Orgapack H-1465 User manual

08/07
OR-T 300
Battery-hand tool for plastic strapping
Before using the tool,
read the operating
instructions carefully.
H-1465

Page 2 of 12
ORGAPACK OR-T 300
1TECHNICAL DATA
TABLE OF CONTENTS
Page
41atadlacinhceT1
51noitamrofnilareneG2
2.1 Information on environmental protection 15
61snoitcurtsniytefaS3
3.1 Safety instructions for battery
61yrettabdnaregrahc
71noitpircseD4
71noitcurtsnoC1.4
4.2 71lenapgnitarepO
4.3 71noitcnuF
81regrahcyrettaB4.4
91noitarepolaitinI5
5.1 91regrahcyrettaB
5 91egrahcyrettabtsriF2.
91yrettabehtgnigrahC3.5
6 Operating instructions 20
02lootehtgnitarepO1.6
6.2 12laesehtgnikcehC
6.3 22lenapgnitarepO
6.3.1 Checking battery charge 22
22noisnetpartsgnitteS2.3.6
22emitgnidlewgnitteS3.3.6
6.3.4 Setting strap tension range 23
6.4 32htdiwpartsgnitteS
7 Preventive and corrective maintenance 24
7.1 Cleaning/replacing tension wheel 24
7.2 Cleaning/replacing tooth plate 24
7.3 Replacing cutting knife 24
8 Recommended spare parts 47
8.1 74tsilstraP
35gniwarddedolpxE
DECLARATION OF AGREEMENT
EN 1050, EN 50082-2, IEC 61000-6-2, EN 55022,
EN 50081-1
CH-8953 Dietikon, March 2005
General Manager General Manager
Sales & Marketing: Products:
P. Spreng M. Binder
We take sole responsibility for declaring that the
tool OR-T 300, to which this declaration refers, is
in full compliance with the current requirements of
the guidelines laid down by the council on 22th
June 1998 (98/37/EEC), “Machine Guidelines“.
Furthermore, electrical installations are in compli-
ance with the guideline laid down by the council on
3th May 1989 (89/336/EEC) “EMV Guidelines“.
According to norm:
EN ISO 12100-1, EN ISO 12100-2, EN 349,
Weight 4.2 kg (9.9 lbs) (incl. battery)
Dimensions Length 375 mm (14.7“)
htdiW 130 mm (5.1“)
)“5.5(mm041thgieH
Strap tension 400–3300 N (88–727 lbs)
Tension speed 250 mm/s (9.8“/s)
Sealing Friction welded
Emission sound pressure
levels, measurement
type A (EN ISO 11202) LpA 85 dB (A)
Vibrations at handle
(EN ISO 8662-1) ah,w 2.2 ms-2
BATTERY Bosch 14.4 V HD
Strappings with
one battery charge 120–250 (PP)
)TEP(051–08
parts,partsnognidneped
egakcapdnanoisnet
Service life Up to approx 2000
chargings
BATTERY CHARGER IFC 1702d
Voltage 100–240 V
Mode of operation Discharge/Charge
Charging time approx. 60–75 minutes
)gnigrahcsidsuoiverp.lcni(
PLASTIC STRAP
Strap quality Polypropylene (PP)
)TEP(retseyloP
Strap width
adjustable to 15–16 mm (5/8“) (PET),
(mm91–81 3/4“) (PET, PP)
Strap thickness Polypropylene
)“930.–“130.(mm0.1–8.0
retseyloP
0.8–1.3 mm (.031“–.051“)
08/07

