ORKEL DENS-X Hi-X Compactor User manual

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
Johan Gjønnes' veg 25
7320 Fannrem, Norway
Valid from serial number: 20427005
Orkel part number: 16776
orkel.no/qr/hi-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 19
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 Hi-X 24
3.3 Feed hopper 24
3.3.1 Control panels 24
3.3.2 Settings 24
3.4 Elevator and sub conveyor 25
3.4.1 Settings 25
3.5 Chamber 25
3.5.1 Opening speed settings 25
3.5.2 Chamber pressure settings 25
3.6 Plastic tying unit 26
3.6.1 Principle of operation 26
3.6.2 Brake and feed speed 26
3.6.3 Settings 27
3.6.4 Remote control 28
3.7 Wrapping table 28
3.7.1 Wrapping settings 28
3.7.2 Film cutter settings 29
3.7.3 Wrapping table tilt speed 30
3.7.4 Wrapping table ultrasonic sensor 30
3.7.5 Microsonic sensor (S1) 30
3.8 Drawbar 31
3.8.1 Telescopic drawbar 31
4 Operation 32
4.1 Safety 33

4.1.1 Safe work routine 33
4.1.2 Operator safety 33
4.1.3 Other people's safety 33
4.1.4 Assembly on site 33
4.1.5 Elements of hazard during operation 34
4.1.6 Danger zones during operation 34
4.1.7 Risk of overturning 34
4.1.8 Leaving the machine 34
4.2 Connection and setting up the machine 34
4.2.1 Rig up 34
4.2.2 Telescopic drawbar and feed hopper F10 35
4.2.3 Lever/Controls overview 36
4.2.4 Lever list 36
4.2.5 Leveling the machine 37
4.2.6 Placing the tractor with telescopic drawbar 37
4.2.7 Power take off 37
4.2.8 PTO Speed 37
4.2.9 Electrical power source 37
4.2.10 Hydraulic connections 37
4.2.11 Oil temperature 38
4.2.12 Stairs 38
4.3 Daily checklist 38
4.3.1 Daily checklist prior to startup 38
4.3.2 Checkpoints while baling 39
4.4 Break-in period 39
4.4.1 Precautions during the break-in period 39
4.4.2 After the first 50 hours of operation 39
4.5 Automatic operation 40
4.6 Film roller storage 41
4.7 Wrapping arms 42
4.7.1 Wrapping arm emergency stop 42
4.7.2 Installing a new film roller in the wrapper 42

4.8 Parking brake 44
4.9 Operators platform 44
4.10 Compressed air cleaner system 44
4.10.1 Mode of operation 45
4.10.2 Recommendations 45
5 Transport 47
5.1 Transport safety 47
5.1.1 Speed limit 47
5.1.2 On road preparation 47
5.1.3 Lifting points 47
5.1.4 Strapping and tie down 48
5.1.5 Dismantling the machine 48
5.2 Highway use 49
5.2.1 Transport preparation, Telescopic drawbar and feed
hopper F10 49
6 Control system 50
6.1 User interface 50
6.1.1 Main page 50
6.1.2 Icons for starting program sequences 51
6.1.3 Menu 51
6.1.4 User settings [Language and screen] 52
6.1.5 System information 53
6.1.6 Manual controls 53
6.1.7 Machine settings 55
6.1.8 Quick settings 56
6.1.9 Presets 57
6.1.10 Sensors 57
6.1.11 Messages 58
6.1.12 Time and date 59
6.1.13 User data 59
6.1.14 Weighing system 61
6.1.15 Reset 61

6.1.16 Software 61
6.1.17 Settings and explanations 63
7 Maintenance and mechanical adjustments 65
7.1 Safety 66
7.1.1 Before maintenance 66
7.1.2 Safety precautions during maintenance and mechanical
adjustments 66
7.1.3 Elements of hazard during maintenance 67
7.1.4 Control after repair or maintenance 67
7.2 Electrics 67
7.2.1 Fuses 68
7.3 Wheels 68
7.4 Chains 68
7.4.1 Chain tensioner A 68
7.4.2 Chain tensioner B and C 69
7.5 Feed hopper 70
7.5.1 Tightening the feed hopper belts F10 70
7.5.2 Ball bearings 71
7.6 Drive chains 71
7.6.1 Drive chains overview 71
7.6.2 Drive chains tensioning 72
7.7 Elevator and sub conveyor 72
7.7.1 Conveyor belts and feeder carrier 72
7.7.2 Adjusting the conveyor chains 73
7.7.3 Chain tensioner, sub conveyor 74
7.7.4 Chain tensioner, elevator F10 74
7.7.5 Ball bearings elevator 74
7.8 Baling chamber 75
7.8.1 Inspection 75
7.8.2 Adjusting the front chamber belt 75
7.8.3 Adjusting the rear chamber belt 76

