPERATION...

  • Page 44: Parking Brake

    User resources for installing new film rollers may be found at www.orkel.com/qr 4.8 PARKING BRAKE The parking brake is located near the right side wheel (Figure 4.6). Rotate clockwise to engage, and counter clockwise to disengage NOTE: Always make sure the parking brake is disengaged before moving the compactor. Figure 4.6 : Parking brake 4.9 OPERATORS PLATFORM...

  • Page 45: Mode Of Operation

    Figure 4.8 : Compressed air cleaner system on the plastic tying unit 4.10.1 Mode of operation The three different cleaning processes are triggered by specific signal sequences. 1. Chamber door Cleans the chamber door contact surfaces when the bale is transported towards the wrapping table.
  • Page 46 Figure 4.9 : Valve and filter, location It is recommended to use an external compressor, located outside the polluted area of operation. IMPORTANT: To use the tractors compressor is not recommended due to insufficient compressor capacity. 4 OPERATION...

  • Page 47: Transport

    5 Transport 5.1 Transport safety 5.1.1 Speed limit 5.1.2 On road preparation 5.1.3 Lifting points 5.1.4 Strapping and tie down 5.1.5 Dismantling the machine 5.2 Highway use 5.2.1 Transport preparation, Telescopic drawbar and feed hopper F10 5.1 TRANSPORT SAFETY Be aware of the danger of tipping when driving off road. 5.1.1 Speed limit 5.1.2 On road preparation This machine is designed for being towed by the drawbar only.

  • Page 48: Strapping And Tie Down

    Rear: Use lifting points on the hydraulic jack stands NOTE: Use only certified lifting gear with sufficient lifting capacity. Lifting and strapping points Figure 5.1 : 5.1.4 Strapping and tie down Secure the machine from moving if transported by lorry, train or boat. Only use approved securing straps or chains, designed for this purpose.

  • Page 49: Highway Use

    5.2 HIGHWAY USE The compactor is designed for a maximum speed of 40 km/h. Exceeding this speed is considered dan- gerous. Furthermore, the speed must be limited according to national speed limits. Before using the machine the operator must ensure that all covers and hatches are closed and secured. Be aware of overhanging power lines.

  • Page 50: Control System

    6 Control system 6.1 User interface 6.1.1 Main page 6.1.2 Icons for starting program sequences 6.1.3 Menu 6.1.4 User settings [Language and screen] 6.1.5 System information 6.1.6 Manual controls 6.1.7 Machine settings 6.1.8 Quick settings 6.1.9 Presets 6.1.10 Sensors 6.1.11 Messages 6.1.12 Time and date 6.1.13 User data 6.1.14 Weighing system...

  • Page 51: Icons For Starting Program Sequences

    Figure 6.1 : Main page with icon names 6.1.2 Icons for starting program sequences Start auto mode / stop This icon starts the machine in automatic mode. The machine can be stopped by press- ing the icon again (red symbol). Start net/film system This icon starts a complete sequence in which the net/film system lays net or film on the bale in the chamber.

  • Page 52: User Settings [Language And Screen]

    Figure 6.2 : Menu screen 6.1.4 User settings [Language and screen] From main page; press menu and then the icon for Language and screen settings. Choose the desired language. The system will remember which language is chosen and use it as default. The screen’s brightness as well as key tone volume may also be set from this page.

  • Page 53: System Information

    Figure 6.3 : Language and screen settings page 6.1.5 System information From main page; press menu and then the icon for System information This page shows information about the installed software (SW), voltage and logged data. Figure 6.4 : System information screen 6.1.6 Manual controls From these pages the machine’s various functions may be operated manually by pressing and holding the respective icon.
  • Page 54 Manual control, page 1 Figure 6.5 : Page 2 Figure 6.6 : Manual control, page 2 Run elevator, low speed Run elevator, high speed Run elevator and chamber Run sub-conveyor, transport speed Run sub-conveyor, recycling speed Run hopper 6 CONTROL SYSTEM...