ORGAPACK OR-T 300
CAUTION!
Used where there is dan-
ger to life and health.
WARNING!
Used for danger which
can cause material
damage.
NOTE!
Used for general infor-
mation and information
which, if not followed
can cause faults in the
operating sequence.
2GENERAL INFORMATION
These operating instructions are intended to simplify
familiarisation with the strapping tool and its proper
use for the intended purpose. The operating instruc-
tions contain important information concerning the
safe, proper and efficient use of the strapping tool.
Compliance with the instructions will help to avoid
danger, reduce repairs and stoppages and increase
the reliability and service life of the strapping tool.
The operating instructions must always be available at
the place of operation of the strapping tool. They must
be read and observed by all persons concerned with
work on the strapping tool. This work specifically
includes operation, refilling of operating material, fault
elimination and maintenance.
In addition to the operating instructions and the regu-
lations for accident prevention effective in the country
of use and place of application, the recognised techni-
cal regulations for safety and proper operation must
also be observed.
2.1 INFORMATION ON ENVIRONMENTAL
PROTECTION
This tool is manufactured without any physical or che-
mical substances which could be dangerous to health.
For disposal of all the parts, the governmental instruc-
tions must be observed. The electrical assemblies
should be dismantled so that the mechanical, electro-
mechanical and electronic components can be dis-
posed of separately.
naedivorpsrelaeD
-yllatnemnorivne
yrettabyldneirf
ecivreslasopsid
• Do not open the
.yrettab
• Do not throw the
-uohotniyrettabdesu
roerfi,etsawdlohes
.retaw
desuroevitcefeD
aogrednuseirettab
gnilcyceretelpmoc
.ssecorp
Page 3 of 12 08/07

ORGAPACK OR-T 300
Original ORGAPACK spare
parts must be used exclusi-
vely!
Not using original spare parts
will dissolve the warranty and
the liability.
Use for the intended purpose
This tool is designed for strapping packages, pallet
loads and the like.
The tool was designed and manufactured to provide
safe handling during the strapping operation.
The tool is designed for use with plastic straps (poly-
propylene and polyester).
Possible misuse
The use of steel straps is not possible.
3.1 SAFETY INSTRUCTIONS FOR BATTERY
CHARGER AND BATTERY
Always inspect the electrical
plug and cable before use. If
damaged, they must be
replaced by qualified personnel.
• Do not charge other types of batteries (see chapter
5.1) and use original accessories only.
• Keep the battery charger slot free of foreign objects
and protect against dirt.
• Protect the battery charger against humidity and
use it in dry areas only.
• Do not open the battery. Protect the battery against
impact, heat and fire. Risk of explosion!
• When the battery is outside the battery charger,
cover its battery terminals to avoid short circuits
with metal objects. Risk of fire and explosion!
• Keep battery dry and protected against frost. Do
not store it at temperatures over 50°C or below
10°C.
• Damaged batteries should not be used longer.
3SAFETY INSTRUCTIONS
Inform yourself!
Read the operating instructions
carefully.
Preventive and corrective main-
tenance on the tool may only
be carried out by trained per-
sonnel.
Protect yourself!
When operating the tool, wear
eye, face and hand protection
(cut-proof gloves).
Power source!
Before starting preventive or
corrective maintenance, remo-
ve battery from the tool.
Warning:
Strap will snap forward!
When cutting the strap, hold
the upper portion and stand
safely away from the strap.
Caution:
The lower strap will snap
forward.
Warning:
Strap could break!
Do not stand in line with the
strap while it is tensioned. The
strap could break!
Caution:
Only strap packed goods!
Do not put hands or other parts
of the body between the strap
and the package during the
strapping process.
Caution:
Danger of squeezing!
Do not put your fingers into the
tension wheel area.
Do not use water!
Do not use water or steam to
clean the tool.
ORGAPACK
Original
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Page 4 of 12 08/07

ORGAPACK OR-T 300
4DESCRIPTION
4.3 FUNCTION
– Clamping of the straps by tooth plate on rocker
(3/1).
– Tensioning by feed wheel (3/2) anti-clockwise.
– Friction welding (3/3) of the straps.
– Upper strap is cut by knife (3/4).
4.1 CONSTRUCTION
1 Operating panel
2 Strap tensioning push button
3 Handle
4 Battery
5 Rocker lever
6 Welding/cutting button
7 Welding/Cutting
8 Tensioning
9 Battery charger (refer to chapter 4.4)
4.2 OPERATING PANEL
1 Welding time push button
2 Strap tension push button
3 Battery push button
4 LED-indicators 1–7
Green = Strap tension setting
Red = Battery empty indicator
5 Setting – push button
6 Setting + push button
For detailed information of the operating
panel, refer to chapter 6.3.
12
34
Fig. 3
Fig. 2
7 6 5 4
3 2 1
1
2
3
4
5
6
7
6
5
4 3
2
1
Battery charger IFC1702d
Ladegerät14.4V
Discharge-before-Charge
I
Fig. 1
1
2
3
4
5
6
7
89
Note on performance
In order to achieve peak performance, only
original batteries and charger may be used.
Page 5 of 12 08/07

