ORKEL HiQ smartbaler User manual

Serial number:
Manufacturer:
Orkel AS Johan Gjønnes veg 25
N-7320 Fannrem Norway
Operator’s manual
Orkel HiQ smartbaler
Original operator’s manual. Published 2013
From serial number: 20319001

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Congratulations on the purchase of your new Orkel HiQ Smartbaler
Orkel machines are well-known for their quality and strength. They are designed for use in
tough environments and high efficiency. This is the result of continuous product develop-
ment and thorough quality control prior to shipping. We have conducted an assessment pro-
cedure in accordance with the EC -machinery directive and the machine is CE-marked.
1.Introduction
1.1 Identification:
A plate, stating the round bailer serial number is located at the drag bars right side.
An additional serial number (wrapper) is stamped on the top of the left rear main frame.
Serial numbers must always be at hand when contacting your supplier to order spare parts or
any other technical support.
Before any operational use or maintenance of this machine, you must read the safe-
ty instructions in this manual. Read them carefully to ensure that you are familiar
with all the safety issues.
This Operator’s manual is standard for:
Orkel HiQ smartbaler, New Holland Rollbaler 135 Ultra, Case IH RB 544 Silage pack HD
Check that this Operator’s Manual matches your baler. We require that the instructions in
this manual are followed in order to maintain your personal safety and ensure the lifespan of
the machine. Remember – always state the serial number when ordering spare parts!
Information in the manual relating to personal safety is marked with
the above sign and with bold text. Please pay special attention to these sections.
Yours sincerely,
Orkel AS
Serial number (plate), round bailer Serial number, wrapper

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INDEX:
1.Introduction
1.1 Identification
1.2 General
1.3 Dimensions and weight
1.4 Safety
1.5 Main sections
2. Safety instructions
2.1 Introduction
2.2 General safety instructions
2.3 Mechanical connection and disconnection
2.4 Adjustment
2.5 Maintenance and service
2.6 Lifting
2.7 Use
2.8 Transport
2.9 Parking
2.10 Dismantling
2.11 Warning signs/ labels
2.12 Warning signs, explanations
3. Connections
3.1 Electrical
3.2 Hydraulic
3.3 Mechanical
3.4 PTO axle
3.5 PTO speed
4 Settings
4.1 Height /tow bar adjustment
4.2 Settings in control box
4.3 Mechanical settings
4.4 Hydraulic settings
5 Preparations before driving
5.1 Installing the wide film or net roller to the HiT system
5.2 Installing wrapping film
5.3 Lubrication system. Refill
5.4 Ensiling fluid.

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6. Start-up
6.1 Control before starting up
6.2 Control box, introduction
6.2.1 Control box unit, general function
6.2.2 Control box, menus
6.3 Driving technique
6.3.1 Driving technique, hillsides /slopes
6.4 Obstruction in pick-up or feeder unit
7 Technical information
7.1 Electric system
7.2 Hydraulic system
7.3 HiT system overview
7.3.1 HiT system, hydraulic valves
7.3.2 HiT valves, adjustment
7.4 Lubrication system
7.4.1 Lubrication system, troubleshooting
7.5 Drive chains
7.5.1 Sprockets
7.6 Sensor overview and location
7.6.1 Sensor scheme
7.7 Program menus
7.7.1 Main programs
7.7.2 Ensiling fluid/Additives
7.7.3 Timers and speeds
7.8 Program menu, screen pictures in control box
7.8.1 Program menu, chamber calibration
7.8.2 Program menu, pick up settings
7.9 Hydraulic scheme
7.10 Wrapper, manual operation
7.11 Wrapper film, overlap adjustment

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8 Maintenance
8.1 Daily maintenance.
8.2 Knives
8.2.1 Knives, disassembly/assembly
8.2.2 Knives, changing/sharpening
8.2.3 Knives, control
8.4 Release lever Hit system, adjustment
8.5 Lubrication, manual points
8.6 Service
8.7 Cleaning.
8.8 Long time storage, winter storage.
8.9 Wheels and tyres
8.10 Jacking points
8.11 Spare parts
9 Contact
9.1 Vital phone numbers.
9.2 e-mail and webpage.
10 Technical data
10.1 Specifications
10.2 Options
11 Transport
11.1 Tying down / strap
11.2 Lift/Hoist
11.3 Parking
12 Declaration of conformity
13 Warranty
13.1 Terms and conditions
13.2 Warranty and warranty claims
14 Notes:

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1.2 General
The Orkel HiQ Smartbaler is meant for baling grass, straw and hay, and for these
purposes only. The HiQ is a high effective baler, designed for farmers and
entrepreneurs acting on a larger scale.
The bales will have a diameter up to 1300 mm, and a width of 1220 mm.
The bales might weigh 1000 kg or more.
The HiQ Smartbaler has to be used accordingly to the instructions given in this
manual.
If you are in doubt regarding the range of use of the machine, contact Orkel AS, or
your local Orkel representative.
1.3 Dimensions and weight:
HiQ smartbaler (Rollbaler 135 Ultra / RB 544 Silage pack HD)
Weight: 5200Kg
Height: 280cm
Width: 275/292cm
Length: 620cm
1.4 Safety
Before any use, or doing any kind of work on the machine, the
“safety instructions” in chapter 2 has to be read carefully and understood.