  • Page 55: Machine Settings

    Raise wrapping table Lower wrapping table Open film cutters Close film cutters Run wrapper, low speed Run wrapper, high speed Run wrapper to home position Run wrapper, complete sequence Open chamber door Close chamber door Shortcut to machine settings Run chamber (applies to both page 1 and page 2) Open net/film knife Close net/film knife...

  • Page 56: Quick Settings

    Machine settings screen Figure 6.7 : 6.1.8 Quick settings Figure 6.8 : Quick settings Certain machine settings can also be accessed from the main page, also when the machine is running in auto mode. 6 CONTROL SYSTEM...

  • Page 57: Presets

    6.1.9 Presets From main page; press menu and then the icon for Presets. This page (see 6.1.9) allows the operator to create and activate complete setups of machine settings. A setup is loaded by moving the marker to the chosen setup and clicking the activation icon. Subsequent changes to the settings will be stored automatically in the selected setup.

  • Page 58: Messages

    Figure 6.10 : Sensor overview with status 6.1.11 Messages From main page; press menu and then the icon for Messages. This page shows a list containing the previous 100 operational messages, including error messages. 6 CONTROL SYSTEM...

  • Page 59: Time And Date

    Figure 6.11 : Message screen 6.1.12 Time and date From main page; press menu and then the icon for Time and date settings. The values can be changed up and down by pressing the arrows on the right hand side and left hand side respectively.
  • Page 60 Figure 6.13 : User data page When pressing the upper left icon, the control unit generates a printable text file containing the customer log. NOTE: Insert the mini-USB-USB-adapter and flash drive into the control unit. The text file prints directly on the flash drive when pressing the «generate»-button.

  • Page 61: Weighing System

    User list Figure 6.14 : 6.1.14 Weighing system Weighing system is not supported by the software version described in this doc- ument. 6.1.15 Reset From main page; press menu and then the icon for Reset. The reset icon resets the baling process, so that this starts from the beginning when the machine is put in auto mode.
  • Page 62 Before the software update, the new software must be copied onto the display unit by the following steps: Place the software (zip archive) on an empty USB stick and insert the stick in the USB port on the back of the display. Use a mini-USB-USB-adapter. The USB port is behind the black cap to the far left.

  • Page 63: Settings And Explanations

    6.1.17 Settings and explanations Settings Explanation Chamber speed, baling Chamber speed during baling Chamber speed, net feed Chamber speed during net/film feed Chamber speed, net pull Chamber speed when net/film is put on the bale Chamber speed, drop Chamber speed when bale is ejected from the chamber. Import- ant in context of both stiction and loss Chamber max pressure Pressure limit at which the net/film sequence starts (maximum...
  • Page 64 Settings Explanation Film release, 2nd Defines at which of the wrapper rounds the cutters releases the film, second time Film release, 3rd Defines at which of the wrapper rounds the cutters releases the film, third time Film release duration Defines the duration of the cutter film release. Should be adjusted in context of the cutters speed (manual valve) Bale drop dwell time Defines the wrapping tables dwell in lower position during bale...

  • Page 65: Maintenance And Mechanical Adjustments

    7 Maintenance and mechanical adjustments 7.1 Safety 7.1.1 Before maintenance 7.1.2 Safety precautions during maintenance and mechanical adjustments 7.1.3 Elements of hazard during maintenance 7.1.4 Control after repair or maintenance 7.2 Electrics 7.2.1 Fuses 7.3 Wheels 7.4 Chains 7.4.1 Chain tensioner A 7.4.2 Chain tensioner B and C 7.5 Feed hopper 7.5.1 Tightening the feed hopper belts F10...

  • Page 66: Safety

    7.10.2 Adjusting the wrapping table belt 7.11 Frame, drawbar, attachments 7.11.1 Frame 7.11.2 Main components, fastening points 7.12 Chamber roller bushings 7.12.1 Wear inspection 7.12.2 Permissible wear 7.12.3 Remove sprockets 7.13 Hydraulics 7.13.1 Hydraulics oil 7.13.2 Hoses and connections 7.13.3 Hydraulic pump, gearbox 7.13.4 Heat exchanger 7.14 Oil change and oil filter 7.14.1 Changing oil and filter...

