ORKEL Dens-X Compactor Manuel utilisateur

User Manual

Dens-X Compactor

Rev.Dens-X.UM.2A.EN

Original version. Published 2020.

According to Directive 2006/42/EC, Annex | 1.7.4.1

Orkel AS

Johan Gjønnes' veg 25

7320 Fannrem, Norway

Valid from serial number: 20427005

Orkel part number: 16774

orkel.no/qr/dens-x

Table of contents

1 General 11

1.1 Introduction 11

1.1.1 Foreword 11

1.1.2 Disclaimer 11

1.1.3 Range of use 12

1.2 Control before delivery 12

1.2.1 Preparation at customer location 12

1.3 Identification of the machine 12

1.4 The operators manual 13

1.4.1 How to use this manual 13

1.5 Warranty 13

1.6 Declaration of conformity 14

2 Safety 15

2.1 Introduction 15

2.2 Symbols 15

2.2.1 Warning, danger and caution 15

2.3 Emergency stop 17

2.4 To the operator 18

2.4.1 Exercise of security 18

2.4.2 Personal protection 18

2.4.3 Personal safety 19

2.4.4 Safe operation 19

2.4.5 Important issues 19

2.4.6 Danger zones 19

2.5 Precautions 20

2.5.1 Know your machine 20

2.5.2 Equipment control 20

2.5.3 Cleaning 20

2.5.4 Environmental protection 20

2.6 Break-in period 20

3 Settings and hydraulic adjustments 22

3.1 Main parts 23

3.1.1 Principle of operation 23

3.2 Hydraulics 23

3.2.1 Guidelines for hydraulic adjustments 24

3.2.2 Tank valves Dens-X 24

3.3 Feed hopper 24

3.3.1 Control panels 24

3.3.2 Settings 25

3.3.3 Correction of the sideways movement of the feed hop-

per-F25 25

3.4 Elevator and sub conveyor 26

3.4.1 Settings 26

3.5 Chamber 26

3.5.1 Opening speed settings 26

3.5.2 Chamber pressure settings 27

3.6 Plastic tying unit 27

3.6.1 Principle of operation 27

3.6.2 Brake and feed speed 28

3.6.3 Settings 29

3.6.4 Remote control 29

3.7 Wrapping table 30

3.7.1 Wrapping settings 30

3.7.2 Film cutter settings 31

3.7.3 Wrapping table tilt speed 32

3.7.4 Wrapping table ultrasonic sensor 32

3.7.5 Microsonic sensor (S1) 32

3.8 Drawbar 33

3.8.1 Flexible drawbar 33

4 Operation 35

4.1 Safety 36

4.1.1 Safe work routine 36

4.1.2 Operator safety 36

4.1.3 Other people's safety 36

4.1.4 Assembly on site 36

4.1.5 Elements of hazard during operation 37

4.1.6 Danger zones during operation 37

4.1.7 Risk of overturning 37

4.1.8 Leaving the machine 37

4.2 Connection and setting up the machine 37

4.2.1 Rig up 37

4.2.2 Flexible drawbar and feed hopper F25 37

4.2.3 Lever/Controls overview 40

4.2.4 Lever list 40

4.2.5 Leveling the machine 41

4.2.6 Power take off 41

4.2.7 PTO Speed 41

4.2.8 Electrical power source 41

4.2.9 Hydraulic connections 41

4.2.10 Oil temperature 42

4.2.11 Stairs 42

4.3 Daily checklist 42

4.3.1 Daily checklist prior to startup 42

4.3.2 Checkpoints while baling 43

4.4 Break-in period 43

4.4.1 Precautions during the break-in period 43

4.4.2 After the first 50 hours of operation 43

4.5 Automatic operation 44

4.6 Film roller storage 45

4.7 Wrapping arms 46

4.7.1 Wrapping arm emergency stop 46

4.7.2 Installing a new film roller in the wrapper 46

4.8 Parking brake 48

4.9 Operators platform 48

4.10 Compressed air cleaner system 48

4.10.1 Mode of operation 49

4.10.2 Recommendations 49

5 Transport 51

5.1 Transport safety 51

5.1.1 Speed limit 51

5.1.2 On road preparation 51

5.1.3 Lifting points 51

5.1.4 Strapping and tie down 52

5.1.5 Dismantling the machine 52

5.2 Highway use 53

5.2.1 Transport preparation, Flexible drawbar and feed hop-

per F25 53

6 Control system 54

6.1 User interface 54

6.1.1 Main page 54

6.1.2 Icons for starting program sequences 55

6.1.3 Menu 55

6.1.4 User settings [Language and screen] 56

6.1.5 System information 57

6.1.6 Manual controls 57

6.1.7 Machine settings 59

6.1.8 Quick settings 60

6.1.9 Presets 61

6.1.10 Sensors 61

6.1.11 Messages 62

6.1.12 Time and date 63

6.1.13 User data 63

6.1.14 Weighing system 65

6.1.15 Reset 65

6.1.16 Software 65

6.1.17 Settings and explanations 67

7 Maintenance and mechanical adjustments 69

7.1 Safety 70

7.1.1 Before maintenance 70

7.1.2 Safety precautions during maintenance and mechanical

adjustments 70

7.1.3 Elements of hazard during maintenance 71

7.1.4 Control after repair or maintenance 71

