Руководство по эксплуатации PT6260-800R

SCRAP METAL COMPACTING AND
CUTTING UNIT WITH LOADING CRANE
PT6260 - 800 R
USE AND MAINTENANCE INSTRUCTION MANUAL

USE AND MAINTENANCE INSTRUCTION MANUAL PT6260 - 800 R PAGE 2
Dear Customer, thank you for having chosen our products. In case of need
contact us at the following number:
TELEFAX: 0039 0425 465 052
You find here our telephone numbers to get a quicker service:

SPARE PARTS STORE: 0039 0425 465 080
AFTER-SALES SERVICE: 0039 0425 932 313
SALES DEPARTMENT: 0039 0425 932 133
ACCOUNTING DEPARTMENT: 0039 0425 932 135
In case of after-sales service or spare parts orders please send us a fax at the
above-mentioned number otherwise your requests cannot be taken into account.
FOREWORD
This manual contains all the information necessary to the setting at work, use according to the safety
rules and routine maintenance of the machine. We suggest you to read it carefully, to observe the
instructions it contains and to keep it in an accessible place to be able to consult it whenever it is
necessary. Do not hesitate to contact Colmar S.p.A. for any necessary spare part or if you need to
consult us on any special equipment or if need be. We suggest the filling in of the following form to the
owner of the machine, as the information it contains are absolutely necessary to require both after-sale
service and spares.
Machine model: ............................................................................................................................................
Machine serial number: ................................................................................................................................
Engine serial number:...................................................................................................................................
Year of manufacturing: .................................................................................................................................
Date of purchase: .........................................................................................................................................

SUMMARY
CHAPTER 1 - GENERAL DESCRIPTION............................................................................................................................ 5
1.1. Preliminary information................................................................................................................................................... 5
1.2. Foreword ........................................................................................................................................................................ 5
1.3. Warranty......................................................................................................................................................................... 6
1.4. Liability ........................................................................................................................................................................... 6
1.5. Safety instructions .......................................................................................................................................................... 7
1.5.1. Instructions for use and conservation of the manual ............................................................................................. 7
1.5.2. Purpose and limits of the manual........................................................................................................................... 7
1.5.3. General instructions ............................................................................................................................................... 8
1.5.4. Definitions .............................................................................................................................................................. 8
1.5.5. Unified safety symbols on the machine ................................................................................................................. 9
1.6. Characteristics of the machine ..................................................................................................................................... 10
1.6.1. Description of the machine .................................................................................................................................. 10
1.6.2. Operator training requirements ............................................................................................................................ 10
1.6.3. Noise.................................................................................................................................................................... 10
1.6.4. Conformity to standards....................................................................................................................................... 11
1.6.5. Work diagram....................................................................................................................................................... 11
1.6.6. Description of operation ....................................................................................................................................... 12
1.6.7. Hoisting device .................................................................................................................................................... 12
1.6.8. Hoisting power diagram ....................................................................................................................................... 12
1.7. Machine diagrams ........................................................................................................................................................ 13
CHAPTER 2 - SAFETY....................................................................................................................................................... 14
2.1. Safety standards .......................................................................................................................................................... 14
2.2. Safety warnings............................................................................................................................................................ 15
2.2.1. Accident prevention ............................................................................................................................................. 15
2.2.2. Environmental conditions suitable to the machine ............................................................................................... 15
2.3. General safety rules ..................................................................................................................................................... 16
2.3.1. Unsuitable performances ..................................................................................................................................... 16
2.3.2. Suitable performances ......................................................................................................................................... 16
2.3.3. Care and maintenance......................................................................................................................................... 16
2.4. Essential operator instructions ..................................................................................................................................... 17
CHAPTER 3 - SPECIFIC CHARACTERISTICS ................................................................................................................. 18

3.1. Technical data .............................................................................................................................................................. 18
3.2. Handling symbols ......................................................................................................................................................... 20
3.3. Instrument system ........................................................................................................................................................ 21
3.3.1. Operator’s cab dashboard ................................................................................................................................... 21
3.3.2. Remote control..................................................................................................................................................... 22
3.3.3. Control board ....................................................................................................................................................... 23
3.3.4. Analogies between remote control and control board functions .......................................................................... 24
3.3.5. Acoustic and light indicators ................................................................................................................................ 24
3.4. Machine identification................................................................................................................................................... 25
3.5. Machine main wordings................................................................................................................................................ 26
3.6. Machine starting ........................................................................................................................................................... 27
3.6.1. Start-up ................................................................................................................................................................ 27
3.6.2. Checks at the start of each workday .................................................................................................................... 28
3.7. Protection and storage ................................................................................................................................................. 28
3.7.1. Machine idle for a short period............................................................................................................................. 28
3.7.2. Machine idle for a long period.............................................................................................................................. 28
3.7.3. Machine restarting after a long idle period........................................................................................................... 28
3.8. Refuelling ..................................................................................................................................................................... 29
3.9. Oprator’s cab access.................................................................................................................................................... 29
3.10. Machine lifting ............................................................................................................................................................ 29
3.11. Compacting cylinder positioning................................................................................................................................. 30
3.12 Bucket assembly ......................................................................................................................................................... 31
CHAPTER 4 - USE OF THE MACHINE.............................................................................................................................. 32

4.1. Engine start .................................................................................................................................................................. 33
4.1.1. Cold starting......................................................................................................................................................... 33
4.1.2. Engine stop .......................................................................................................................................................... 33
4.2. Material to be compacted ............................................................................................................................................. 33
4.3. Hydraulic bulkehead positioning................................................................................................................................... 34
4.4. Turrett rotation limiting device ...................................................................................................................................... 34
4.4.1. Rotation limiting device cutting out ...................................................................................................................... 35
4.5. Turret rotation check pin............................................................................................................................................... 36
4.6. Operator’s cab heating ................................................................................................................................................. 36
4.7. Material loading ............................................................................................................................................................ 37

4.8. Material compaction ..................................................................................................................................................... 36
4.9. Material crushing .......................................................................................................................................................... 37
4.10. Material ejecting / removing ....................................................................................................................................... 38
4.11. Materiale cutting ......................................................................................................................................................... 39
4.11.1. Manual cutting cycle .......................................................................................................................................... 39
4.11.2. Automatic cutting cycle ...................................................................................................................................... 40
4.11.3. Automatic cutting cycle restoring after a standstill ............................................................................................. 40
4.11.4. Adjusting the length of the material.................................................................................................................... 41
4.12. Loading crane controls ............................................................................................................................................... 42
4.12.1. Safety push buttons ........................................................................................................................................... 42
4.12.2. Accelerator lever ................................................................................................................................................ 42
4.12.3. Telescopic extension control push buttons ........................................................................................................ 42
4.12.4. Bucket rotation control push buttons.................................................................................................................. 42
4.12.5. Right manipulator............................................................................................................................................... 43
4.12.6. Left manipulator ................................................................................................................................................. 43
4.12.7. Compacting/cutting cylinder control ................................................................................................................... 43
4.13. Hydraulic oil preheating.............................................................................................................................................. 44
CHAPTER 5 - MAINTENANCE .......................................................................................................................................... 45

5.1. Foreword ...................................................................................................................................................................... 45
5.2. General maintenance procedure.................................................................................................................................. 45
5.3. Maintenance chart........................................................................................................................................................ 46
5.4. Hydraulic chart ............................................................................................................................................................. 47
5.5. Lubricating oil chart ...................................................................................................................................................... 48
5.6. Engine oil chart............................................................................................................................................................. 48
5.7. Lubricating grease chart............................................................................................................................................... 49
5.8. Coolant chart ................................................................................................................................................................ 49
5.9. Greasing....................................................................................................................................................................... 50
5.10. Hydraulic system ........................................................................................................................................................ 52
5.10.1. Hydraulic cylinders............................................................................................................................................. 52
5.10.2. Crane rotating joints........................................................................................................................................... 52
5.10.3. Hydraulic system................................................................................................................................................ 52
5.10.4. Hydraulic oil ....................................................................................................................................................... 53
5.10.5. Magnetic rod ...................................................................................................................................................... 53
5.11. Filters.......................................................................................................................................................................... 54
5.11.1. Hydraulic oil filters.............................................................................................................................................. 54
5.11.2. Diesel engine air filter ........................................................................................................................................ 54
5.11.3. Diesel engine oil level and diesel engine oil filter............................................................................................... 55
5.11.4. Diesel engine gas filter....................................................................................................................................... 55
5.12. General mechanics .................................................................................................................................................... 56
5.13. Telescopic arm slinding blocks................................................................................................................................... 56
5.14. Turret rotation reduction gear..................................................................................................................................... 56
5.15. Coupling gear ............................................................................................................................................................. 57
5.16. Batteries ..................................................................................................................................................................... 57
5.17. Fuses.......................................................................................................................................................................... 57
5.18. Radiator...................................................................................................................................................................... 58
5.19. Pressure bar and shear guides .................................................................................................................................. 58
5.20. Shear blades .............................................................................................................................................................. 60
CHAPTER 6 - SCRAPPING AND DISPOSAL ................................................................................................................... 60
CHAPTER 7 - EMERGENCY.............................................................................................................................................. 61
7.1. Emergency stop ........................................................................................................................................................... 61
7.2. Dead man safety solenoid valve .................................................................................................................................. 61
7.3. Fire ............................................................................................................................................................................... 62
7.4. Operator’s extractiobn from the cab in case of illness.................................................................................................. 62
CHAPTER 8 - TROUBLESHOOTING ................................................................................................................................ 63
CHAPTER 9 - HYDRAULIC SYSTEM ................................................................................................................................ 64

9.1. Components list............................................................................................................................................................ 64
9.2. Hydraulic plan............................................................................................................................................................... 65
CHAPTER 10 - ANNOTATION ........................................................................................................................................... 66

CHAPTER 1 - GENERAL DESCRIPTION

1.1. PRELIMINARY INFORMATION
This document is the use and maintenance manual of the machine in accordance with annex V of the Machinery
Directive 98/37/CE and subsequent amendments and integrations.
Do not destroy or alter this manual; integrate only with inserts.
Manual code: M-PT6260-02-06

Revision No.: 06
Compiling date: 10.01.2003
Machine type: Scrap metal compacting and cutting unit with loading crane
Model: PT6260 – 800 R
Manufacturer: Colmar S.p.A. Colmar S.p.A. - Export department
Via Statale 16 N.3 45031 Viale dei Colli Euganei No.88, Flat 5-6
Arquà Polesine (RO) - Italy 35041 - Battaglia Terme (PD) - Italy
Telephone: Telephone:
Sales Department - Italy 0039 0425 932 133 Overseas sales Department 0039 049910 1349
Accounting Department 0039 0425 932 135
Spare parts Department 0039 0425 452 081 Colmar USA, Inc.
After-sales Department 0039 0425 932 313 3790 Commerce Crt. Suite 100
Fax 0039 0425 465 052 Wheatfield, NY 14120 – U.S.A.
http://www.colmarspa.com Telephone 716 693 9877
e-mail: [email protected] Fax 716 693 9869
List of enclosures:
- CE declaration
- Declaration of conformity
- Diesel engine manual
- Manual of crane load lifting device
- Manual / schemes control board
- Remote control manual