  • Page 67: Elements Of Hazard During Maintenance

    Be cautious when cleaning belts and rollers to avoid crushing or squeezing of body parts. Use proper shoes and work wear to avoid slipping and other injuries when working on the machine. 7.1.3 Elements of hazard during maintenance If you fail to comply with instructions given it could result in personal injury or loss of life Squeezing/crushing of fingers and hands near chains and sprockets Squeezing/crushing of finger and hands during cleaning of conveyor belts and rollers.

  • Page 68: Fuses

    Check the road lights and work lights Check the emergency buttons for malfunction. 7.2.1 Fuses The machine is equipped with one fuse unit inside the electrical cabinet. See section 10.2 "Electrical cab- inet power supply rail" 7.3 WHEELS Check the condition of the tires, they should have sufficient pattern depth and be without excessive wear. Control the tire inflation and wheel nut torque before transport to a new location.

  • Page 69: Chain Tensioner B And C

    Implications during adjustment: When adjusting either the left side (drive chain tension) or the right side (belt tracking) of this roller, these adjustments influence each other. Hence, you have to adjust both sides multiple times, until you achieve the ultimate chain tension and belt tracking combination. Adjustment: 1.

  • Page 70: Feed Hopper

    7.5 FEED HOPPER 7.5.1 Tightening the feed hopper belts F10 This belt are of chain type with welded carriers. Check the belt tensioning and look for uneven wear. Figure 7.3 : Feed hopper conveyor, F10 Procedure: Loosen the four bolts holding the bracket. Untighten the counter nut and tighten the bolt on the chain tensioner until correct belt tension is achieved.

  • Page 71: Ball Bearings

    Chain tensioner, feed hopper F10 Figure 7.4 : 7.5.2 Ball bearings The rollers in the feed hopper should be without deformations and cracks. Check the bearing clearances without belt tension. Replace worn bearings. 7.6 DRIVE CHAINS 7.6.1 Drive chains overview Figure 7.5 : Drive chains, left side 7 MAINTENANCE AND MECHANICAL ADJUSTMENTS...

  • Page 72: Drive Chains Tensioning

    Drive chains, right side Figure 7.6 : 7.6.2 Drive chains tensioning The chain tensioning is done by turning the adjustment bolts as shown on the pics below. One bolt on each side of the compactor. IMPORTANT: The hopper halves must be lowered all the way to the ground before one can adjust the chain. Figure 7.7 : Adjustment bolt location, both sides 7.7 ELEVATOR AND SUB CONVEYOR...

  • Page 73: Adjusting The Conveyor Chains

    The sub conveyor and elevator are of chain type with welded carriers. Check the chain tensioning and look for uneven wear. 7.7.2 Adjusting the conveyor chains Same procedure on both chains. Tighten the chain tensioner, until all play is gone. Adjust equally on both sides, and check that the tracking of the chain is centered.

  • Page 74: Chain Tensioner, Sub Conveyor

    7.7.3 Chain tensioner, sub conveyor Figure 7.10 : Chain tensioner sub conveyor 7.7.4 Chain tensioner, elevator F10 Figure 7.11 : Chain tensioner F10 elevator 7.7.5 Ball bearings elevator The rollers in the elevator and belt under should be without deformations and cracks. Check the bearing clearances without belt tension.

  • Page 75: Baling Chamber

    7.8 BALING CHAMBER All repair and maintenance work inside the chamber is associated with great danger. Secure the chamber door lifting cylinders, by closing the securing valves on both sides. The machine must be stopped and PTO disconnected. 7.8.1 Inspection Chamber - rollers - bearings - belts The bale chamber must be checked frequently.