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1.5 Main sections
Drag bar
Net/film holder
Pick up
Wrapper
Wrapper table
Wrapper arms Film holders
Chamber

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2. SAFETY INSTRUCTIONS, INDEX
2.1 Introduction
2.2 General safety instructions
2.3 Mechanical Connection/disconnection
2.4 Adjustments
2.5 Maintenance
2.6 Lifting
2.7 Use
2.8 Transport
2.9 Parking
2.10 Dismantling
2.11 Label warnings
2.12 Label warnings, explanation

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2.1 Safety introduction
Danger of severe injury is present if the machine is not being handled pursuant to
descriptions made in this Operator`s manual /safety instructions.
All care and attention has been taken in design and production of this Orkel machine, to min-
imize the danger in operating the baler. However, there is a certain amount of risk to person-
nel operating the baler. It is strongly recommended that the operators, take all possible pre-
cautions to ensure both their own safety, and others who may be in the area.
NOTE: Orkel HiQ smartbaler can only be used for baling grass, hay and straw!
Before operating, adjusting or servicing the machine, it is important that operators manual
and safety instructions are carefully read and understood by the operator.
Operator’s manual should be regarded as a part of the machine. Make sure this guide is fol-
lowing the baler if “resale”
By reading this operator’s manual you will be able to understand:
1 How the machine operates.
2 How to operate it safely without hazard to either the operator or persons in the area
3 How to successfully use the machine to its fully potential.
WARNING: Ignoring the safety instructions can result in death or serious injury!

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2.2 General safety instructions
Before any maintenance, cleaning, disassembly of parts and adjustment is made on the ma-
chine. Always: Disengage the PTO drive clutch. Stop the tractor engine, activate the hand
brake and remove the key to prevent the tractor from being started accidentally.
Before operation:
Thoroughly read and understand the relevant chapter in the operators manual. Do not start
the tractor before all persons are in safe distance to the machine. Keep children and specta-
tors off and away from machine when operating. The area around the machine should be
kept clear at all times. Keep area between tractor and baler clear of people under coupling
and uncoupling.
Operation:
Do not wear loose or baggy clothing, when working on the machine and keep hands, feet
and clothing away from moving parts. Stop tractor engine before removing guards and
shields. Keep all guards and shields in place and in correct order. Use ear protection if the
noise of the machine and tractor is too loud. (without cabin)
It is not allowed to stay on the machine when operating.
Never remove material from machine when operating, and never feed material (twine, net or
crop) manually into machine. Stop tractor engine and remove the key before unblocking pick
up.
When baling dry material like dry grass, hay or straw, extra care has to be taken.
Service/maintenance:
Before starting, make sure of the machine is clear of people, and that all tools and loose ob-
jects have been removed and correctly stowed. Do not do service or remove hydraulic hoses
when the hydraulic system is under pressure.
Owner:
The owner is responsible for making this information available to the operator. This to en-
sure safe use and proper maintenance of the baler.
WARNING: CHILDREN UNDER 16 YEARS OF AGE MUST NEVER OP-
ERATE THE MACHINE!

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2.3 Mechanical connection/disconnection
Keep people away from area between tractor and baler during connection and disconnection.
Squeezing hazard!
Disconnection has to take place on plain ground, and the baler has to be parked in a stable
position to prevent overturn.
Make sure that the PTO direction of rotation, and rotation speed RPM of the tractor corre-
spond to the machine’s settings. Wrong direction or RPM can lead to serious damage to the
machine.
Make sure the hydraulic couplings are clean and undamaged before connecting and activat-
ing the hydraulic system.
Before starting, ensure the machine is clear of people and all tools and loose objects have
been removed and correctly stowed.
When PTO shaft is removed from the tractor it must be secured to the baler with the chain
provided to prevent accidental damage to the shaft.
Stop tractor engine and ensure that there is no pressure on the hydraulic system, when dis-
connecting.
Oil can penetrate through human skin and cause inflammation.
Use eye and skin protection to prevent direct contact with oil.
Disconnect the hydraulic hoses and electric cables before moving the tractor away.