CAUTION
DO NOT USE THE MACHINE BEFORE

HAVING READ THIS ENTIRE MANUAL.
1.2. FOREWORD
These operating instructions together with the lift capacity tables the stabilising and pressure tables, form an
integral part of the machine.
Furthermore, these operating instructions are addressed to operators who have already received specific training
on the use of machines of this type and contain all the necessary information for the safe and correct use of the
machine.
Hurried and inadequate preparations lead to improvised solutions which are the cause of many accidents.
Before operating the machine, read the following recommendations carefully:
1) before carrying out any manoeuvres, familiarise yourself with the machine and its operation in all permissible
operating conditions;
2) always keep the instruction manual and the hoisting power chart to hand for quick reference;
3) carefully observe the instructions of this manual concerning possible dangerous situations;
4) plan all routine and extraordinary maintenance operations carefully;
5) make sure that all the necessary equipment is always available: slings and certified cables in good condition;
6) acquire all the necessary information on the work site and how the machine is to be used: load-bearing
capacity of the ground, weight and dimensions of the loads to be lifted, the lifting height and arm extension
required, any restrictions to movement such as buildings, electrical power lines, etc.;
7) before starting work check that the safety devices are in good working order; never use the machine if you
have any doubt about the operation of a safety device;
8) constant and careful preventive maintenance will ensure that the machine is always in a condition of maximum
safety; never defer necessary repairs and make sure that all repairs are carried out by qualified personnel.
Use original spare parts only.
1.3. WARRANTY
Materials supplied by Colmar S.p.A. are warranted for a period of 12 months starting from the date the machine is
put into service, as evidenced by the delivery note.
The warranty applies according to the Sales and use conditions of Colmar S.p.A.
Colmar S.p.A. undertakes to repair or replace parts which it deems defective during the warranty period.
The liability of Colmar S.p.A. is limited to the replacement of defective parts and does not extend to any costs
incurred by the Dealer or the Dealer's customer, or to any damage, either present or future, or to any loss of
income, penalty, etc..
Routine and extraordinary maintenance must be performed in accordance with the instructions given in this
manual.
Any change of the suggested scheduled maintenance operations will render the warranty terms void.
The warranty does not cover the parts subject to normal wear, deterioration, wear-out.
Spare parts not covered by warranty are engine oil filters, engine air filter, diesel filter, hydraulic oil filters, shear
blades, pressure bar and shear guides, all hydraulic cylinders seals.
The equipment which have not been manufactured by Colmar S.p.A. are warranted by their own manufacturer.
The warranty expires by right in the following cases:
• when the Customer has not respected the contract payment clauses;
• when the machine is not used as per the manufacturer’s indications (machine tampering, operation mistakes,
overload, use of non-fit fuel, hydraulic oil, cooling lubricant or water, non-respect of maintenance standards
even during non-operative periods, etc.);
• when a breakdown depends on the use of accessories/equipments Colmar S.p.A. has not authorised or when
the machine has been modified or repaired without Colmar S.p.A. authorisation;
• when non-genuine spares are used or when interventions of extraordinary maintenance and/or repairing are
carried out by personnel non-authorised by Colmar S.p.A.
For all cases not covered by the above and for all assistance, please contact Colmar S.p.A. directly by registered
letter or fax, even in the event of arrangements agreed by telephone.
Colmar S.p.A. accepts no liability for any delays in or failure to provide assistance.
Colmar S.p.A. accepts no liability for any damage or malfunctions arising from work carried out on the machine by
unauthorised personnel.
1.4. LIABILITY
Colmar S.p.A. shall not be liable for any injury to persons or damage to objects sustained consequent to the
following:
• failure to adhere to the instructions given by Colmar S.p.A. regarding the driving, transport, use and
maintenance of the machine;
• violent actions or incorrect manoeuvres performed during the transport, use and maintenance of the machine;
• modifications made to the products without prior written authorisation of Colmar S.p.A.;
• events outside the normal and correct use of the machine.
In the event of a claim for damages resulting from a defect of the machine, the user is required to demonstrate that
the damage incurred was a principle and direct consequence of such defect.
The owner/user of the machine is solely liable for the formation, instructing, training and updating of the personnel
who use the machine described in this manual.
CAUTION
Use exclusively original spare parts for maintenance and repairs.

Colmar S.p.A. shall accept no liability for any damaged incurred as a consequence of the use
of non-original parts.
The machine is warranted in accordance with the contractual agreements stipulated at the
time of sale.
Failure to adhere to the safety and operating instructions contained in this manual shall render
the warranty void.
1.5. SAFETY INSTRUCTIONS
1.5.1. INSTRUCTIONS FOR USE AND CONSERVATION OF THE MANUAL
The operating instructions contained in this manual apply exclusively to the compacting machine Colmar Mod.
PT6260 - 800 R (hereafter referred to as "machine").
Read the manual carefully before starting and operating the machine.
The instruction manual must be read and used as follows:
• carefully read the instruction manual and consider it as an integral part of the machine;
• the instruction manual must be readily available to all personnel assigned to the operation and maintenance of
the machine;
• the manual must be retained for the entire service life of the machine;
• make sure that all the received updates are incorporated in the body of the manual;
• the manual must be consigned to any future user or subsequent owner of the machine;
• use the manual carefully so as not to damage it;
• on no account remove, tear out or overwrite any part of the manual;
• keep the manual in a place where it is protected from humidity and heat;
• should the manual be lost or in part illegible, obtain a new copy from the manufacturer.
Pay attention to the following warnings and to their meaning.
The following wordings are used to denote points of particular importance such as:
DANGER (white symbol in a red background) It indicates hazards associated with the described activity. In case of
"danger" the use of the machine may give rise to the risk of personal injury.
CAUTION (black symbol in a yellow background) It indicates hazards associated with the described activity. In
case of "caution" the use of the machine may give rise to the risk of damaging the machine.
IMPORTANT (black signal in a white backgroung) It indicates important information or suggestions regarding the
correct use of the machine and its basic characteristics.
1.5.2. PURPOSE AND LIMITS OF THE MANUAL
This manual is addressed to owners, users, maintenance engineers, and to anyone involved with the use,
transport, routine maintenance, and dismantling of the machine Colmar Mod. PT6260 - 800 R.
Purpose of this manual is :
• to explain the main features and the working of the machine;
• to describe norms and instructions for a proper and safe use of the machine;
• to supply instructions as regards transport, use, and routine maintenance of the machine;
• to be a useful training instrument for the staff that will use, transport, maintain, or dismantle the machine.
This manual can in no way replace the suitable experience that the operators must have already acquired on
similar equipment or that they can acquire on this machine under the guide of already trained staff according to
what stated in this manual.
The use of the machine is subject to compliance with the prescriptions contained in this manual and with all safety
standards foreseen by the special laws in force in the country in which the machine is used.
NOTE: the translation and/or the extract from a part or the whole manual without prior written authorisation of
Colmar S.p.A. is forbidden.
1.5.3. GENERAL INSTRUCTIONS
1) The machine bears a number of adhesive warning signs that convey important information regarding its safe
operation. It is essential that these signs are replaced if for any reason they become illegible.
2) The machine must only be operated by persons who have acquired previous experience on similar machines.
3) The employer shall provide the user of the machine with individual safety clothing (gloves, shoes, overalls, etc.)
complying with the law in force.
4) In situations where the operator does not have a direct view of the working area, he must be assisted by a
signaller who has been specifically assigned to the task.
5) Regularly check the wholeness and the working conditions of all parts subject to wear (pins, valves, hoses
etc.). Replace when necessary with original spare parts.
6) Do not tamper with the hydraulic system and under no circumstances remove the seals from the valves,
otherwise the warranty shall be rendered void. For valve calibration, contact an authorised service centre.
7) Do not tamper with the electrical system by any reason, otherwise the warranty shall be rendered void.
8) Overheating of the hydraulic fluid causes damage to the seals and deterioration of the fluid itself. Overheating
is caused by oil escaping through the pressure relief valves. Avoid therefore prolonged operation with the
cylinders at the end-of-stroke position or the hydraulic engine rotation locking.
1.5.4. DEFINITIONS
Machine = machine Colmar Mod. PT6260 - 800 R.

Assembled machine = the machine cutting unit is connected to the compacting unit.
Disjoined machine = the machine cutting unit is not connected to the compacting unit.
Equipment = lifting device (orange-peel bucket).
Interface (rotating) = device used to connect the equipment to the arm of the machine, which allows the load
orientation through rotation.
Operator = Technical staff in charge of the machine operation under working conditions, of the machine handling
and of the normal machine checking and cleaning.
He cannot be handicapped or suffer from serious health problem.
Skilled personnel or maintenance engineers = Technical staff in charge of the machine ordinary maintenance
and of the assembly, disassembly and reassembly of some parts of the machine.
He cannot be handicapped or suffer from serious health problem.
Operator's assistant = Technical staff who has to help the operator to manouvre the machine (machine handling
at yard in case of poor visibility, lorry loading and unloading, etc.).
He cannot be handicapped or suffer from any health problem.
Authorised personnel = Technical staff in charge of the machine extraordinary maintenance and of the assembly,
disassembly and reassembly of special parts of the machine.
It must be authorised in written to operate on the machine by the Company Colmar S.p.A.
Authorised workshop = Workshop formed by the technical staff in charge of the machine extraordinary
maintenance and of the assembly, disassembly and reassembly of special parts of the machine.
It must be authorised in written to operate on the machine by the Company Colmar S.p.A.
Work area = The work area dedicated to the machine working manoeuvres.
Mechanical device = lifting device manoeuvred by the operator from a shielded control place far from the load
(machine equipped with loading crane, self-propelled loading machine or other mechanical device).
Compactible material = See paragraph 4.2 of this manual.
To define the other terms used in this manual please refer to the standard UNI EN 292.
1.5.5. UNIFIED SAFETY SYMBOLS ON THE MACHINE
The following unified symbols are used to indicate possible dangerous manoeuvres or situations which may arise
from the use of the machine: the symbols are in different colours according to whether they indicate danger,
caution or an important situation.
CAUTION
Should the adhesive warning signs (above mentioned) become illegible,

they must be replaced with new ones.

Sign showing danger or
caution according to its Sign showing that the use
colour and always and maintenance manual
accompanied by one of the has to be consulted.
following symbols.
Sign showing crushing Sign showing cutting

hazard caused by moving hazard caused by moving
parts such as doors, parts such as doors,
hydraulic cylinders, etc. hydraulic cylinders, etc.
Sign showing burn hazard

Sign showing cutting in the high temperature
hazard caused by the areas near the diesel
engine fan. engine (muffler, manifolds,
etc.).
HIGH TEMPERATURE
Sign showing entangling Sign showing hazard

hazard caused by moving caused by sudden or
parts such as doors, unexpected movements
hydraulic cylinders, belts, as the machine is remote-
etc. controlled. CAUTION:
REMOTE-CONTROLLED
MOVING PARTS
MACHINE
Sign showing hanging Sign showing people have

loads falling hazard. to keep a safety distance
Do not stay in the machine from the machine when it
range of operation. is working.
Sign showing that only LOAD/UNLOAD