  • Page 76: Adjusting The Rear Chamber Belt

    Figure 7.12 : Front chamber belt is tracking towards A/B Figure 7.13 : Front chamber distance C Loosen the attaching bolts, to allow a movement of the bracket. Loosen the counter nut and adjust the dis- tance C by turning on the adjustment nut. Tighten the counter nut and the attaching bolts of the bracket when the belt has a correct tracking.
  • Page 77 Figure 7.15 : Tension roller By increasing the distance C, the belt tracking will go towards B (Figure 7.15). When decreasing the dis- tance C, the belt tracking will go towards A. If the belt still goes towards one of the sides, this operation must be carried out on the left side bearings, but in reverse order.
  • Page 78 Figure 7.17 : Adjusting brackets, rear chamber belt Upper adjustment roller C Prior to this adjustment it´s very important to ensure that the machine is levelled. Adjusting the belt tracking is performed by changing the distance D on the roller C (Figure 7.18).

  • Page 79: Adjusting The Chamber Belt Tensioner

    7.8.4 Adjusting the chamber belt tensioner The tension of the belts is under the influence of the force from the twin springs on both sides of the cham- ber. Figure 7.20 : Belt tensioner, right side Basic settings: Turn the nut B, until there’s a clearance A of 1 mm between the coils (Figure 7.20).

  • Page 80: Plastic Tying Unit

    Figure 7.21 : Belt with locking rod and washer 7.9 PLASTIC TYING UNIT The tying unit, containing wide film or net is located on top of the chamber. Plastic tying unit, location Figure 7.22 : 7.9.1 Control and maintenance 1. Clean and lubricate the slides for feed rollers. 2.

  • Page 81: Wrapping Table

    Figure 7.24 : Feed rollers, seen from oper- ator's platform Figure 7.23 : Free wheel, seen from wrapping table 7.10 WRAPPING TABLE 7.10.1 Inspection Check the function of both emergency stop handles. Tighten the hinge bolts so that the handles barely returns to the start position.

  • Page 82: Adjusting The Wrapping Table Belt

    Knife bed Figure 7.26 : 7.10.2 Adjusting the wrapping table belt The tension of the wrapping table belt must be adjusted as shown in Figure 7.27. Correct belt tension, wrapping table Figure 7.27 : The belt tension can be changed by relocating the roller. There are six alternative holes to mount the roller support (Figure 7.28)
  • Page 83 Figure 7.28 : Holes for roller support Loosen the upper bolt to allow some movement on the bearing housing. Dismount the lower bolt and pull the roller to a suitable position. Insert the bolt in a suitable hole. Both sides must be equally mounted. If the belt tracking is incorrect, try to change location (side) of the belts.

  • Page 84: Frame, Drawbar, Attachments

    7.11 FRAME, DRAWBAR, ATTACHMENTS 7.11.1 Frame Check the welding for cracks or deformations once a month. 7.11.2 Main components, fastening points Check all major bolt connections and re-tighten if necessary. Drawbar—frame Drawbar—eye Chamber—frame Feed hopper—frame Elevator—frame Pay extra attention to the bolts fixing the draw bar and eye. (574 Nm) Fixing bolts for drawbar eye Figure 7.30 : 7.12 CHAMBER ROLLER BUSHINGS...

  • Page 85: Permissible Wear

    Figure 7.31 : Check for play in the bushings. Red markings indicate areas on the bushings. There are two typical conditions of a worn out bushing, depending on where the bushing is located on the machine. Read the description and see Figure 7.31.

  • Page 86: Remove Sprockets

    New bearing: 40 mm inside diameter, 44mm outside diameter. Defect bearing: ≥ 42,2 mm inside diameter. Measure the diameter several places to get the correct impression of the bearing ovality. Large type, 50 mm New bearing: 50 mm inside diameter, 55 mm outside diameter Defect bearing: ≥...

  • Page 87: Hydraulics

    Sprocket removal Figure 7.34 : 7.13 HYDRAULICS 7.13.1 Hydraulics oil The oil level is monitored by the control unit. An alarm stating “oil level - low” is displayed in the control unit. Top up if necessary. The oil level can also be visually checked through an oil glass placed in/on the oil tank.