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2.4 Adjustments
When adjusting machine always disengage the PTO drive, stop tractor motor and remove the
key. Wait until all moving parts have stopped.
Working on knife system. Read instructions closely!
Always close the safety valve, securing the tailgate lifting cylinders while working inside the
chamber.
Working on HiT knife/wrapper. Read instructions closely!
Be ware of sharp edges, always use personal safety gear
2.5 Maintenance/service
Before carrying out a major service or repairs to the machine it should be thoroughly cleaned
or washed down if necessary. The machine should stand on a flat surface and the wheels
blocked to prevent movement.
Cleaning
To give the baler a “real clean” The two side panels can be removed when cleaning is done.
The rollers may be activated slowly, by engaging the power shaft to move them to various
positions.
Warning: Hazardous operation! Before doing this operation, the machine must be clear of
all other personnel.
Fire hazard!
Dry material mixed with oil spill in/on the baler represent a very flammable combination.
Fire precautions must taken when welding and grinding is done to the machine. Under these
conditions a fire extinguisher should always be at hand.
2.6 Lifting
Only use lifting gear with sufficient capacity to lift the machine.
Hook-up points are marked with a label. (see to the left)
Do not lift the machine by hooking elsewhere.
P_030

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2.7 Use:
Keep children and others away from the machine when operating. The area around the baler
should be kept clear at all times. Make sure that no one is behind the baler when unloading a new
bale.
NOTE: Avoid uncontrolled unloading of bale in slopes/hillsides.
Material will feed into baler very fast. Never remove or add material manually from/to the ma-
chine when operating!
Beware of moving rotor or rollers. Never manually feed net into machine.
2.8 Transport:
The standard speed limit is set to 30 km/h (road conditions.)
In some countries, the baler could be labelled with a speed limit of 40Km/h. Make sure you know
the traffic regulations/speed limits in your country, before entering the road.
2.9 Parking:
The machine should stand on a flat surface and the wheels blocked with
chocks. Remember to disconnect hydraulic hoses and electric cables before
moving the tractor away.
2.10 Dismantling:
The centre of gravity of the machine will change depending on witch parts being removed. Make
sure all parts are secured sufficiently. Always wear proper personal protecting-gear when disman-
tling the machine.
Lifting chains/strap used in lifting operations, must be labelled with the right lifting capacity.
Make sure they are in good condition.
Take necessary fire-precautions and observe safety instructions and safe working practices when
using cutting torch or angle grinder. Be aware of sharp edges that may occur from cutting or
grinding.
NOTE: Always recycle all the materials removed from the machine.
Materials who could endanger the environment must be delivered at a suitable
disposal plant, (special-waste, rubber, electrical equipment, oils and plastics)
Chock , stored on top

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2.11 Label warnings and tags: see also section 2.12
10
7
1211
456
89
123

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2.11 Label warnings and tags: see also section 2.12
P_038
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P_039
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16
14
17 18
19 20 21

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2.12 Labels, warning and signs. Explanation of symbols
1. Do not operate the machine before you have read and understood the operator’s manual and the safety in-
structions.
2. Stop the tractor`s engine before cleaning, adjusting or servicing the machine. Remove the ignition key to
prevent the tractor from being started accidentally.
3. Keep area between tractor and wrapper clear of people during coupling.
4. Keep children away from machine when it is running. Especially small children can do unforeseeable
things.
5. No person is allowed to stay behind the baler. When opening the chamber, there is a great risk of getting
squeezed between tailgate and an other object.
6. Persons near the baler have to pay attention and keep distance when bale being released from the chamber.
Bales can roll several meters away, especially when operating in hills /slopes.
7. When working with open chamber, the tailgate must be secured, all the time.
8. The net knife is very sharp. Pay attention during loading of net rollers, and adjusting the knife.
9. Make sure that the PTO drive direction and the revolution speed of the tractor correspond to the machine.
Faulty revolution speed can cause damage. The machine is built for 540E (750) or 1000 RPM.
10. Do not enter net roller area when the unit is rotating. When net goes into the baling chamber, the net roller
rotates extremely fast.
11. Chains and sprockets inside cover. Do not touch when machine is running.
12. Serious injury might occur if you work in the pick-up or feeding units when the machine is operating. Keep
away from all moving parts.
13. Use parking chocks when parking the machine.
14. Keep away from the PTO shaft while the driving line is engaged. Do not wear loose or baggy clothing. En-
sure all protections are in place and correctly secured at all times. Ensure shaft length fits to tractor and ma-
chine.
15. Lifting points for fork lift.
16. Never start the P.T.O. axle when the reversing key it’s still fitted to the shaft!
17. Safety distance 5 meters. No persons allowed closer than 5 meters from the machine, when machine is in
operation.
18. Hazard of injury. The film cutter/ film holder has sharp knife, and opens and closes with heavy pressure.
19. Hazard of injury. Safety distance. Keep clear of rotating parts
20. Hazard of injury. Accumulator warning, risk of explosion.
21. Strapping point, See operator’s manual.