mechanical means must THROUGH Sign showing it is
be used to load and unload MECHANICAL forbidden to get/climb
the material inside the
DEVICES ONLY onto the machine.
machine tank.
NO CLIMBING
1.6. CHARACTERISTICS OF THE MACHINE
1.6.1. DESCRIPTION OF THE MACHINE
The scrap metal compacting and cutting units COLMAR Mod. PT6260 - 800 R have been designed to compact and
cut scrap metals of medium-light size.
The whole machine construction consists of special high tensile steel (WELDOX 700 - T1 A).
The machine consists basically of:
− Compacting unit: it allows the scrap metal compaction.
− Cutting unit: it allows the cutting of the compacted material at a pressure consistent with the shearing force. It
is installed at the end of the compacting unit.
− Control board: it allows the hand or automatic control of all the machine functions and it automatizes the
cutting cycle of the material inside the tank; It includes the instrument board.
− Remote control: it allows the hand and automatic control of the compacting-shearing cycle.
− Loading crane: it allows to load the material which has to be compacted into the machine tank.
The material feeding tank is 6,000 mm long and is made of very high tensile and abrasio-resistant steel (HARDOX
500).
Both tank closing walls, also made of special steel, are controlled by Nr. 3 pairs hydraulic cylinders.
The compacting of the material inside the tank is performed through a hydraulic cylinder having a 220 Ton thrust
force.
The baler is equipped with a loading crane having a max. hoisting power of 950 Kg.; the crane allows to load into
the machine tank the material which has to be compacted and, if required, the unloading of the compacted
material.
The control place is located in a comfortable operator’s cab with a wide visibility range. Controls can be operated
directly, by remote control or by servo control.
A cutting unit is supplied together with the compacting unit. The cutting unit allows to cut the compacted material by
means of a special steel blade operated by two hydraulic cylinders having a thrust force of 800 Ton.
The cutting cycle can be executed in manual or automatic mode, and in the automatic operation it is possible to set
the length of the sheared material.
An automatic greasing system has been installed to avoid the manual greasing of the cutting unit slide guides.
A diesel engine drives:
- A piston pump and a gear pump to perform the machine movements (tank doors and compacting cylinder
opening and closing, pressure bar and shear operation)
- A gear pump to perform the movements of the crane
- A gear pump for the cooling and the filtering of the hydraulic oil.
- A gear pump to perform the movements of the hydraulic bulkhead.
- A gear pump for servocontrol.
Colmar S.p.A. accepts no liability for any damage caused by the incorrect use or any use of the machine other than
stated above.
1.6.2. OPERATOR TRAINING REQUIREMENTS
All operators must carefully read this manual in its entirety and adhere to the instructions herein.
The employer is responsible for verifying that everybody assigned to operation of the machine has the necessary
aptitude and has studied this manual carefully.
Moreover the employer shall provide the user of the machine with individual safety clothing (gloves, shoes,
overalls, etc.) complying with the law in force.
1.6.3. NOISE
The following acoustic radiation pressure level and acoustic power level have been taken when the machine diesel
engine reaches its peak rpm.
The acoustic radiation pressure level and acoustic power level can be seen in the operator’s cab by mains of
pictograms.
These values must be included in this manual as provided in the Standard for Machine 98/37/CE implemented by
D.P.R. of 24TH July 1996 No. 459.
• Equivalent continuous weighteid sound pressure level LPA at the work station is equal to 80 dB (A).
• Equivalent continuous weighteid sound power level LWA at the work station is equal to 106 dB (A).
1.6.4. CONFORMITY TO STANDARDS
The machine has been designed and built in accordance with the requirements of the EEC directives governing
safety and the unification of member state legislation, specifically directives (where applicable):
• 98/37/CE Standard for Machine and subsequent modifications.
• 89/336/EEC Electromagnetic Compatibility Standard and subsequent modifications.
• 73/23/EEC Low Voltage Standard and subsequent modifications.
Moreover the following European standards concerning the safety of the machine (unified standards) were also
adopted during the design and the manufacturing of the machine:
• UNI EN 292-1/2/A1 Main concepts, general design principles
• UNI EN 294 Safety distances to avoid that the upper limbs reach dangerous areas
• UNI EN 349 Min. spaces to avoid the crushing of any part of the body
• UNI EN 414 Safety rules drafting
• UNI EN 418 Emergency stop devices
• UNI EN 457 Audio warning signals
• UNI EN 954 Control system safety
• UNI EN 982 Idraulic system safety requirements
• UNI EN 1037 Unexpected starting prevention
• UNI EN 1050 Method for risk evaluation
1.6.5. WORK DIAGRAM

1.6.6. DESCRIPTION OF OPERATION
The material to be compacted is loaded inside the tank (loading shall be performed using EXCLUSIVELY
mechanical means).
A mechanical means is a lifting device manoeuvred by the operator from a shielded control place far from the load
(machine equipped with loading crane, self-propelled loading machine or other mechanical device).
Compaction of material is performed by means of two doors (doors 1 and 2 in the figure above) driven by a pair of
hydraulic cylinders each.
During the material compacting a bulkhead operated by a thrust cylinder and placed by the output door of the
sheared material is let down in order to be able to put the material compressed by the thrust cylinder against the
bulkhead. During the shearing cycle the bulkhead must be lifted.
When the material has been compacted, the thrust cube squashes the material through the operation of a thrust
hydraulic cylinder with 220 Ton force.
The material can be ejected from the baler tank without being sheared or after being sheared.
In the first case the thrust cube ejects the material through the output door and the shear is not operated.
In the second case the compacted material is pushed forward according to the desired quantity (depending on the
length of sheared material one wishes to obtain) by means of the thrust cube.
The material is stabilized by the pressure bar, a stopper driven by a hydraulic cylinder having a force of 88 Ton,
then it is sheared with 800 ton by the shearing blade fitted at the end of the shear cylinder.
1.6.7. HOISTING DEVICE
When the machine is used as hoisting device by means of tools such as buckets, orange-peel buckets, etc, make
sure that the maximum hoisting power listed in the table do not include the mass of the tools themselves. The
masses are printed on labels placed on the tools the machine is equipped with.
1.6.8. HOISTING POWER DIAGRAM
Hoisting power diagram

with safety factor
8
MAX HOISTING 6
POWER
5
950 Kg.
4
(with current orange-
peel bucket) 3
3
0 1 2 3 4 5 6 7 8 9 10
1.7. MACHINE DIAGRAMS

1019
11090
13846
3830
3501
3291
2562 1770
2500
Weight
Weight of compacting unit 40.000 Kg
Weight of cutting unit 21.000 Kg
Weight of shear-baler with complete equipment 61.000 Kg

CHAPTER 2 - SAFETY
2.1. SAFETY STANDARDS
ACQUIRE A THOROUGH KNOWLEDGE OF THE WEAR SAFETY CLOTHING

MACHINE
Wear close-fitting clothing and use safety equipment
The machine must only be used by qualified according to the law in force.
personnel.
The operator must know the positions and the
functions of all the controls, instruments, indicators,
pilot lights and of the various labels.

WARNINGS FOR TESTING AND MAINTENANCE
Attach a "MACHINE UNDER TEST" sign to the door of the cab or to the manipulators.
During maintenance operations, always rest the end of the arm directly on the ground (never rest it on other
supports such as stacks of materials, containers, vehicles, etc.)
Stop the diesel engine and remove the switch key from the dashboard.
UNDER TEST
USE SAFETY EQUIPMENT TESTING THE MACHINE
Keep a first aid box and a fire extinguisher in the Test the machine each day it is started following the
machine. Make sure that the fire extinguisher is list of operations contained in this manual. Start and
always fully charged and use it according to the law operate the machine only from the driver’s seat.
in force. Never allow any people to climb on board when the
machine is working. To climb or to go down from the
cab use the provided steps and handholds.
Only start the engine in ventilated areas. Before
starting the machine make sure there are no people
in its range of action.
2.2. SAFETY WARNINGS
The machine has been designed and built in accordance with the current state of the art and regulations governing
the compacting machine for scrap metals (in Europe).
All applicable legal requirements, prescriptions, ordinances and directives have been observed.
The materials and components used, as well as the production and quality control processes, meet the most
stringent requirements for safety and reliability.
Providing the machine is used only for the purposes specified in this manual, and is operated with due care and
attention, and is maintained and serviced in a workmanlike manner, it can be expected to provide high
performance, continuity of service and a long lifetime.
2.2.1. ACCIDENT PREVENTION
The manufacturer accepts no liability for any accidents, operating abnormals and/or damages which may occur
during the use of the machine as result of the failure of the user to observe laws, requirements, prescriptions, and
regulations governing machines for the lifting and compacting of materials.
2.2.2. ENVIRONMENTAL CONDITIONS SUITABLE TO THE MACHINE
The standard configuration machine has been designed to be used in the following temperature range:
− Operative temperature: + 25°C
− Max. permissible temperature: + 40°C
− Min. permissible temperature: – 20°C
− Relative humidity: 20% - 80% (without condensate)
The standard configuration machine shall not be used under environmental conditions exceeding this range.
CAUTION
It is forbidden to use the standard configuration machine under environmental conditions

different from those above mentioned.
The possible use of the machine under unsuitable environmental conditions may cause the
malfunction or the breaking of hydraulic or electrical parts of the machine itself.
Special equipment of the machine are required if there are the following elements in the work environment:
− Temperatures higher than + 40°C
− Temperatures lower than – 20°C
− Condensate
− Brackish water
− Corrosive agents (acid or basic)
− Deflagration hazard in the environment
− Environments full of dust
− Radiations
− Insufficient lighting/illumination
− Diesel engines for outside use only
Specific custom-made equipment are available, to allow the machine to operate under conditions different from
standard.
2.3. GENERAL SAFETY RULES
2.3.1. NOT ALLOWED PERFORMANCES
− The machine is used for purposes other than those for which it is intended.
− The machine is not handled, manoeuvred and operated in accordance with the operating/safety instructions.
− The machine is not cared for and/or maintained in the prescribed manner or non-original spare parts are used.
− Using the machine under environmental conditions exceeding the allowed range.
− Lifting loads with unsuitable tools.
− Using the machine when its safety devices have been cut out or tampered with.
− Using the machine without safety devices in good working conditions.
− Using the machine after it has been modified without the prior written consent of Colmar S.p.A.
− Using the arm as point of support for the machine positioning.
− Loading by hand the material to be compacted in the tank.
− Compacting the material when the doors are open.
− Compacting boxes and/or under-pressure tanks even if empty, or inert materials.
− Compacting heavy members such as reduction gears, beams, etc, special steel parts or springs.
− To try to pull the engine out of the car housing by means of the machine.
− Performing abrupt movements and/or accelerations of the arm and of the turret.
− Using the machine when the operator’s cab has been taken apart or when the door is open or disassembled.
− Leaving the machine without removing the switch key from the dashboard.
− Using the machine to lift or transport people.
− Hoisting loads over transit areas. Should this not be avoided, inform by means of warning signals about the
starting of operation.
− Leaving the machine during its normal working.
2.3.2. ALLOWED PERFORMANCES
− Using the machine as a scrap metal compacting machine obseving the restrictions stated in the chapter 4.2.
− Using the machine as a loading crane equipped only with compatible tools under the specified pressure and
loading conditions. Any other tool must be authorized by Colmar S.p.A.
− Lifting loads obsering the hoisting power diagram and using the allowed equipment. Any other use of the
machine has to be considered unsuitable.
− Loading/unloading the material in the tank only by means of mechanical means (self-propelled crane or crane
provided).
2.3.3. CARE AND MAINTENANCE
Many accidents and cases of machine damage can be attributed to inadequate maintenance, such as:
− lack of oil, grease and antifreeze;
− lack of cleaning;
− hydraulic system faults (damage to hoses, loose fittings, worn gaskets, etc..).
Careful maintenance of the machine is also necessary to ensure the operator safety. Never defer repairs. Only
allow qualified personnel to carry out repairs to the machine.
The following safety rules must always be observed, even by experienced operators:
− Always keep tidy the windowpanes of the operator’s cab.
− Before starting work, check that all machine movements are working correctly.
− Check that the dead-man control works perfectly (controls on zero position and lever mechanical lock if the
pushbutton on the manipulators has not been operated). Constantly check that nobody is within the range of
operation of the machine. Call out or sound the horn to warn people to keep clear of the machine and interrupt
work immediately if people do not leave the danger zone!
− Unauthorized people must not get into the operator’s cab.
− Do not use the machine to lift peoeple.
− Do not leave the operator’s cab when the load is being lifted or the engine is on.
− When the machine is working as a crane keep constantly an eye both on the load and on the hook.
− Use sling equipments having a known and certified hoisting power.
2.4. ESSENTIAL OPERATOR INSTRUCTIONS
ESSENTIAL INSTRUCTIONS FOR THE USE OF THE MACHINE