ORGAPACK OR-T 300
4.4 BATTERY CHARGER
The battery charger (IFC1702d) is a special device
with both charging and discharging functions for maxi-
mum battery power and life.
– When a battery is placed in the charger, the remai-
ning charge level is tested first. If the battery is not
completely discharged, the charger will first empty it.
– After discharging, the battery charger switches auto-
matically to charge. The battery will be fully charged
in four steps by the pulse charging technique.
Battery discharging time: approximately 15 minutes
with discharged battery from
strapping machine
Battery charging time: 14.4 V/2.4 Ah
> +/- 60 minutes
Fig. 4
Battery charger IFC1702d
Ladegerät
Chargeur
Input 100.240VAC/ 47.63Hz /100W
Output 14.4VDC/ 4A
Battery charger indicators:
Process / Status Function red LED green/orange LED
Charger switched on Standby lit LED lit green
Battery inserted Discharging off LED blinks orange
Battery inserted Charging off LED blinks green
Battery inserted Charged, Trickle charging off LED lit orange
Battery removed Standby lit LED lit green
Page 6 of 12 08/07

ORGAPACK OR-T 300
5INITIAL OPERATION
5.1 BATTERY CHARGER
The mains supply must comply with the specifications
on the rating plate (Fig. 5).
The battery charger is suitable only for charging
batteries from the Bosch range of tools (NiCd/
NiMH) with the voltage of 14.4 V.
5.2 FIRST BATTERY CHARGE
Please observe the following points in order
to ensure optimum battery life:
– Connect battery charger (6/2) to mains supply.
– Insert battery (6/1) into battery charger slot.
For the first charge, leave the battery in the char-
ger for at least five hours, regardless of the bat-
tery indicator (the charging time for all subsequent
charges is about 60 minutes).
For all subsequent charges, only recharge the
battery when the LED indicator on the tool indica-
tes battery empty or the battery charge indicators
shows a minimum of level 5 or lower (see Chapter
6.3.1). Avoid charging when the battery is not yet
discharged. This will ensure optimum battery ca-
pacity and life.
Maximum battery output will be reached after four or
five charging/discharging cycles.
5.3 CHARGING THE BATTERY
The charging process and error functions are indica-
ted by a LED (6/3) (see chapter 4.4).
The charging time is approximately 60–75
minutes.
The maximum charging current flows when the tem-
perature of the battery is between 15–40°C. Avoid
charging the battery at temperatures below 0°C and
above 40°C.
If the battery is not to be used for a longer
period (several days), it should be remo-
ved from the tool and charged/stored in the batte-
ry charger.
Battery charger IFC1702d
Ladegerät
Chargeur
Input 100.240VAC / 47.63Hz /100W
Output 14.4VDC / 4A
Fig. 6
1
2
3
Fig. 5
Input 90-135VAC, 170-264VAC / 47...65 Hz
Battery Type: Bosch NTC-Battery 14,4V
Page 7 of 12 08/07

ORGAPACK OR-T 300
6OPERATING INSTRUCTIONS
Fig. 7 Place strap around package
1
Fig. 9 Strap tensioning
1
Fig. 8 Slide straps into tool
1
6.1 OPERATING THE TOOL
– Insert charged battery (7/1) into strapping tool.
– Place strap round goods to be packaged, so that
the straps lie one above the other on top of
package. The beginning of the strap is underneath.
Hold the straps with the left hand so that the strap
beginning is approximately 20 cm (8“) ahead of the
hand.
– Take the tool in the right hand and lift the rocker
lever (8/1) towards the handle.
– Slide the straps, one on top of the other, into the
tool up to the stop.
The strap lead is now approximately 5 cm
(2“) beyond the tool.
– Release the rocker lever.
– Press the push button (9/1). The strap is tensioned
until the required or pre-selected strap tension is
reached.
– The strap tension can be adjusted on the oper-
ating panel (see Chapter 6.3.2).
– The strap can be re-tensioned at any time.
Releasing strap tension
In order to release the strap tension after the tension-
ing process, lift rocker lever (8/1) against handle.
Tensioning – welding:
The welding process is started only when the
minimum strap tension of 400 N has been attained.
Page 8 of 12 08/07