7.8.4 Adjusting the chamber belt tensioner 79
7.8.5 Replacing chamber belt 79
7.9 Plastic tying unit 80
7.9.1 Control and maintenance 80
7.10 Wrapping table 81
7.10.1 Inspection 81
7.10.2 Adjusting the wrapping table belt 82
7.11 Frame, drawbar, attachments 84
7.11.1 Frame 84
7.11.2 Main components, fastening points 84
7.12 Chamber roller bushings 84
7.12.1 Wear inspection 84
7.12.2 Permissible wear 85
7.12.3 Remove sprockets 86
7.13 Hydraulics 87
7.13.1 Hydraulics oil 87
7.13.2 Hoses and connections 87
7.13.3 Hydraulic pump, gearbox 87
7.13.4 Heat exchanger 88
7.14 Oil change and oil filter 88
7.14.1 Changing oil and filter 89
7.15 Welding and grinding 90
7.15.1 Precautions when welding 90
7.16 Service history 91
8 Lubrication 92
8.1 Lubrication system, beka max EP 1 92
8.1.1 Oil lubrication, mode of operation 92
8.1.2 Grease lubrication, mode of operation 92
8.1.3 Beka max grease lubrication system 94
8.2 Refilling lubricants 94

8.2.1 Refilling the oil reservoir 95
8.2.2 Adjusting the amount of grease 95
8.2.3 Bleeding the grease system 95
8.3 Electric pump and main distributor 96
8.4 Troubleshooting for Beka max 96
8.5 Oil temperature 97
8.6 Approved lubricants 97
8.6.1 Hydraulics 97
8.6.2 Chain lubrication 97
8.6.3 Greasing 97
8.6.4 Gearbox and gears for hydraulic motors 98
8.7 Manual lubrication charts 99
8.7.1 The compactor 99
8.7.2 Feed hopper F10 100
8.7.3 Telescopic drawbar 101
8.8 Lubrication list - Manual greasing points 102
9 Preservation 103
9.1 Cleaning 103
9.1.1 Using high pressure washer 103
9.2 Storage 103
9.2.1 Long time storage 103
9.2.2 Oil filling in the grease lubrication storage 103
10 Electrics 104
10.1 Main power supply, e-stop switches and electrical
cabinet 105
10.2 Electrical cabinet power supply rail 106
10.3 Sensors and manual controls 107
10.4 Valves, fan motors and pumps 108
10.5 Inputs and outputs 109
10.5.1 IO block 1 109
10.5.2 IO block 2 109

10.5.3 IO block 3 110
10.5.4 IO block 5 110
10.5.5 IO block 6 111
10.5.6 IO block 7 112
10.6 Power supply 112
10.6.1 Supply block 1 112
10.6.2 Supply block 2 113
10.7 Inputs and outputs sorted by number 114
10.7.1 IO list 1 114
10.7.2 IO list 2 115
10.7.3 IO list 3 116
10.8 Inputs and outputs sorted by type 116
10.8.1 Inductive sensors 116
10.8.2 Other sensors and switches 117
10.8.3 Directional valves 117
10.8.4 Sensors, 7-lead cable 118
10.8.5 Film system remote control 118
10.8.6 Radio remote control 118
10.8.7 Proportional valves 118
10.8.8 Valves 118
10.8.9 Cable detection 119
10.9 Sensor overview 120
10.10 Sensor list and function 121
11 Hydraulics 123
11.1 Hydraulic diagram 123
11.1.1 Complete diagram 124
11.1.2 Wrapping table, chamber and elevator control 125
11.1.3 Plastic tying unit, sub conveyor and feed hopper 126
11.1.4 Hydraulic diagram list 126
11.2 Valve overview 128
11.2.1 Valve chart for Hi-X 128

11.2.2 Valve list for Hi-X 129
12 Specifications 130
12.1 Electrical system 130
12.2 Power take off 130
12.3 Lubrication system beka-max 130
12.4 Hydraulic system 131
12.5 Wheels and tyres 131
12.6 Dimensions and weight 131
12.6.1 Measurements 131
12.6.2 Power requirements 131
12.6.3 Dimensional sketch F10, operating mode 132
12.6.4 Dimensional sketch F10, transport mode 133
Glossary 134
Index 136