1. The machine shall be operated and used only by authorized people.
2. Make sure that the control levers are in neutral position before starting the engine.
3. Make sure that there are nobody within the range of operation of the machine before starting any manouvre.
If necessary signal the machine operation by means of a warning horn.
4. Constantly check the working area for dangerous points such as demolition areas, means or persons transit
areas.
5. Put no object in the operator’s cab; put the maintenance tools back in their special compartment.
6. The machine shall be positioned on even, practically horizontal and consistent floor.
7. Do not use the machine when there are unsteady stacks or heaps of materials nearby that might collapse
onto the machine.
8. Before compacting the material make sure it does not contain explosives and/or inflammables (gas oil,
petrol, oil, etc.).
9. Compact medium-light weight material. Avoid compacting heavy elements such as reduction gears, axle
shafts, beams, etc, special steel parts or springs (helical or leaf springs), boxes and/or under-pressure tanks
even if empty, or inert materials.
10. Only use mechanical means to load/unload the material in the tank.
11. Compact the material only after that the tank doors have been completely closed.
12. When the compacted material is ejected or removed from the tank make sure that the people by the work
area keep a safe distance of at least 20 m. from the machine.
13. Do not accumulate compacting cycle residuals or dirt by the compacting cylinder head (rod side). If
necessary clean the area by the compacting cylinder head (only when the machine engine has come to a
complete stop).
14. Stop the engine when leaving the driving position and take the switch key out of the dashboard. Lock the
door of the operator’s cab if you leave the machine for long.
15. Stop the diesel engine and take the switch key out of the dashboard before performing any maintenance
operation.
16. Before operating with the loading crane remove the turret rotation check pin.
17. When using the machine avoid sudden accelerations, starting and quick movements of the jib.
18. Do not use the machine and the equipment to lift or transport people.
19. Never lift loads higher than the machine hoisting power (max. hoisting power 950 Kg.).
20. Do not perform non-vertical lifting manoeuvers and towing.
21. The lifting of different kinds of load shall be performed only by means of equipment suitable to the use.
22. Do not use the arm as point of support for the machine positioning.
23. When leaving the driving position switch the engine off, let the equipment down and rest it on the extremity
of the tank.
24. Do not hoist or transport loads over working or transit areas. Should this not be avoided inform by means of
warning signals about the starting of operation and the transit of the load.
25. When working with the orange-peel bucket make sure that the people by the work area keep a safe distance
of at least 20 m. from the machine.
26. The manoeuvers concerning the turret rotation and the arm luffing are proportional. In proximity to the max.
hoisting power reduce the movement speed.
27. In case of transport on trucks the check pin has to be inserted to lock the turret rotation.
CAUTION
Since a complete list of all possible safety rules cannot be copiled, we trust in the common
sense of the operator, whose careful and prudent beheaviour assures the machine working
under the best safety conditions.
CHAPTER 3 - SPECIFIC CHARACTERISTICS

3.1 TECHNICAL DATA
Dimensions of compacted material

Length Depending on the loaded material
Width 820 mm
Height 620 mm
Quantity of compacted material 8 – 10 Ton/h
Dimensions of shared material
Length Depending on type of the material loaded
Blade length 900 mm
Quantity of sheared material 10 – 11 Ton/h
Loading crane
Loading arm with rotation obtained by means of a radial piston hydraulic engine with one-stage epicyclic
reduction gear having a pinion gear acting on an external teeth slew ring. Shock-resistant valves
integrated in the hydraulic engine.
Slew ring diameter 620 mm
Max. range 7,000 mm
Non-continuos rotation 270°
Max. hoisting power with standard orange-peel bucket 950 Kg.
Orange-peel bucket volume 280 lt
Overall weight of the crane with orange-peel bucket 2,000 Kg.
Hydraulic system
No.1 fixed displacement axial piston pump
(compacting and cutting unit movements)
Max. capacity 190 lt/min
Max. working pressure 300 bar
No.1 gear pump (compacting and cutting unit
movements)
No.1 cooling gear pump
No.1 piston pump (loading crane movements)
No.1 gear pump (servocontrols)
No.1 gear pump (hydraulic bulkhead and cab)
Electrical system
Working voltage 24 V
Alternator 40 A
Starter motor 4 kW
12 V batteries in series 2x100 Ah
Materials
Baler structure Steel HARDOX 500 - WELDOX 700 - T1 A
Shear structure Steel Fe 510 C
Bin Abrasion resistant steel HARDOX 500
Shear blade Steel 45NiCrMoV166
Diesel engine
Make SAME
Model 1000.6 WTI-S
Cycle Turbocharged water/air chargecooler
Cylinders 6 in line
No. of strokes 4
Injection Direct Injection
Bore x stroke 105 x 115.5 mm
Displacement 5999 cm3
Compression ratio 16:1
Max. power 132 kW [179 HP]
Nominal power DIN 70020 121 kW [164 HP]
Calibration speed 1800 revs/min
Pull-in torque DIN 70020 607 Nm at 1550 revs/min
Specific consumption 204 gr/kWh
Fuel Diesel gas
Cooling Liquid
Operator’s cab
The soundproof cab, with automatic turnover, is made of sheet steel and has a wide visibility range,
safety windowpanes, windshield wiper and safeguard, adjustable anatomic seat, instrument board with
engine oil pressure gauge, fuel gauge, hour-meter, working control lamps and switches, homologated
acoustic and light alarm system, control stick servo-asisted controls.
Height 1.600 mm
Length 1.200 mm
Width 900 mm
Fuel and fluid capacities
Hydraulic oil tank capacity 700 lt
Hydraulic circuit total capacity 1600 lt
Diesel gas 200 lt
Diesel engine coolant 35 lt
Diesel engine oil 15 lt
Rotation reduction gear oil 3 lt
Power take off distributor 6 lt
3.2. HANDLING SYMBOLS
1 14 13 12
2 11
3 10
4 9
5 8
6 7
3.3. INSTRUMENT SYSTEM
3.3.1. OPERATOR’S CAB DASHBOARD
1. Battery recharge warning light HYDRAULIC

BULKHEAD
RAISE
2. Voltage on warning light
HYDRAULIC
3. Engine cooling water temperature warning light BULKHEAD
LOW
4. Air cleaner clogged warning lamp
5. Engine oil pressure warning light
6. Raised bulkhead warning light
7. Lowered bulkhead warning light
8. Low fuel warning lamp
9. Windshield wiper
10. Working light on cab
11. Fan - heating
12. Working light on boom

13. Working compacting cylinder warning light
BACKWARD CLOSE
14. Not working compacting cylinder warning light
15. Compacting cylinder steering arm

FORWARD OPEN
16. Door 2 steering lever CYLINDER DOOR 2 DOOR 1
17. Door 1 steering lever
18. Pressure bar steering arm
19. Shear steering arm

LOW
20. Hydraulic bulkhead steering arm
21. Compacting cycle start push button RAISE
PRESSURE BAR SHEAR HYDRAULIC

22. Compacting cycle stop push button BULKHEAD
23. Accelerator lever
24. Shutdown push button

- 0 +
25. Switch key
26. Warning horn
27. Hydraulic oil pre heating

STOP CYCLE START CYCLE THROTTLE
28. Start engine
EMERGENCY STOP 0
R
START H
H
S
3.3.2. REMOTE CONTROL
CLOSE CLOSE GAS

PUSH 2 1 +
OPEN OPEN GAS

JACK IN 2 1 -
BATTERY
CHECK
AUTOMATIC
ST
0 AR
T
CONNECTION
MANUAL REMOTE CONTROL
A. Emergency push button G. Remote control enable selector switch

B. Diesel engine starting selector switch H. Battery charge test warning lamp
C. Pressure bar selector switch I. Thrust piston control lever
D. Shear selector switch J. Door 2 open/close lever
E. Automatic cycle start-end selector switch K. Door 1 open/close lever
F. Automatic-manual cycle selector switch L. Accelerator lever
NOTE: Refer to the special remote control manual.

3.3.3. CONTROL BOARD
START STOP
0 I ENGINE ENGINE
F4
F8
80 1/2
120 4/4
F11
F3
F7
°C
F10
ORE
F2
F6
0000002 4
HOURS 8
F9
F1
F5
ENGINE TEMPERATURE CONTROL BOARD TEMPERATURE
RAISED
COMPACTING HYDRAULIC
HATCH 2 HATCH 1 PRESSURE BAR SHEAR
CYLINDER BULKHEAD
OPEN OPEN RAISING RAISING RAISING
CLOSE CLOSE
CYCLE ACCELERATOR
LENGTH
STOP START S.C.P. 1 0 2
1. Engine oil pressure 20. Pressure bar raising/lowering selector switch

2. Fuel gauge 21. Shear raising/lowering selector switch
3. Hour meter 22. Shear automatic greasing selector switch
4. Cooling water temperature 23. Cycle start push button (red warning lamp)
5. Battery recharge warning light 24. Cycle stop push button (green warning lamp)
6. Engine oil pressure warning light 25. Closing safety door button (S.C.P.)
7. Low fuel warning lamp 26. Accelerator selector switch
8. Air cleaner clogged warning lamp 27. Automatic-manual lock selector switch
9. Switch key 28. Sheared material length selector switch
10. Voltage warning light 29. Start diesel engine
11. Fuses 30. Stop diesel engine
12. Compacting cylinder backwards warning light 31. Oil heater TCC
13. Compacting cylinder forwards warning light 32. Low temperature
14. Cooling water temperature warning light 33. Stop burner
15. Raised bulkhead warning light 34. Burner ready
16. Lowered bulkhead warning light 35. Burner working
17. Compacting cylinder selector switch 36. Engine temperature
18. Door 1 opening/closing selector switch 37. Control board temperature
19. Door 2 opening/closing selector switch
3.3.4. ANALOGIES BETWEEN REMOTE CONTROL AND CONTROL BOARD FUNCTIONS
The machine has been designed to be controlled through the remote control most of the time.
Although the control board has more functions, it must be used in case of battery low charge or remote control
failure or to perform material adjustment operations.
Since the main operations can be controlled both from the control board and from the remote control, the following
table shows the operations that can be performed by both control units.
CONTROL REMOTE
FUNCTION DASHBOARD
BOARD CONTROL
Diesel engine starting 25 9 B
Diesel engine accelerator selector switch 23 26 L
Shutdown push-button 24 / A
Compacting cylinder selector switch 15 17 I
Door 1 opening/closing selector switch 17 18 K
Door 2 opening/closing selector switch 16 19 J
Pressure bar raising/lowering selector switch 18 20 C
Shear raising/lowering selector switch 19 21 D
Shear raising/lowering selector switch 22 20 /
Automatic-manual cycle selector switch 27 25 F
Automatic cycle start push button 21 23 E
Automatic cycle stop push button 22 24 E
3.3.5. ACOUSTIC AND LIGHT INDICATORS
The machine is provided with

acoustic and light indicators for
identification of working phases
during the automatic cutting
A
cycle.
The baler is equipped with three
rotating lamps (positions
indicated by the arrow B in the B
right figure), while the shear is
equipped with three lamps and
an acoustic siren (positions
indicated by the arrow A in the
right figure).
When the automatic mode for
material shearing is selected
and the cycle is started in the
automatic mode, the indicators
are light to show the different
cycle phases.
The function and signalling logic is described as follows:
Compacting unit (arrow B):

Red rotating lamp: thrust cylinder forward and backward
Orange rotating lamp: thrust cylinder and doors 1 and 2 under maximum pressure
Yellow rotating lamp: thrust cylinder completely retracted
Horn: doors 1 and 2 closing
Cutting unit (arrow A):

Red lamp: shear down
Green lamp: shear up
Orange lamp: cut refusal
Siren: doors 1 and 2 opening
3.4. MACHINE IDENTIFICATION
The serial number is marked on a

metal plate.
The baler and the shear have two
different identifications.
- Shear: the plate is on the body
side near the output of the
sheared material (left arrow in
the figure).
- Baler: the plate is on the front
plate of the tank (right arrow in
the figure).
CE Plate placed under the

operator’s cab (actual dimensions
95 x 125 mm).
LPA L WA
INDEX LEVEL ACOUSTIC POWER