  • Page 88: Heat Exchanger

    Figure 7.35 : Dipstick with max and min level indicators Figure 7.36 : Location dipstick The oil level must be between max and min on the level indicator. Top up if necessary. The gear oil must be changed minimum once a year, or when needed. See approved lubricants in section 8.6.4 "Gearbox and gears for hydraulic motors"...

  • Page 89: Changing Oil And Filter

    Oils can be hot. Some pressure can remain in the hydraulic system/hoses/pipes, even though the machine is shut down. IMPORTANT: Always change filters when changing the hydraulic oil! 7.14.1 Changing oil and filter Hydraulic oil 1. Heat the oil up to about 30°C. 2.

  • Page 90: Welding And Grinding

    4. Drain until empty. 5. Clean the oil spill. 6. Mount the new filter. 7. Dispose with the old filter according to environmental regulations. IMPORTANT: Always use original parts when changing filter. Changing gear oil For main gear, feed hopper, elevator and wrapping table: 1.

  • Page 91: Service History

    Always use goggles, gloves, and suitable working clothes. Always keep a fire extinguisher available. 7.16 SERVICE HISTORY We recommend to fill in all service/maintenance work in this table Date/year Service/maintenance/major repair Performed by; Name/company 7 MAINTENANCE AND MECHANICAL ADJUSTMENTS...

  • Page 92: Lubrication

    8 Lubrication 8.1 Lubrication system, beka max EP 1 8.1.1 Oil lubrication, mode of operation 8.1.2 Grease lubrication, mode of operation 8.1.3 Beka max grease lubrication system 8.2 Refilling lubricants 8.2.1 Refilling the oil reservoir 8.2.2 Adjusting the amount of grease 8.2.3 Bleeding the grease system 8.3 Electric pump and main distributor 8.4 Troubleshooting for Beka max...
  • Page 93 Figure 8.1 : Pump element, suction phase Figure 8.2 : Pump element, pressure phase The grease lubrication system is a progressive system. It operates all types of grease of NLGI kl. 2 type. See recommended lubricants in section 8.6.3 "Greasing". A progressive lubrication system, means that all the bearings are lubricated one by one.

  • Page 94: Beka Max Grease Lubrication System

    8.1.3 Beka max grease lubrication system Beka Max grease lubrication pump system, exploded view with description on major Figure 8.3 : parts. 1. Reservoir, transparent 7. Delivery piston 2. Stirrer scrape 8. Non return valve 3. Suction area, pump 9. Pressure relief valve 4.

  • Page 95: Refilling The Oil Reservoir

    8.2.1 Refilling the oil reservoir The grease lubrication system is sensitive to the influence of external contamination, such as dust and dirt. Keep the cap on and refill through the male sleeve nipple (no. 11, section 8.1.3 "Beka max grease lub- rication system") when refilling grease.

  • Page 96: Electric Pump And Main Distributor

    4. Activate the function greaser from the control box once more (the pump will run as long as the but- ton on the control box is activated). 5. Disconnect the tube from the first distributor block and activate the pump until you have a constant flow from this outlet.

  • Page 97: Oil Temperature

    Problems Cause Remedy NOTE: Correct motor mounting Air pocket in pump Bleed the pump Pump is working but does not supply Level in reservoir is too low Refill the reservoir grease Pump element not building up pressure (no Replace the pump element air pocket) Pump does not work Refer to pump not working above.

  • Page 98: Gearbox And Gears For Hydraulic Motors

    8.6.4 Gearbox and gears for hydraulic motors Gear oil: Renolin unisyn CLP 220N 8 LUBRICATION...

  • Page 99: Manual Lubrication Charts

    8.7 MANUAL LUBRICATION CHARTS 8.7.1 The compactor 8 LUBRICATION...

  • Page 100: Feed Hopper F10

    8.7.2 Feed hopper F10 8 LUBRICATION...

  • Page 101: Telescopic Drawbar

    8.7.3 Telescopic drawbar 8 LUBRICATION...

  • Page 102: Lubrication List - Manual Greasing Points

    8.8 LUBRICATION LIST - MANUAL GREASING POINTS Hi-X: Description: Qty on each side: Location: Total Intervall Elevator, lower Left and right Handbrake Right Sub conveyor, elevator side Left and right Brake shaft, support Left and right Under elevator, bearings on rollers Left and right Elevator, upper Left and right...