ORGAPACK OR-T 300
– Depress button (10/1) completely to the stop. The
straps are welded together and the upper strap is
cut off. The LED indicator (10/2) indicates the cooling
time of the sealing:
LED flashing
After finishing the friction wel-
ding, the green LED flashes for
approx. two seconds.
Do not remove the tool during
this time!
Continuous LED and audible
signal
The sealing cycle is finished.
If the straps have not been welded and an
audible signal sounds, this means the
minimum strap tension was not attained –> re-tension.
– After the LED has stopped flashing and the audible
signal sounds, raise the rocker lever up to the
handle.
– Swing the tool away from the strapping backwards
and to the right.
– Check the seal (refer to chapter 6.2).
If the tool is used in a dirty environment, it is
recommended that it should be cleaned daily.
In particular the tension wheel and the tooth plate
should be checked for damage and kept clean. This is
best performed by blasting with compressed air (wear
goggles).
Fig. 10 Welding straps
1
2
Fig. 11 Removing tool
6.2 CHECKING THE SEAL
– Check appearance of seal (see fig. 12) regularly.
If the straps are poorly welded, check the welding
time setting (refer to chapter 6.3.3).
1Good seal (the complete surface is cleanly welded
without excess material being forced out sideways).
2 Poorly welded seal (not welded over the complete
surface), welding time too short.
3 Poorly welded seal (excess material is forced out
sideways), welding time too long.
An incorrectly welded strapping cannot
secure the package and can thus lead to
injuries.
Never transport or move packaged
goods with incorrectly welded seals.
+
~2 sec.
Fig. 12 Checking of seal
1
23
Page 9 of 12 08/07

ORGAPACK OR-T 300
6.3 OPERATING PANEL
a) Standard indication (green)
The current strap tension setting is monitored with
inserted and charged battery.
1 = minimum strap tension (approx. 400 N)
7 = maximum strap tension (approx. 1400/3300 N*)
* depending on strap tension range, refer to chap-
ter 6.3.4.
– For adjustment of strap tension, refer to chapter
6.3.2.
b) Battery empty indication (red)
If the inserted battery is empty, the LED switches to
red and the battery must be charged, refer to chapter
5.3.
Fig. 13
7
6
5 4 3
2 1
a) Standard indication
green
red
b) Battery empty indication
max. min.
7 6 5 4 3 2
1
7 6 5 4 3 2 1
6.3.1 CHECKING BATTERY CHARGE
– Depress battery push button (14/1) briefly. Read off
battery charge on LED indicator (14/2).
1 = empty battery
1–3 = minimum charge (battery must be charged
soon)
1–5 = decreasing charge (charging possible)
1–6 = good charge (charging would damage the
battery)
1–7 = maximum battery charge (charging would
damage the battery)
6.3.2 SETTING STRAP TENSION
– Depress strap tension push button (15/1) briefly
until LED indicator (15/3) flashes.
– Depress –or +push button (15/2) until flashing
LED indicator shows required strap tension (wait
two seconds until new setting is saved).
1 = minimum strap tension (ca. 400 N)
7 = maximum strap tension (ca. 1400/3300 N*)
* refer to Chapter 6.3.4.
6.3.3 SETTING WELDING TIME
– Depress welding time push button (16/1) briefly
until LED indicator (16/3) flashes.
– Depress –or +push button (16/2) until flashing
LED indicator shows required welding time (wait
two seconds until new setting is saved).
1 = minimum welding time
7 = maximum welding time
Cutting:
The cutting of the strap is influenced by the
welding time. If the tool cuts badly, extend the welding
time by one interval.
Fig. 14
7
6
5
4
3
2
1
max. min.
red
1 2
Fig. 15
12
7 6
5 4
3
2 1
green
max. min.
3
Fig. 16
12
red
max. min.
3
7
6 5 4 3 2 1
Page 10 of 12 08/07