(Actual dimensions 75 x 85 mm) (Actual dimensions 75 x 85 mm)
3.5. MACHINE MAIN WORDINGS
PT6260 - 800 R
MAX HOISTING POWER 950 Kg.
MOVING PARTS
CAUTION:
REMOTE-
CONTROLLED
MACHINE
LOAD/UNLOAD
WITH
MECHANICAL
DEVICES ONLY
HIGH
TEMPERATURE NO CLIMBING
3.6. MACHINE STARTING
3.6.1. START-UP
The machine is normally delivered and tested by the manufacturer or by an authorised workshop. If the delivery of
the machine is at the Customer’s expense position the machine according to what indicated at chapter 3.10. At any
rate perform what follows:
1. Make sure that the machine has its own:
- CE Declaration
- Declaration of conformity
- Diesel engine manual
- Equipment manual
- Cycle automation control board manual
- Remote control manual
2. General visual check of the machine
3. Verify the adhesive identification and warning labels
4. Verify the battery power level and connection
5. Verify the power level of the remote control batteries
6. Check of the machine to verify if there are leaks in the following components and plants:
- Hydraulic system
- Crane cylinders
- Door closing cylinders
- Thrust cylinder
- Pressure bar cylinder, shear and bulkhead
7. Check the level of fuel and fluids such as:
- Fuel
- Hydraulic oil
- Engine oil
- Turret rotation reduction gear oil
- Grease on automatic greasing system
- Battery electrolyte
8. Verify the state of the hoses (check if there are cuts, abrasions, tears, etc.)
9. Verify the state of the steel pipes (check if there are cuts, holes, cracks, etc.)
10. Verify the state of the chromium plated parts (check if there are scorings or dents on the cylinder rods)
11. Verify the state of the electrical cables (check if there are abrasions, loose connections, skinned wire or
sheaths, etc.)
12. Verify the good working of the automatic greasing system
13. Verify the good working of the emergency and safety devices
14. Verify the efficiency of the machine controls and warning lamps (located on the control board, on the remote
control and in the crane operator’s cab.)
15. Verify the state of painting
16. Check the tightening of the thrust cylinder collar
17. Verify the good working of the lighting installation
18. Verify the good working of the cutting unit greasing system
19. Perform an idling test under all the expected working conditions
20. After the tests have been performed verify if there are leaks
21. Before starting to work warm the machine up.
The machine will be delivered with the correct lubricant level in the engine, in the turret rotation reduction gear and
in the pump coupling gear reduction gear; moreover it will be delivered with the oil tank completely full and the fuel
tank containing enough diesel gas to start up the machine. To start the machine refer to the instructions contained
in this manual and especially to the chapters 3 and 4.

CAUTION
Before starting the machine the operator in charge

has to read this manual thoroughly
3.6.2. CHECKS AT THE START OF EACH WORKDAY
Before the beginning of each workday checks what follows:

1. General check of the machine to verify if there are leaks
2. Verify the state of the hoses (check if there are cuts, abrasions, tears, etc.)
3. Verify the state of the steel pipes (check if there are cuts, holes, cracks, etc.)
4. Verify the state of the chromium plated parts (check if there are scorings or dents on the cylinder rods)
5. Verify the state of the electrical cables (check if there are abrasions, loose connections, skinned wire or
sheaths, etc.)
6. Verify the good working of the emergency and safety devices
7. Verify the efficiency of the machine controls and warning lamps (located on the control board, on the external
control panel, on the remote control and in the crane operator’s cab.)
8. Worn-out state of pressure-bar and shear guides.
9. Verify frease level and good working of the automatic greasing system
10. Check the tightening of the thrust cylinder collar
11. Verify the power level of the remote control batteries
12. Verify the battery power level and connection
13. Verify the hydraulic oil and fuel level.
14. Verify the absence of compacting cycle remnants or dirt near the compacting cylinder head (see paragraph
3.11).
Do not use the machine if one or more of the above checks are not satisfying and take measures to restore
optimum efficiency. In particular, if one or more of the first seven checks are not satisfying call Colmar Customer
Service (Tel. 0039 0425 932 313).
3.7. PROTECTION AND STORAGE
If the machine has to be idle for a short or a long period precautions shall be taken to preserve the efficiency of the
machine itself.
3.7.1. MACHINE IDLE FOR A SHORT PERIOD
− Rest the machine in a safe position (doors 1 and 2 closed, compacting cylinder in transport position, arm in a
safe position, tool on the tank of the machine, pressure bar and shear completely lowered).
− Lock the operator’s cab, remove the key and keep it in a safe place.
− Disconnect the battery disconnecting device located below the control board.
− Insert the turret rotation check pin.
− Clean the machine and lubricate all units provided with lubricator.
3.7.2. MACHINE IDLE FOR A LONG PERIOD
As above, moreover:
− Change the engine oil, the hydraulic oil, the reduction gear oil and replace the filters.
− Clean the diesel engine air filter.
− Protect the silencer to avoid the penetration of foreign matters.
− Spray the entire machine with protective oil.
− Store the machine in a sheltered, well-aired, dry and without dust place, if possible, otherwise protect it against
the weather with a plastic sheet.
− Keep the remote control in a safe place.
− Grease the battery electrodes to potect them against corrosion.
− Recharge batteries once a month.
− If the machine has been stored in a place which can become icy we suggest you to remove the batteries and
keep them in a suitable place and to substitute the coolant in the radiator with an antifreeze.
3.7.3. MACHINE RESTARTING AFTER A LONG IDLE PERIOD
− Clean the machine carefully.

− Remove the silencer protection.
− Locate the batteries and check the electrolyte level and the battery power level.
− Verify the level of the fuel, hydraulic oil, engine oil and turret rotation reductin gear oil.
− Grease all the parts needing greasing (see paragraph 5.9).
− Start the engine and let it idle for some minutes.
− Verify the good working of the emergency and safety devices.
− Verify the efficiency of the machine controls and warning lamps.
3.8. REFUELING
The diesel gas tank shaIl be filled by means of

the pipe union placed on the tank itself, under
the operator’s cab (opposite to the diesel
engine).
CAUTION
The particular structure of this
machine means that special care
must be taken during refueling /
topping up operations.
To access the filling points, use
exclusively steps according to the
law in force.
If refueling / topping up is to be
carried out using cans, remember
that the maximum capacity of each
can is 25 l.
3.9. OPERATOR’S CAB ACCESS
To enter the operator’s cab of the machine use

the handles set to this purpose. Make use of the
special grips and steps to rise and descend from
the cab.
The grips and the steps installed on the machine
are shown by the arrows in the alongside figure.
3.10. MACHINE LIFTING
On some points on the machine, as

illustrated in the figure (marked with
stickers), there are holes for
hooking and lifting the machine.
We remind that the machine mass
is approximately 61,000 Kg.
Therefore great care is to be given
to resistance and length of the
ropes to be used, which will have to
be homologated and suitable for
the kind of operation to be
performed.
The two disjoined units of the machine (compacting and cutting units) can be raised separately.
Please remind that the mass of the compacting unit is of about 40.000 Kg. and the mass of the cutting unit is of
about 21.000 Kg.
A hoisting equipment having a min. hoisting power of 100 Tons is required to raise the machine units.
DANGER
The machine (both complete and disjoined into the compacting and cutting units) shall be
raised only by skilled personnel by means of suitable hoisting equipment (loading crane,
ropes, hooks) complying with the law in force.
3.11. COMPACTING CYLINDER POSITIONING
The compacting cylinder rests in a

tubolar support.
The compaction power is
discharged on the front side of the
support.
Keep clean the thrust cube THRUST CUBE
housing from the compacting
cycle residuals to assure the
proper rest of the support of the
compacting cylinder head and its
relative tubolar support.
Avoid the accumulation of the
compacting cycle residuals or
dust by the compacting cylinder COMPACTING
head (circled in the figure above). JACK LINER
If necessary clean the area by the COMPACTING COMPACTING
compacting cylinder head before JACK SUPPORT JACK HEAD
performing any machine
manoeuvre.
DANGER
Clean the area by the compacting cylinder head ONLY when

the diesel engine has come to a complete stop.
On the compacting cylinder rod a movable collar has been installed to stop the machine engine by means of a
microswitch if the thrust cube approaches the shear too much and incurs the risk of being sheared. During cutting
the anti-shearing safety device of the compacting cylinder shall be brought into action.
To start this safety device act as follows:
1. Start the diesel engine

2. Lower the hydraulic bulkhead as described at
paragraph 4.3
3. Extend the compacting cylinder into its working
position
4. Move forward the compacting cylinder until it
touches the pressure bar
5. Stop the diesel engine
6. Loosen the collar (shown by the arrow in the right
figure) and let it slide on the cylinder rod until it is
by the miscroswitch
7. Tighten the collar by means of the screw placed
under the miscroswitch fiducial axis.
To remove the anti-shearing safety device of the

compacting cylinder (necessary to modify the
compacting unit from working to transport configuration)
unscrew the screw placed under the collar and move
the collar backward until it reaches the cylinder
extremity.
CAUTION
If the anti-shearing safety device of the compacting cylinder is not brought into action the
thrust cube or the compacting cylinder itself can be seriously damaged during the material
cutting.
3.12. BUCKET ASSEMBLY
Normally the machine is delivered completely assembled by the manucfacturer and the user has only to assemble
the equipment which has to be installed at the extremity of the machine.
To mount the bucket on the machine, contact the authorised personnel and follow the indications here below:
Be sure that the grab has the CE mark. Approach the second arm extremity to the equipment.
The gripping equipment must be on flat and compacted
ground on a stable position.
Switch off the engine and lock the cab door. Fasten the pin with the standard bolt.
Connect the two parts with the fitted pin by hammering it
in for all its length.
WARNING
If the hydraulic hoses were connected in the inverted

order, the manoeuvres would be inverted too. Before
working with the equipment, check the correct motion
direction.
Connect the hydraulic hoses taking care to gather and

throw the spilled hydraulic oil away as prescribed by the
regulations in force.
DANGER
Shock and crush danger: pay attention during lifting and transport operations. be sure that
there are no persons in danger of grab fall.
CHAPTER 4 - USE OF THE MACHINE

CAUTION
DO NOT USE THE MACHINE BEFORE

HAVING READ THIS ENTIRE MANUAL.
IMPORTANT
As the machine can be differently equipped with (with remote control, control board, electric
motor, etc.) only the functions of the machine equipped with operator’s cab and loading crane,
with control board and with remote control will be here described.
As for instructions concerning differently equipped machine refer to chapter 5.
CAUTION
In case of dangerous situations or which escape the control of the operator any movement of
the machine can be stopped by means of any EMERGENCY STOP push button (red
mushroom-head push button on yellow background) located on the dashboard, on the control
board or on the remote control (see chapter 7).
CAUTION
If the machine is operated by remote control we advise you to stay always in a position from
which you can see the control board, to be able to act promptly if the warning lights on the
control board indicate any anomaly.
IMPORTANT
Most machine functions can be controlled without distinction from the control board as well as
from the remote control.
If you use the remote control, any operation actuated from the control board is inhibited
(emergency stop excepted).
Therefore, if you use the control board to operate the machine, make sure that nobody can
unintentionally use the remote control in order to avoid any incoherence or dangerous
overlapping of controls.
IMPORTANT
To avoid manoeuvering inconsistency a microswitch has been installed on the seat in the
operator’s cab to exclude any operation given by the remote control when the operator is
seated on the driver’s seat.
IMPORTANT
The operation of the machine through operator’s cab dashboard, through control board and
through remote control is described in the following pages.
The controls on the dashboard and on the control board are identified by means of numbers,
while those on the remote control are identified by means of letters.
As for the position of the controls refer to paragraphs 3.3.1, 3.3.2 and 3.3.3 for the dashboard,
the remote control and the control board respectively.
4.1. ENGINE START
Open the engine acceleration lever of a quarter. Turn the switch key to HS position to start the starter. As soon as
the engine has been started let the switch key back to H position. Position R allows to switch the lights on. Before
repeating the starting, make sure that both engine and starter are off.
The machine can be started without distinction from the dashboard in the operator’s cab as well from the control
board (see paragraph 3.3).
To feed the machine electrical system it is necessary to actuate the battery disconnecting device located in front of
the batteries, by rotating it of 90°. If this device is not brought into action, the electrical circuit cannot be fed by the
batteries and no kind of machine operation will be possible.
To bring the battery disconnecting device into action turn the lever of 90° counter clockwise until it protrudes of
approximately 2 cm. To bring the battery disconnecting device out of action turn the lever of 90° clockwise until it
retracts of approximately 2 cm.
When the battery disconnecting device is brought into action both the pilot lights in the operator’s cab dashboard
and the voltage red warning light on the control board shall be ON (only if the switch key is in R position).
To start the engine from the control board: Turn the starting key (number 25) to the right to HS position to start
the starter motor; release the key as soon as the engine has been started.
To start the engine from the control board: Turn the starting key (number 9) to the right to HS position to start
the starter motor; release the key as soon as the engine has been started.
To start the engine from the remote control: Turn the starting key (number 25) or on the control board (number
9) to the right to H position, then push the lever (letter B) upwards; release the lever as soon as the engine has
been started.
IMPORTANT
To increase the execution speed of the machine movements increase the number of
revolutions of the diesel engine. The revolution speed can be governed by means of the
controls on the control board, on the remote control or in the crane driver’s cab:
1. To govern the engine revolutions from the crane driver’s cab turn the lever (number 23) to
the right or to the left.
2. To govern the engine revolutions from the control board, turn the special selector
(number 25) to the right or to the left.
3. To govern the engine revolutions from the remote control push the lever (letter L)
upwards or downwards.
4.1.1. COLD STARTING
Before starting the machine, let the pump idle for 15 minutes with diesel engine at mean r.p.m.
4.1.2. ENGINE STOP
To stop the machine diesel engine let the engine idle and turn the switch key counter clockwise to position 0.
The machine diesel engine can be stopped by means of the controls on the control board, on the dashboard and
on the remote control.
To stop the engine from the dashboard: Turn the starting key (number 25) towards left to position 0.
To stop the engine from the control board: Turn the starting key (number 9) towards left to position 0.
To stop the engine from the remote control: Push down the lever (letter B).
To stop the engine in emergency cases: Press any emergency stop button (red mushroom on yellow
background) on the dashboard (number 24), on the control board (number 14) or on the remote control (letter A).
Moreover refer to chapter 7 of this manual.
4.2. MATERIAL TO BE COMPACTED
CAUTION
Colmar S.p.A. shall not be liable for any damage to the machine caused
by the compacting of materials which MUST NOT be compacted.
The machine has been designed to compact scrap metals. To avoid anomalous working stress, which can cause
damages to the machine, the material to be compacted shall be homogeneous and not very heavy.
Materials which can be compacted: Materials which MUST NOT be compacted:

• Unitised body frame car housing All materials not explicitly mentioned in “Materials which can be
• Household appliances compacted” and especially:
• Light scrap metals • Side member frame car housing
• Light scrap (classification CECA cat. 50, • Electrical and explosion engines
50/SC, 50/Z, 51, 52) • Axle shafts
• Steel I-beams
• Helical or leaf springs
• T-beams or H-beams
• Sheets and section bars whose thickness is higher than 3 mm
• Boxes and/or under-pressure tanks even if empty
• Inert materials (under-pressure gas cylinders, fuel tanks even
if empty).
DANGER
Before compacting any material make sure it does not contain explosives and/or inflammables
(gas oil, petrol, oil, etc.) or inert materials
4.3. HYDRAULIC BULKHEAD POSITIONING
The hydraulic bulkhead (see arrow A) can take two

different positions during the working phases.
To lift or lower the hydraulic bulkhead act on the lever 20
on the dashboard.
When the bulkhead has been raised, the warning light
on the control board (number 15) and that on the
dashboard (number 6) light on.
When the bulkhead has been lowered, the warning light
on the control board (number 16) and that on the
dashboard (number 7) light on.
- The bulkhead must be lowered when the material is
A
loaded to be compacted or when it is compacted.
- The bulkhead must be lifted when the material has
to be sheared. If during the automatic shearing cycle
the hydraulic bulkhead has not been lifted, the cycle
cannot start.
NOTE: if the hydraulic bulkhead is non lifted during the

automatic shearing cycle, the cycle cannot start.
4.4. TURRET ROTATION LIMITING DEVICE
By the loading crane slew ring two limit switches have

been installed (see the arrows in the figure). They limit
the rotation of the crane turret to an angle which avoids
impacts between the lifting device and the tank doors, if
these are open. Any turret rotation performed by the
operator, which can cause impacts, will be locked.
4.4.1. ROTATION LIMITING DEVICE CUTTING OUT
In case of fault of the limit switches that limit the crane

turret rotation, the rotation limiting device can be cut out
by unplugging the solenoid valves from the solenoid
valve unit (see arrow in the figure).
Cut out the turret rotation limiting device only if the limit
switches are fault.
CAUTION
If the rotation limiting device is cut out, no protection will avoid possible impacts between the
lifting device and the tank doors, should these be open.
Therefore turn the turret very carefully.
4.5. TURRET ROTATION CHECK PIN
During the transport of the machine insert the check pin

placed on the circle of the loading crane slew ring to
lock the rotating turret in a fixed position.
The lower fixed locator shall correspond to the mobile
upper one.
During working put back the pin in the housing by the
slew ring (see figure).
4.6. OPERATOR’S CAB HEATING
To heat the operator’s cab open the hot water

circulation valve located by the radiator (see figure) and
operate the cab fan switch on the dashboard.
The cab is heated by the same burner used to heat the

hydraulic oil.
Switch on the thermostat located behind the seat on the
left side and adjust the temperature.
4.7. MATERIAL LOADING
DANGER
The material to be compacted shall be loaded into the tank ONLY by

means of mechanical means (self propelled crane or crane provided)
complying with the use instructions contained in the relevant manual.
Doors 1 and 2 shall be completely open and

compacting cyclinder completely retracted during
material loading.
The material loaded must comply with the carrying

capacity of the machine.
The level of the material loaded depends on whether it

has to be either compacted or sheared.
In case the material has to be compacted, its level never

has to exceed the height of the tank containing sheet
(see picture on the right).
On the other hand, if the material has to be sheared, its

level has to slightly exceed the compacting cylinder rod
height (see picture on the right).
IMPORTANT
If the material is loaded to be compacted, make sure that the hydraulic bulkhead has been
lowered. If the material is loaded to be sheared, make sure that the hydraulic bulkhead has
been raised. To raise or lower the hydraulic bulkhead refer to paragraph 4.3.
CAUTION
To avoid irregular stresses which might lead to machine failures, take care that the material to
be compacted is homogeneous and not particularly heavy.
CAUTION
The material to be compacted shall be middle or light weight.

Avoid compacting heavy elements such as reduction gears, axle shafts, etc. special steel
parts or springs (helical or leaf springs), boxes or under-pressure tanks containing explosive
and/or inflammable substances
CAUTION
Avoid crushing inside the machine tank by using the holding device of the hoisting equipment
used to load the material.
CAUTION
In case of dangerous situations or which escape the control of the operator any movement of
the machine can be stopped by means of any EMERGENCY STOP push button (red
mushroom-head push button on yellow background) located on the dashboard, on the control
board or on the remote control (see chapter 7).
4.8. MATERIAL COMPACTION
Material compaction can be carried out through the controls on the

dashboard, on the control board or on the remote control.
To compact material from the dashboard:

- Close the lateral door (door 1) pushing up the lever (number
17).
- Close the upper door (door 2) pushing up the lever (number 16)
leftwards.
To compact material from the control board:

- Close the lateral door (door 1) turning the selector (number 18)
leftwards.
- Close the upper door (door 2) turning the selector (number 19)
leftwards.
To compact material from the remote control:

- Close the lateral door (door 1) pushing up the lever (letter K).
- Close the upper door (door 2) pushing up the lever (letter J).
Close door 1 to actuate the movement indicated in the right above

figure.
Close door 2 to actuate the movement indicated in the right central
figure.
The right closing sequence is indicated above (door 1 + door 2).
During the material compacton the angle between the doors 1 and
2 must be 90°.
If necessary, insist on the controls to be sure the doors are closed.
When the angular spread is reached the horn rings for about 10
seconds.
In the right below figure you can see the dimensions of the
compacted material.
DANGER
Before compacting, make sure that the tanks of materials loaded into the tank (e.g. motor
vehicles) containing fuel, lubricants and/or inflammable materials are completely empty or
made inert in order to avoid explosion or fire danger.
DANGER
Make sure that no people stand by the machine during material compaction.
IMPORTANT
If the orange rotating light lights up during door closing, it means that pressure has reached a
maximum peak. Partially open the doors to release pressure and let the material settle, then
close the doors again.
4.9. MATERIAL CRUSHING
To complete the material compaction it is necessary to operate the compacting cylinder.

The compacting cylinder can be operated through the controls on the dashboard, on the control board or
on the remote control.
- To advance the cylinder from the dashboard push down the lever (number 15).
- To advance the cylinder from the control board turn the selector (number 17) rightwards.
- To advance the cylinder from the remote control push up the lever (letter I).
Before operating the compacting cylinder, make sure that the pressure bar has been lowered.
- To lower the pressure bar from the dashboard push up the lever (number 18).
- To lower the pressure bar from the control board turn the selector (number 20) rightwards.
- To lower the pressure bar from the remote control push up the lever (letter C).
CAUTION
Operate the compacting cylinder only when the doors 1 and 2 are completely closed. If
necessary, insist some seconds on the controls to be sure the doors are closed.
4.10. MATERIAL EJECTING/ REMOVING
REMOVING COMPACTED AND CRASHED MATERIAL (HYDRAULIC BULKHEAD LOWERED):
Before removing the compacted and crashed material doors 1 and 2 shall be completely open and compacting
cylinder completely retracted.
The compacted material shall be removed from the tank ONLY by means of mechanical means (self propelled
crane or crane provided) complying with the use instructions contained in the relevant manual.
EJECTING COMPACTED BUT NOT CRASHED MATERIAL (HYDRAULIC BULKHEAD RAISED):
Before ejecting the compacted material retract the compacting cylinder of 10-20 cm. to reduce pressure on
the pressure bar:
- To retract the cylinder from the dashboard push up the lever (number 15).
- To retract the cylinder from the control board turn the selector (number 17) leftwards.
- To retract the cylinder from the remote control push down the lever (letter I).
To eject the compacted material without shearing it operate the compacting cylinder making sure that both
the pressure bar and the shear have been raised.
- To raise the pressure bar from the dashboard push down the lever (number 18).
- To raise the pressure bar from the control board turn the selector (number 20) leftwards.
- To raise the pressure bar from the remote control push down the lever (letter C).
- To raise the shear from the dashboard push down the lever (number 19)
- To raise the shear from the control board turn the selector (number 21) leftwards.
- To raise the shear from the remote control push up the lever (letter D).
Eject the compacted material letting the compacting cylinder advance:

- To advance the cylinder from the dashboard push down the selector (number 15).
- To advance the cylinder from the control board turn the selector (number 17) rightwards.
- To advance the cylinder from the remote control push up the lever (letter I).
DANGER
Make sure that nobody stands by the material output during material ejection.
Do not stand by the material output if the compacting cylinder is being operated from the
remote control.
DANGER
The safety plate located near the material output shall have to be lowered during the
compacted material ejection.
4.11. MATERIAL CUTTING
The cutting of the material can be performed in manual or in automatic mode.