  • Page 103: Preservation

    9 Preservation 9.1 Cleaning 9.1.1 Using high pressure washer 9.2 Storage 9.2.1 Long time storage 9.2.2 Oil filling in the grease lubrication storage 9.1 CLEANING 9.1.1 Using high pressure washer The compactor can be cleaned with a high pressure washer. Avoid directing the beam towards any elec- trical connections and components.

  • Page 104: Electrics

    10 Electrics 10.1 Main power supply, e-stop switches and electrical cabinet 10.2 Electrical cabinet power supply rail 10.3 Sensors and manual controls 10.4 Valves, fan motors and pumps 10.5 Inputs and outputs 10.5.1 IO block 1 10.5.2 IO block 2 10.5.3 IO block 3 10.5.4 IO block 5 10.5.5 IO block 6...

  • Page 105: Main Power Supply, E-Stop Switches And Electrical Cabinet

    10.1 MAIN POWER SUPPLY, E-STOP SWITCHES AND ELECTRICAL CABINET 10 ELECTRICS...

  • Page 106: Electrical Cabinet Power Supply Rail

    10.2 ELECTRICAL CABINET POWER SUPPLY RAIL 10 ELECTRICS...

  • Page 107: Sensors And Manual Controls

    10.3 SENSORS AND MANUAL CONTROLS 10 ELECTRICS...

  • Page 108: Valves, Fan Motors And Pumps

    10.4 VALVES, FAN MOTORS AND PUMPS 10 ELECTRICS...

  • Page 109: Inputs And Outputs

    10.5 INPUTS AND OUTPUTS 10.5.1 IO block 1 Loc. ID Description Type Hi Mid Low X1.1 V02 Chamber open ·1 ·2 X1.2 V03 Chamber close ·1 ·2 X1.3 V04 Wrapper bypass off ·1 ·2 X1.4 ---------- NOT IN USE ---------- X1.5 ---------- NOT IN USE ---------- X1.6 V36 Elevator &...

  • Page 110: Io Block

    Loc. ID Description Type Hi Mid Low X2.14 ---------- NOT IN USE ---------- X2.15 ---------- NOT IN USE ---------- X2.16 S07 E-Stop redundancy input X13.3 X2.17 S37 Remote open feed rollers B.Bl B.Br X2.18 V33 Cooler fan run (suck) X2.19 S19 Feed rollers opened X2.20 S20 Feed rollers closed X2.21 V34 Cooler fan reverse (blow) X2.22 S38 Remote close feed rollers...
  • Page 111 Loc. ID Description Type Hi Mid Low X5.5 V13 Grease pump FB X5.6 ---------- NOT IN USE ---------- X5.7 V09 Wrapping arm slow ·1 ·2 X5.8 V10 Wrapping arm fast ·1 ·2 X5.9 ---------- NOT IN USE ---------- X5.10 ---------- NOT IN USE ---------- X5.11 ---------- NOT IN USE ---------- X5.12 S14 Oil temperature...

  • Page 112: Power Supply

    Loc. ID Description Type Hi Mid Low X6.23 S10 Table upper position 10.5.6 IO block 7 Loc. ID Description Type Hi Mid Low X7.1 ---------- NOT IN USE ---------- X7.2 - V5 reference voltage X7.3 ---------- NOT IN USE ---------- X7.4 ---------- NOT IN USE ---------- X7.5 S42 Flip up...
  • Page 113 Loc. Terminal block function Comment X12.3 GND - I/O X12.4 GND - I/O X12.5 GND - I/O X12.6 X12.7 X12.8 X13.1 Supply - CU1 870-831 X13.2 Supply - CU2 870-831 X13.3 E-stop relay 870-831 X13.4 E-Stop circuit 870-826 X13.5 E-Stop circuit 870-826 X13.6 Various...