ORGAPACK OR-T 300
6.4 SETTING STRAP WIDTH
The tool can be used with two different strap
widths (15–16 mm (5/8“) or 18–19 mm (3/4“).
a) Change strap width from 15–16 mm to 18–19 mm
– Remove battery from tool.
– Release sunk screw (18/2) and remove strap stop
16 mm (18/1).
– Lift the rocker lever towards the handle, release
sunk screw (18/4) and remove strap guide 16 mm
(18/3).
– Release sunk screw (19/3) and cylinder screw (19/1)
and remove cover (19/4).
– Release cylinder screw (19/5) turn strap stop (19/2)
180° and remount it.
– Unscrew threaded bolt eight turns with screwdriver
(19/6).
– Pull down strap guide (19/7) and turn it 180° until
19 mm indicator appears.
– Tighten threaded bolt with screwdriver (19/6) and
mount cover (19/4).
– Secure screws (19/1) and (19/3) with Loctite 222.
b) Change strap width from 18–19 mm to 15–16 mm
– Sequence as described under point a).
– Mount 16 mm strap stop (18/1) and secure sunk
screw (18/2) with Loctite 222.
– Mount 16 mm strap guide (18/3) and secure sunk
screw (18/4) with Loctite 222.
– Turn strap stop (19/2).
– Turn strap guide (19/7) until “16“ indicator appears.
6.3.4 SETTING STRAP TENSION RANGE
The following two strap tension ranges can
be set on the tool:
A = 400–3300 N (standard)
B = 400–1400 N (eg for PP-straps)
Check strap tension range
– Depress and hold down “–“ push button (17/2), and
depress strap tension push button (17/1) for one
second.
– If the LEDs 1–7 are flashing = A (400–3300 N)
– If the LEDs 1–4 are flashing = B (400–1400 N)
Change strap tension range
– Depress and hold down “–“ push button (17/2), and
depress strap tension push button (17/1) for one
second.
– Depress “–“ or “+“ push button briefly so strap
tension range changes (wait two seconds until new
setting is saved).
Fig. 17
7
6 5
4
3
2
1
7
6
5
4
3
2
1
= A
= B
12
Fig. 18
1 2 3 4
Fig. 19
180°
180°
8 x
16/19
1
2
3
4
5
7
6
* Standard values! Actual value on package depends
on strap and package.
A)
1 2 3 4 5 6 7
400* 750* 900* 1300* 1600* 2000* 3300 N*
B)
1 2 3 4 5 6 7
400* 600* 7500* 900* 1100* 1300* 1400 N*
Page 11 of 12 08/07

ORGAPACK OR-T 300
7PREVENTIVE AND CORRECTIVE MAINTENANCE
7.1 CLEANING/REPLACING TENSION WHEEL
Removal
– Remove battery from tool.
– Release three sunk screws (20/3) and remove cover
(20/2) with ball bearing.
– Carefully remove tension wheel (20/1).
– Clean the tension wheel with compressed air (wear
goggles).
– If the tension wheel teeth are covered with heavy
dirt, they must be carefully cleaned with the wire
brush supplied or a sharp tool.
– Check tension wheel for worn teeth. If a few teeth
are worn, replace tension wheel.
The tension wheel must not be cleaned
while it is rotating. There is a risk of
breaking teeth!
Installation
– Install the parts in reverse order.
– Grease gear teeth of tension wheel lightly with
Klüber grease GBU Y 131 (Microlube).
– Secure sunk screw (20/3) with Loctite 222.
7.2 CLEANING/REPLACING TOOTH PLATE
Removal
– Remove battery from tool.
– Release sunk screw (21/1) and remove tooth plate
(21/2).
– Clean tooth plate with compressed air (wear
goggles).
– If the tooth plate teeth are covered with heavy dirt,
they must be carefully cleaned with the wire brush
supplied or a sharp tool.
– Check tooth plate for worn teeth, if necessary
replace tooth plate.
Installation
– Install the parts in reverse order.
– Secure sunk screw (21/1) with Loctite 222.
7.3 REPLACING CUTTING KNIFE
Removal
– Remove battery from tool.
– Release sunk screw (22/2) and cylinder screw
(22/1) and remove cover (22/3).
– Release cylinder screw (22/6) and remove cutting
knife (22/4) with flanged bushing (22/5). Replace
cutting knife.
Installation
– Install the parts in reverse order.
– Before install cutting knife, check that the compres-
sing spring on top of knife is still mounted.
– Secure screw (22/1), (22/2) and (22/6) with Loctite
222.
All preventive maintenance tasks can be
performed with a Phillips screw driver!
Fig. 22
12
3
4
5
6
Fig. 21
1
2
Fig. 19
3
1
2
Page 12 of 12 08/07