The compacting operations described in the previous paragraphs must have been completed before starting the
material shearing.
The material cutting can only be carried out if doors 1 and 2 are completely closed; the warning light (number 27)
shall be on. The machine is equipped with a lot of micro-switches that assure a safe material cutting.
The cutting cycle sequence is the following:
1. Thrust cylinder forwards;
2. Pressure bar downwards;
3. Shear downwards;
4. Shear upwards;
5. Pressure bar upwards;
6. Thrust cylinder forwards;
7. Cut refusal.
If the loaded material exceeds during cut refusal stage (7) the shearing force (800 Ton.), the shear repeats the
shearing operation until it weakens and cuts the material.
The cutting of the material can be carried out both in automatic or in manual mode and can be operated from the
control board or from the remote control.
Before cutting the material the anti-shearing safety device of the compacting cylinder shall have to be brought into
action as described at paragraph 3.11.
CAUTION
If the anti-shearing safety device of the compacting cylinder is not brought into action the
thrust cube or the compacting cylinder itself can be seriously damaged during the material
cutting.
4.11.1. MANUAL CUTTING CYCLE
DASHBOARD
Perform the material cutting:
- Advance the compacting cylinder: push down the lever (number 15).
- Lower the pressure bar: push up the lever (number 18).
- Lower the shear: push up the lever (number 19).
Eject the sheared material:
- Raise the shear: push down the lever (number 19).
- Raise the pressure bar: push down the lever (number 18).
- Advance the compacting cylinder: push up the lever (number 15).
CONTROL BOARD
To select the manual cutting cycle turn the selector (number 30) leftwards.
- Advance the compacting cylinder: turn the selector (number 17) rightwards.
- Lower the pressure bar: turn the selector (number 20) rightwards.
- Lower the shear: turn the selector (number 21) rightwards.
- Raise the shear: turn the selector (number 21) leftwards.
- Raise the pressure bar: turn the selector (number 20) leftwards.
- Advance the compacting cylinder: turn the selector (number 17) leftwards.
REMOTE CONTROL
To select the manual cutting cycle push down the lever (letter F).
- Advance the compacting cylinder: push up the lever (letter I).
- Lower the pressure bar: push up the lever (letter C).
- Lower the shear: push down the lever (letter D).
- Raise the shear: push down the lever (letter I).
- Raise the pressure bar: push down the lever (letter C).
- Advance the compacting cylinder: push up the lever (letter D).
4.11.2. AUTOMATIC CUTTING CYCLE
The automatic cutting cycle is operated from the automatization board which governs all the steps necessary to
shear the material which has already been compacted.
To start the automatic cutting cycle the doors 1 and 2 must be completely closed and both the pressure bar and the
shear must be completely raised. After the automatic cutting cycle has been started, the diesel engine shall
automatically reach its peak rpm to quicken the cylinders movements.
At the end of the automatic cutting cycle the doors 1 and 2 shall be opened and the diesel engine shall idle.
DASHBOARD
To actuate the automatic cutting cycle the control board must be prearranged from the remote control by pushing
up the lever (letter K) for about 2 seconds.
Then switch off the remote control through the control board and make sure that nobody can switch it on during the
cycle.
To start the cycle press the push-button RUN (number 21).
To stop the cycle press the push-button STOP (number 22).
CONTROL BOARD
Then switch off the remote control through the control board and make sure that nobody can switch it on during the
cycle.
To select the automatic cutting cycle turn the selector (number 27) leftwards.
To start the cycle press the push-button RUN (number 23).
To stop the cycle press the push-button STOP (number 24).
REMOTE CONTROL
To select the automatic cutting cycle push up the lever (letter F).
To start the cycle push up the lever (letter E).
To stop the cycle push down the lever (letter E).
4.11.3. AUTOMATIC CUTTING CYCLE RESTORING AFTER A STANDSTILL
The automatic cutting cycle can be stopped as described in the previous paragraph (normal stop) or as described
in chapter 6 (emergency stop). In both cases it is possible to stop the cycle from the dashboard, from the control
board as well as from the remote control.
Automatic cycle normal stop:

FROM THE DASHBOARD: press the push-button STOP (number 22).
FROM THE CONTROL BOARD: press the push-button STOP (number 24).
FROM THE REMOTE CONTROL: push down the lever (letter E).
Automatic cycle restoring after a normal stop:

Prearrange the control board from the remote control by pushing up the lever (letter F) for about 2 seconds.
FROM THE DASHBOARD: press the push-button STOP (number 21).
FROM THE CONTROL BOARD: press the push-button RUN (number 23).
FROM THE REMOTE CONTROL: push up the lever (letter E).
Automatic cycle emergency stop:

FROM THE DASHBOARD: press the emergency stop push-button (number 24) or remove the
switch key (number 25).
FROM THE CONTROL BOARD: remove the switch key (number 9).
FROM THE REMOTE CONTROL: press the emergency stop push-button (letter A) or push down the
lever (letter E).
FROM OUTSIDE THE MACHINE press the red push-buttons on yellow background located on the
machine corners
Automatic cycle restoring after an emergency stop:

Prearrange the control board from the remote control by pushing up the lever (letter F) for about 2 seconds.
FROM THE DASHBOARD: press the push-button RUN (number 21).
FROM THE CONTROL BOARD: press the push-button RUN (number 23).
FROM THE REMOTE CONTROL: push up the lever (letter E).
When a cycle is restored after an emergency stop (see above), it is necessary to prearrange the emergency button
again by turning the red mushroom clockwise for about ¼ turn until it comes out of a few millimetres.
When a cycle is restored after an emergency stop, the diesel engine will run slow. Therefore the number of
revolutions will have to be increased gradually as follows:
FROM THE DASHBOARD: push the lever (number 23) rightwards.
FROM THE CONTROL BOARD: turn the selector (number 26) rightwards.
FROM THE REMOTE CONTROL: push up the lever (letter L).
CAUTION
When a cycle is restored after an emergency stop,

it will start from the beginning of the operation sequence.
After an emergency stop of the automatic cycle, the board is reset.

Therefore it is necessary to restore all consents to start the automatic cycle again.
To restore all electrical consents close doors 1 and 2 completely and raise the both the pressure bar and the
shear.
4.11.4. ADJUSTING THE LENGTH OF THE MATERIAL
During the automatic shearing cycle it is possible to select the length of the material to be sheared by adjusting the
timer ring on the control board (number 28).
The numbers on the ring refer to the seconds of thrust cylinder feed before the cylinder stops and the shear is
actuated.
DANGER
Make sure that there are no persons near the material output during ejection of sheared
material.
Do not stand near the material output if the thrust cylinder is operated from the remote control.
CAUTION
The machine has been designed to work with the timer settings set in the calibration stage.
Colmar S.p.A. is not responsible for any accident and/or problems caused by tampering with
the calibration values.
4.12. LOADING CRANE CONTROLS
You will find above the instructions concerning the controls which can be performed from the loading crane
operator’s cab.
The following movements (concerning the loading crane) can be controlled from the operator’s cab only:
- Turret rotation
- Main, secondary and telescopic arm motion
- Rotation and holding device opening/closing.
Moreover can be controlled the movements concerning:

- Pressure bar and shear
- Doors 1 and 2
- Compacting cylinder.
4.12.1. SAFETY PUSH BUTTONS
To perform any manoeuvre press the push button placed at the top of manipulators (letter N in the figure below).
The release of the push button stops immediately the manoeuvre.
DANGER
Before carrying out any operation, block access to the working area with barriers making sure
that there are no persons within the range of operation of the machine.
Range of operation means a distance of at least 10 m.
4.12.2. ACCELERATOR LEVER
Turning the switch on the dashboard

governs the diesel engine rotation speed L M N O
(letter M in the right figure).
IMPORTANT
To increase the speed of
the machine movements
increase the diesel engine
rpm.
4.12.3. TELESCOPIC EXTENSION

CONTROL PUSH BUTTONS
The push-buttons placed on the right

manipulator (letter O in the right figure)
govern the positioning of the crane arm
telescopic extension.
4.12.4. BUCKET ROTATION

CONTROLPUSH BUTTONS
The push-buttons placed on the left

manipulator (letter L in the right figure)
govern the clockwise or counter
clockwise rotation of the bucket at the
end of the machine arm to orient the
load.
4.12.5. RIGHT MANIPULATOR
The right manipulator governs the

bucket opening/closing and the main
arm raise/descent. The following
movements can be carried out: E/F G/H C/D A/B
A Bucket opening
B Bucket closing
C Main arm descent
D Main arm raising
4.12.6. LEFT MANIPULATOR
The left manipulator governs the turret

rotation and the secondary arm
raise/descent. The following movements
can be carried out:
E The turret rotates rightwards
F The turret rotates leftwards
G Secondary arm descent
H Secondary arm raising
NOTE: Some crane controls may differ

from the above mentioned ones. Refer
to the movements diagram you can find
on an adhesive plate in the operator’s
cab.
The manoeuvres concerning the turret
rotation and the arm raise/descent are
proportional. Reduce the movement
speed in the proximity of the max.
hoisting power.
4.12.7. COMPACTING/CUTTING P Q R S T U
CYLINDERS CONTROL
The movements of the compacting

/cutting cylinders are governed by the
levers located on the dashboard.
P Thrust cylinder opening and
closing
Q Door 2 opening and closing
R Door 1 opening and closing
S Pressure bar raising/lowering
T Shear raising/lowering
U Hydraulic bulkhead raising /
lowering
4.13. HYDRAULIC OIL PREHEATING
To use the machine in particularly rigorous weather conditions (temperatures below – 20°C) a burner can be
installed to preheat the hydraulic oil and to avoid damages and malfunctions to the hydraulic components of the
machine itself.
CAUTION
A machine equipped with a hydraulic oil preheating device can work only if the oil reaches the
fixed temperature and the control panel has been started up.
The hydraulic oil heating plant consists of a gas oil

burner, a water tank, a burner starting, check electric
board (installed inside the control board) and the
required pipes and valves.
The burner (see figure on the right) is fed by the same

gas oil tank used for the diesel engine machine.
The burner heats the water of a special tank and a

centrifugal pump lets the water in by means of a coil
immersed in the hydraulic oil tank, which heats the oil
itself.
A thermostat takes the hydraulic oil temperature and

disconnects the burner when the working temperature
has been reached.
NOTE: If the machine is equipped with hydraulic oil

preheating device, the engine oil shall be replaced with
running-in oil for rigorous climate. Refer to paragraph
5.11.3 for engine oil check and topping up.
CHAPTER 5 - MAINTENANCE
CAUTION
Maintenance must be exclusively carried out by Colmar