  • Page 114: Inputs And Outputs Sorted By Number

    Middle- Left Middle-left Middle Right Left right E-stop 4 [Bl] To X2.16 (E-stop) E-stop relay, A1 E-stop 2 [Y] E-stop 3 [R] E-stop 3 [Y] E-stop 4 [Y] E-stop 2 [R] E-stop 1 [Y] E-stop 1 [R] To X10.3 S1 override switch [Y] To X5.19 Check valve [1] Hopper switch [Y]...
  • Page 115 All sensors ID Description Loc. Type Hi Mid Low S31 Chamber speed X3.20 PI Bl Br S32 Net control X3.21 PI Bl Br S33 RF remote ctrl. Stop (OPT) X7.16 DI S34 RF remote ctrl. Drop (OPT) X7.21 DI S35 Elevator speed X3.22 PI Bl Br S37 Remote open feed rollers...

  • Page 116: Io List

    Valves, HIC1, HIC2 and HIC3 ID Description Loc. Type Hi Mid Low V33 Cooler fan run (suck) X2.18 DO V34 Cooler fan reverse (blow) X2.21 DO V35 Air cleaning, door (OPT) X1.18 DO ·1 ·2 V36 Elevator and ch. door speed X1.7 PWM ·1 V36 Elevator and ch.

  • Page 117: Other Sensors And Switches

    10.8.2 Other sensors and switches Other sensors and switches Description Loc. Hi Mid Low S01 Bale on wrapping table X5.19 A.Wh S29 Feed hopper US-sensor X3.6 Gy S14 Oil temperature X5.12 Bk S27 Oil level X6.16 Bk S28 Grease level X6.17 Bk S30 Chamber pressure X3.5 Wh...

  • Page 118: Sensors, 7-Lead Cable

    10.8.4 Sensors, 7-lead cable Sensors, 7-lead cable from wrapper Description Loc. S01 Bale on wrapping table X5.19 A.Wh S05 Wrapping arm home position X6.19 A.Bk S08 Wrapping arm stop X6.20 A.Br S11 Film sensor 1 X7.19 A.Bl S12 Film sensor 2 X7.20 A.Gn 10.8.5 Film system remote control...

  • Page 119: Cable Detection

    Valves, HIC4 (F25) ID Description Loc. V52 Run flip X2.10 ·1 ·2 V53 Flip change direction X6.5 ·1 ·2 V54 Flip check right X6.6 ·1 ·2 V55 Flip check left X6.7 ·1 ·2 V56 Auger bypass X5.16 ·1 ·2 10.8.9 Cable detection Cable detection (Automatic controller identification) Description Loc.

  • Page 120: Sensor Overview

    10.9 SENSOR OVERVIEW 10 ELECTRICS...

  • Page 121: Sensor List And Function

    10.10 SENSOR LIST AND FUNCTION Inputs on controllers for standard system Description Type Brand & type Range Comment Bale on table ultrasound Digital ultrasound Microsonic mic+130/D/TC 100...2000 mm Default 70 cm Table in middle position Inductive PNP Pepperl&Fuchs NBB8-18GM50-E2-V1 3...8 mm Wrapping arm in home pos- Inductive PNP Pepperl&Fuchs NBB8-18GM50-E2-V1 3...8 mm...
  • Page 122 Inputs on controllers for standard system Description Type Brand & type Range Comment pressure S42 Remote control - flip up Switch NO F25 only S43 Remote control - flip down Switch NO F25 only Remote control - hopper Switch NO F25 only start Remote control - hopper...

  • Page 123: Hydraulics

    11 Hydraulics 11.1 Hydraulic diagram 11.1.1 Complete diagram 11.1.2 Wrapping table, chamber and elevator control 11.1.3 Plastic tying unit, sub conveyor and feed hopper 11.1.4 Hydraulic diagram list 11.2 Valve overview 11.2.1 Valve chart for Hi-X 11.2.2 Valve list for Hi-X 11.1 HYDRAULIC DIAGRAM Please refer to section 11.1.1 "Complete diagram"...