7.2 Electrics 71

7.2.1 Fuses 72

7.3 Wheels 72

7.4 Chains 72

7.4.1 Chain tensioner A 72

7.4.2 Chain tensioner B and C 73

7.5 Feed hopper 73

7.5.1 Tightening the feed hopper belts F25 74

7.5.2 Ball bearings 74

7.6 Drive chains 74

7.6.1 Drive chains overview 75

7.6.2 Drive chains tensioning 75

7.7 Elevator and sub conveyor 76

7.7.1 Conveyor belts and feeder carrier 76

7.7.2 Adjusting the conveyor chains 76

7.7.3 Chain tensioner, sub conveyor 77

7.7.4 Chain tensioner, elevator F25 78

7.7.5 Ball bearings elevator 78

7.8 Baling chamber 78

7.8.1 Inspection 78

7.8.2 Adjusting the front chamber belt 79

7.8.3 Adjusting the rear chamber belt 79

7.8.4 Adjusting the chamber belt tensioner 82

7.8.5 Replacing chamber belt 83

7.9 Plastic tying unit 84

7.9.1 Control and maintenance 84

7.10 Wrapping table 85

7.10.1 Inspection 85

7.10.2 Adjusting the wrapping table belt 86

7.11 Frame, drawbar, attachments 88

7.11.1 Frame 88

7.11.2 Main components, fastening points 88

7.12 Chamber roller bushings 88

7.12.1 Wear inspection 88

7.12.2 Permissible wear 89

7.12.3 Remove sprockets 90

7.13 Hydraulics 91

7.13.1 Hydraulics oil 91

7.13.2 Hoses and connections 91

7.13.3 Hydraulic pump, gearbox 91

7.13.4 Heat exchanger 92

7.14 Oil change and oil filter 92

7.14.1 Changing oil and filter 93

7.15 Welding and grinding 94

7.15.1 Precautions when welding 94

7.16 Service history 95

8 Lubrication 96

8.1 Lubrication system, beka max EP 1 96

8.1.1 Oil lubrication, mode of operation 96

8.1.2 Grease lubrication, mode of operation 96

8.1.3 Beka max grease lubrication system 98

8.2 Refilling lubricants 98

8.2.1 Refilling the oil reservoir 99

8.2.2 Adjusting the amount of grease 99

8.2.3 Bleeding the grease system 99

8.3 Electric pump and main distributor 100

8.4 Troubleshooting for Beka max 100

8.5 Oil temperature 101

8.6 Approved lubricants 101

8.6.1 Hydraulics 101

8.6.2 Chain lubrication 101

8.6.3 Greasing 101

8.6.4 Gearbox and gears for hydraulic motors 102

8.7 Manual lubrication charts 103

8.7.1 The compactor 103

8.7.2 Feed hopper F25 104

8.7.3 Flexible drawbar 105

8.8 Lubrication list - Manual greasing points 106

9 Preservation 107

9.1 Cleaning 107

9.1.1 Using high pressure washer 107

9.2 Storage 107

9.2.1 Long time storage 107

9.2.2 Oil filling in the grease lubrication storage 107

10 Electrics 108

10.1 Main power supply, e-stop switches and electrical

cabinet 109

10.2 Electrical cabinet power supply rail 110

10.3 Sensors and manual controls 111

10.4 Valves, fan motors and pumps 112

10.5 Inputs and outputs 113

10.5.1 IO block 1 113

10.5.2 IO block 2 113

10.5.3 IO block 3 114

10.5.4 IO block 5 114

10.5.5 IO block 6 115

10.5.6 IO block 7 116

10.6 Power supply 116

10.6.1 Supply block 1 116

10.6.2 Supply block 2 117

10.7 Inputs and outputs sorted by number 118

10.7.1 IO list 1 118

10.7.2 IO list 2 119

10.7.3 IO list 3 120

10.8 Inputs and outputs sorted by type 120

10.8.1 Inductive sensors 120

10.8.2 Other sensors and switches 121

10.8.3 Directional valves 121

10.8.4 Sensors, 7-lead cable 122

10.8.5 Film system remote control 122

10.8.6 Radio remote control 122

10.8.7 Proportional valves 122

10.8.8 Valves 122

10.8.9 Cable detection 123

10.9 Sensor overview 124

10.10 Sensor list and function 125

11 Hydraulics 127

11.1 Hydraulic diagram 127

11.1.1 Complete diagram 128

11.1.2 Wrapping table, chamber and elevator control 129

11.1.3 Plastic tying unit, sub conveyor and feed hopper 130

11.1.4 Additional feed hopper control for F25 and chamber

drive 131

11.1.5 Hydraulic diagram list 132

11.2 Valve overview 133

11.2.1 Valve chart for Dens-X 133

11.2.2 Valve list for Dens-X 134

12 Specifications 135

12.1 Electrical system 135

12.2 Power take off 135

12.3 Lubrication system beka-max 135

12.4 Hydraulic system 136

12.5 Wheels and tyres 136

12.6 Dimensions and weight 136

12.6.1 Measurements 136

12.6.2 Power requirements 136

12.6.3 Dimensional sketch F25, operating mode 137

12.6.4 Dimensional sketch F25, transport mode 138

Glossary 139

Index 141

Table des matières

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