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3. Connections.
3.1 Electrical connections:
The main power supply cable, cable for lights, and cable for control-box, are delivered
together with the machine. The main power cable has to be connected directly to the tractor`s
battery. Connect then the cable to the round baler.
Cable for lights must be connected to the light socket located on the tractor.
Then connect the signal cable to the control box, and to the round baler.
All electric connections must be carried out as described in this chapter. If not, the warranty of
your round bailer can be limited.
3.2 Hydraulic connections:
Connect the brake hose from the baler to an approved brake pressure outlet on the tractor. Con-
nect the pressure hose (red) to a outlet that preferably gives pressure when lever is locked in
rear position. This is if it’s connected to a double action outlet.
The oil return hose has to be connected to a 3/4” inlet with free flow (max 3,0 bar back
pressure). The supplied coupling is meant for using on the tractor`s return inlet.
This coupling has to be used at all times, to secure free return flow.
Connect the hose for Pickup (yellow) up /down to a vacant outlet on tractor..
Connect the hose for engagement/ disengagement of cutting knives (blue) to a vacant
outlet.
Connect the hose for discharge rotor (green) This could alternatively be connected
parallel to the cutting knives.
If the tractor is equipped with a Load Sense (LS) - system, connect the signal hose from
the baler`s LS valve to the tractor`s LS block.
NOTE: LS must also be turned on in the balers program, if it’s to be used.
NOTE: Hydraulic hoses has limited lifetime. We recommend to change the hydraulic hoses
every 6. year.
3.3 Mechanical connections:
Connect the baler`s tow bar to the pulling device on the tractor.
For installing PTO axle, please see next page.

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3.4 PTO axle.
When installing a new axle, it must be adapted to correct length (see figure below).
Make sure that distance a is sufficient to handle
necessary free motion when operating the
machine in hills/slope conditions.
At the same time, distance b must be as long as
possible.
Lubricate the axle in accordance with the
manufacturer`s instructions. Please see separate
manual for PTO axle.
For instructions regarding height adjustments of
the baler, please see chapter 4.
3.5 PTO speed
The baler is prepared for a PTO speed on 540 rpm. (Standard)
A PTO speed on 1000rpm is available as an option.
The baler will be marked with a warning label, showing maximum PTO speed.
Warning! Using wrong PTO speed, could result in insufficient
power or major mechanical breakdown.
Warning labels, front of the machine

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4. Settings
4.1 Tow bar adjustment.
To obtain optimized utilization of the baler`s qualities, it is vital that this adjustment is car-
ried out in a correct way.
Preparations.
The baler has to be attached to tractor and baler has to be placed on flat ground. Air
pressure in tires has to be set to 1 Bar.
Procedure.
1. Adjust the Pick Up wheels, until the pickup tines has distance of 5cm to the ground.
2. Place a jack under the baler (see picture below). Engage the jack and raise the axle.
(Only to take the load off the pickup-wheel)
3. Untighten the fastening bolts A. Fig 2
4. Untighten the bolts B and remove. Fig 2
5. Lower the pickup so the pickup wheel just touches the ground.
6. Engage the jack, so a gap of 2-3cm is set between pickup cylinder and bolt Fig 1.
7. Replace the bolt B in nearest suiting hole.
8. Tighten the bolts A and B firmly (574Nm).
NOTE: Retighten the bolts after a short period of driving.
Fig 2
Bolt A
Bolt B
Fig 1
Gap 2-3cm
JACK

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4.2 Settings in Control Box
These settings are set correctly by Orkel AS, when leaving the factory.
If changes are necessary, this will be carried out by a mechanic, approved by Orkel AS
during start up service
If further adjustments are required, please contact your dealer, Orkel AS, Technical
Dept. or see this manual`s section 7.
4.3 Mechanical settings
These settings are “standard,” set from the Orkel factory.
If changes are necessary, this will be carried out by Orkel service personnel during
start up or other service. If further adjustments are needed, please contact your dealer,
Orkel Technical Dept. or see additional information in this manual
4.4 Hydraulic settings
These settings are set correctly during final testing before the baler is leaving the Orkel
factory. If changes are necessary, this will be carried out by Orkel service personnel
during start up, service, or contact Orkel Technical Dept., or find additional
information in this manual.
Warning Decal, located in front of
the machine
Read closely and make sure you
understand the instructions given
in this book before any handling
or adjustments are made to the
machine