  • Page 124: Complete Diagram

    11.1.1 Complete diagram 11 HYDRAULICS...

  • Page 125: Wrapping Table, Chamber And Elevator Control

    11.1.2 Wrapping table, chamber and elevator control 11 HYDRAULICS...

  • Page 126: Plastic Tying Unit, Sub Conveyor And Feed Hopper

    11.1.3 Plastic tying unit, sub conveyor and feed hopper 11.1.4 Hydraulic diagram list Outputs on controllers for standard system Description Type Brand & type Current drawn @ 24Vdc Resistance in Ohms Comment Digital valve Comatrol SV-15-34-04 1,38 A Digital valve Comatrol SV-15-34-05 1,38 A Digital valve...
  • Page 127 Outputs on controllers for standard system Description Type Brand & type Current drawn @ 24Vdc Resistance in Ohms Comment Digital valve Comatrol SV-15-34-02 1,38 A Digital valve Comatrol SV-15-34-04 1,38 A Digital valve Comatrol EVK 06/C5 1,1 A Digital valve Comatrol SV-15-34-05 1,1 A Digital valve...

  • Page 128: Valve Overview

    11.2 VALVE OVERVIEW 11.2.1 Valve chart for Hi-X 11 HYDRAULICS...

  • Page 129: Valve List For Hi-X

    11.2.2 Valve list for Hi-X Valve number Description Location Chamber, closing speed In cabinet, on valve block Safety valve, chamber door cylinder Chamber, cylinder, right hand side Safety valve, chamber door cylinder Chamber, cylinder, left hand side Plastic tying unit, feed speed Plastic tying unit Plastic tying unit, brake force Plastic tying unit...
  • Page 130 12 Specifications 12.1 Electrical system 12.2 Power take off 12.3 Lubrication system beka-max 12.4 Hydraulic system 12.5 Wheels and tyres 12.6 Dimensions and weight 12.6.1 Measurements 12.6.2 Power requirements 12.6.3 Dimensional sketch F10, operating mode 12.6.4 Dimensional sketch F10, transport mode 12.1 ELECTRICAL SYSTEM 24 Vdc with alternator located by the pump unit and dual 12 V 55 Ah Power supply:...
  • Page 131 Oil type Motor oil SAE 10W - 30, 15W - 40 Oil consumption 6ml each bale on the table. 0.3 l/h (@ 50 bales/h) Volume container 4,2 l 12.4 HYDRAULIC SYSTEM Chamber drive: 280/340 bar (SW/relief valve) Sub-conveyer, feed hopper and film system: 180 bar Elevator and chamber door: 170 bar...
  • Page 132 12.6.3 Dimensional sketch F10, operating mode 12 SPECIFICATIONS...
  • Page 133 12.6.4 Dimensional sketch F10, transport mode 12 SPECIFICATIONS...
  • Page 134 Glossary Bale chamber The material is transported into the chamber and shaped into a compact bale. After shaping the mater- ial, several layers of net/film is laid on the bale by the net/film system ensuring that the bale main- tains its shape during the transport to the wrapping table. Usually referred to as "the chamber". Elevator Transfers the material from the feed hopper to the chamber.
  • Page 135 Sub conveyor Conveyor belt placed along the frame under the chamber, for transporting the bale from the chamber to the wrapping table, as well as transporting material spillage back to the elevator. Wrapping arms Wraps the bale with film while it lays on the wrapping table by rotating the arms around the bale. Safety features are mounted on the arms so that the emergency stop is triggered if something hits the safety features.
  • Page 136 Index Break-in period 20, 39-40, 87 Control system Machine settings 55 Daily checklist 38 Film roller Installing a new film roller 42 How to use this manual 13 Hydraulics Recommended grease 97 Recommended oil types 23 Valve chart 128 Lubrication Approved lubricants 88, 97 Greasing 39, 75, 97, 102 Lubrication charts 13, 99...
  • Page 137 Maintenance 13, 65, 67 INDEX...

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