Customer Engineering Service or by qualified personnel.
5.1. FOREWORD
To obtain the best performance from the machine and the maximum service life from its components, the use and
maintenance instructions must be followed scrupulously by all maintenance personnel.
We recommend that users read this section thoroughly and consult it whenever a problem arises on the machine.
As the machine is frequently used in contact with water, sand and earth, etc., regular lubrication is extremely
important in order to obtain the longest possible service life from the machine and to keep operating costs to a
minimum.
For further information please contact the Colmar service department:
Contact COLMAR Maintenance Department (Tel. 0039 0425 932 313)
5.2. GENERAL MAINTENANCE PROCEDURE
− All maintenance procedures must be carried out when the machine is switched off and the key disconnected
from the panel.
− Routine maintenance includes all the information necessary to the good working and the conservation of the
machine.
− Maintenance should be always performed by the same engineer who not only has to know the machine deeply
but also what described in the following pages.
− Check the lubricant level when the machine is cooled down and positioned on even floor. Before checking the
levels, carefully clean the areas to be inspected to avoid the penetration of foreign matters. Should the level be
topped up, use clean receivers and make sure that no foreign matters enters the lubricant.
− Hydraulic oil, engine oil, grease, cooling liquid, and every other fluid used for the machine good operation, have
to be good quality ones, free from pollution and newly manufactured.
− Change the engine oil when the machine is warmed up to facilitate the dripping.
− Before injecting new grease in the lubricators by means of the grease gun pump, remove carefully old paint,
dirt, etc. from the lubricator and pump until the old grease has completely dripped out.
− Refer to the use and maintenance manual of the diesel engine for special maintenance operations of the engine
itself.
− Always use suitable strippers, wrenches and tools in order not to damage the pieces during disassembling and
reassembling operations.
− Use copper hammers or wooden mallets to release firmly adhering parts.
− Distinctly separate the parts of the different groups and partially screw the nuts with their pins or studs. Clean
the parts using brushes or cloths then wash them with cleansing solution and remove the remaining impurities
with compressed air.
− Carefully wash the pieces or use compressed air jet after grinding or using abrasive means, and make sure that
any abrasive powder has been removed.
− Make sure that all pieces are clean, then lubricate before reassembling them.
− Pay greatest attention to safety rings and split pins: replace immediately if they show break signs.
5.3. MAINTENANCE CHART
The routine maintenance stated in the following chart shall be performed after the machine has worked for the
number of hours stated in the left column (see hour meter on the dashboard).
Approximately 10 hours correspond to a workday, 50 hours to a week, 250 hours to a month and 2000 hours to a
year.
The column “chapter” refers to the specific chapter of this manual in which the mentioned operation is described.
The entry “manual” refers to the diesel engine manual.
Working
hours
Operation Chapter Lubricant
Check fuel level
Check hydraulic oil level 5.10.4 Classification ISO HV 46
Check engine oil level 5.11.3 Classification SAE 10W30
Check coolant level 5.18
Pressure bar sliding guides greasing 5.9 Consistency NLGI 2
Check grease level of the greasing automatic system tank;
5.9 Consistency NLGI 2
top up if necessary
Pinion/slew ring, telescopic arm pins and sliding blocks
5.9 Consistency NLGI 2
greasing
Check pipe fittings tightening 5.10.3
Check hydraulic system filter cartridges 5.11.1
50
Check bolt tightening 5.12
Check turret rotation reduction gear oil level 5.14 Viscosity class ISO VG 150
Check electrolyte level in batteries 5.16
Check pressure bar and shear slides wearing 5.19
Compacting cylinder greasing 5.9 Consistency NLGI 2
Hydraulic oil topping up, if necessary 5.10.4 Classification ISO HV 46
Clean magnetic rod 5.10.5
First change of hydraulic oil filter cartridge 5.11.1
100 Check diesel engine air filter 5.11.2
First change of diesel engine oil filter cartridge 5.11.3
External cleaning of the hydraulic circuit heat exchanger
5.18
and of the diesel engine water radiator
Check shear blades wearing 5.20
Change diesel engine oil 5.11.3 Classification SAE 10W30
Drainage of fuel condensate drain tray 5.11.5
250 Check coupling gear oil level 5.15
Change shear blades 5.20
Check diesel engine belts tension Manual
Replace hydraulic oil filter cartridge 5.11.1
Replace diesel engine air filter cartridge 5.11.2
500
Replace diesel engine oil filter cartridge 5.11.3
Replace fuel filter cartridge 5.11.4
Check the thickness of telescopic arm sliding blocks 5.13
1000 Change turret rotation reduction gear oil 5.14 Viscosity class ISO VG 150
Clean filter on diesel gas pump Manual
2000 Change hydraulic oil and clean tank 5.10.4 Classification ISO HV 46
or first Change coupling gear oil 5.15 Viscosity class ISO VG 150
year Change coolant 5.18
NOTE: The lubricants in the right column of the chart refer to normal weather conditions. In case of especially
rigorous weather conditions single out the suitable lubricant in the charts of the following pages.
5.4. HYDRAULIC OIL CHART
Only use good-quality hydraulic oil complying with the specifications of the following chart.
The properties of the hydraulic oil suggested for common use shall comply with API-CC or MR-L-2104 and MR-L-
4615.
The characteristics of the hydraulic oil suggested for common use shall be VG 46.
All the specifications ATF - test FZG ≥10 and engine oil HD SAE 10 W 30.
ISO
Viscosity VG 22 VG 32 VG 32 VG 46 VG 46 VG 68 VG 68 VG 100
Class
HLP (HM),
HV
HLP HV HLP HV HLP HV HLP HLP
AGIP / ARNICA 32 OSO 32 ARNICA 46 OSO 46 ARNICA 68 OSO 68 OSO 1000
VITAM GF 32 VITAM GF 46 VITAM GF

ARAL VITAM GF 22 VITAM HF 32
VITAM DE 32
VITAM HF 46
VITAM DE 46
/ VITAM GF 68
100
AVILUB AVILUB AVILUB AVILUB AVILUB AVILUB AVILUB AVILUB

AVIA RSL 22 HVI 32 RSL 32 HVI 46 RSL 46 HVI 68 RSL 68 RSL 100
ENERGOL ENERGOL ENERGOL ENERGOL

HLP 22 ENERGOL HLP 32 ENERGOL HLP 46 HLP 68 ENERGOL
BP ENERGOL SHF 32 ENERGOL SHF 46 ENERGOL
/
ENERGOL HLP 100
HLP D 22 HLP D 32 HLP D 46 HLP D 68
HYSPIN HYSPIN HYSPIN HYSPIN HYSPIN HYSPIN HYSPIN HYSPIN

CASTROL AWS 22 AWH 22 AWS 32 AWH 46 AWS 46 AWH 68 AWS 68 AWS 100
EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL EP HIDR. OIL
CHEVRON 22 32 HV 32
/
46 68 HV 68 100
ESSO NUTO H 22 UNIVIS J 32 NUTO H 32 UNIVIS N56 NUTO H 46 UNIVIS N 56 NUTO H 68 NUTO H 100
HYDRAN HYDRAN HYDRAN

FINA HYDRAN 22
HV 22
HYDRAN 32
HV 46
HYDRAN 46
HV 68
HYDRAN 68 HYDRAN 100
RENOLIN MR RENOLIN MR RENOLIN MR RENOLIN MR

RENOLIN MR
RENOLIN MR 10 RENOLIN MR 15 20 30
FUCHS 5
520 RENOLIN B 1030 RENOLIN B
/
RENOLIN B RENOLIN B
RENOLIN B 5
10 15 20 30
DTE 24 DTE 25 DTE 26
MOBIL DTE 22 DTE 13 HIDR. OIL DTE 15 HIDR. OIL DTE 16 HIDR. OIL DTE 27
HLPD 32 HLPD 46 HLPD 68
TELEX TELEX TELEX TELEX TELEX

REPSOL HVLP 22
TELEX HV 32
HVLP 32
TELEX HV 46
HVLP 46
TELEX HV 68
HVLP 68 HVLP 100
TELLUS TELLUS TELLUS TELLUS TELLUS TELLUS TELLUS TELLUS

SHELL OEL 22 OEL T 32 OEL 32 OEL T 46 OEL 46 OEL T 68 OEL 68 OEL 10
RANDO RANDO
RANDO RANDO RANDO RANDO RANDO
TEXACO OIL HD A-22
OIL HD AZ-
OIL HD A-32
/
IL HD B-46
OIL HD CZ-
OIL HD C-68 OIL HD E-100
32 68
VALVO-
ETC 20 / ETC 25 / ETC 30 / ETC 35 /
LINE
HD Engine
SAE 5 W / SAE 5 W SAE 10 W 30 / SAE 10 W 30 SAE 20 W 20 SAE 30
oil
5.5. LUBRICATING OIL CHART
Only use good-quality lubricating oil complying with the specifications of the chart.
The reduction gears are oil-lubricated.
The characteristics of the lubricant suggested for common use shall be VG 46, EP (extreme pressure) and
viscosity ISO VG 150 (11° - 13° E at 50°C).
Room temperature - 20°C ÷ + 5°C + 5°C ÷ +40°C + 30°C ÷ + 65°C + 40°C ÷ + 65°C
Viscosity ISO VG 100 150 220 320
Viscosity °E / 50°C 7,3 10,8 ÷ 12,5 15 ÷ 18 22 ÷ 26
AGIP BLASIA 100 BLASIA 150 BLASIA 220 BLASIA 320

ENERGOL ENERGOL ENERGOL ENERGOL
BP
GR HP 100 GR HP 150 GR HP 220 GR HP 320
CASTROL ALPHA SP 100 ALPHA SP 150 ALPHA SP 220 ALPHA SP 320
NL GEAR NL GEAR NL GEAR NL GEAR
CHEVRON
CAMPOUND 100 CAMPOUND 150 CAMPOUND 220 CAMPOUND 320
ESSO SPARTAN EP 100 SPARTAN EP 150 SPARTAN EP 220 SPARTAN EP 320
FINA GIRAN 100 GIRAN 150 GIRAN 220 GIRAN 320
IP MELLANA 100 MELLANA 150 MELLANA 220 MELLANA 320
MOBIL / MOBILGEAR 629 MOBILGEAR 630 MOBILGEAR 632
REPSOL TAURO 100 TAURO 150 TAURO 220 TAURO 320
SHELL OMALA EP 100 OMALA EP 150 OMALA EP 220 OMALA EP 320
TOTAL CARTER EP 100 CARTER EP 150 CARTER EP 220 CARTER EP 320
ELF REDUCTELF SP 100 REDUCTELF SP 150 REDUCTELF SP 220 REDUCTELF SP 320
5.6. ENGINE OIL CHART
The diesel engine lubricating oil shall be

chosen according to the chart here on the
right. Only use good-quality lubricating oil
complying with the specifications of this chart.
Verify you are always using a lubricating oil
having the right degree of viscosity according
to the engine operative room temperature
(see the chart lower line).
The lubricating oil shall comply with API CF4
or ACEA E2 specifications in standard loading
conditions and with API CG4 or ACEA E3 in
high loading conditions.
-30 -20 -10 0 10 20 30 40 50 °C

-22 -4 14 32 50 68 86 104 122 °F
NOTE: If the machine is equipped with hydraulic oil preheating device, the engine oil shall be changed with
running-in oil for rigorous climate The first change of the running-in oil shall be performed after the first twenty
operating hours with an 0W30 or 0W40 viscosity class oil.
5.7. LUBRICATING GREASE CHART
Only use good-quality lubricating grease having consistency NLGI 2 and complying with the specifications of the
following chart.
In case of especially rigorous weather conditions we suggest the use of a special low-temperature grease.
AGIP GR MU EP 2
ARAL ARALUB HPL 2
BP GREASE LTX - EP 2
CASTROL SPHEEROL EPL 2
ELF EPEXA 2
ESSO BEACON EP 2
IP ATHESIA EP GREASE 2
MOBIL MOBILUX EP 2
REPSOL GRASA LITICA EP 2
SHELL ALVANIA GREASE 2
VALVOLINE VALVOLINE LB 2
5.8. COOLANT CHART

Freezing point % of coolant % of water
The coolant contained in the radiator shall be
antifreeze and anticorrosion. – 15°C 30 70
The radiator coolant shall be chosen according to – 20°C 35 65
machine operative room temperature.
– 25°C 40 60
Prepare the coolant mixture according to the room
temperature and the specifications of the chart here – 30°C 45 55
on the right. – 35°C 50 50
– 45°C 60 40
5.9. GREASING
According to the maintenance chart, all elements provided with lubricator shall be greased with NLGI 2 consistency
grease (see chart 5.7).
If the machine is used in heavy-duty conditions, grease the elements more frequently.
The lubricators are identified by coloured dust protective caps and are generally located on the articulated joints.
The precise location of lubricators is showed in the following figure.
Cylinder and articulated joint greasing:
Inject the new grease with a suitable grease gun pump

till the old grease has been completely discharged.
The lubricators are identified by coloured dust protective
caps
Before injecting the new grease accurately remove from
the lubricator old paint, dirt, etc.
The lubricators are placed on the articulated joints of the

1 and 2 doors cylinders, on the cylinders of the loading
crane (lifting of 1st and 2nd arm and of telescopic jib) and
of the orange-peel bucket, and on the cab tipping
cylinder.
Slew ring toothing greasing:
Before greasing the loading crane slew ring toothing,

remove by means of a spatula the old grease which
gathers on the rims of the pinion gear and of the slew
ring toothing, then smear the slew ring toothing with
new grease by means of a spatula or a brush.
After having greased the slew ring toothing rotate
sometimes the turret to distribute the new grease on the
whole toothing circumference.
Telescopic arm greasing:
Before greasing the telescopic arm extension, remove

by means of a spatula the old grease which gathers on
the rims of the arm itself, then smear the arm extension
with new grease by means of a spatula or a brush.
After having greased the sliding blocks, draw the arm
extension in and out many times to distribute the new
grease on the whole length of the sliding blocks guide.
Thrust cylinder greasing:
The thrust cylinder outer liner shall be greased by

means of a brush.
Grease by means of a brush and smear the liner for
about 1 meter starting from the collar towards the
external part of the machine with NLGI 2 consistency
grease.
Shear greasing
The shear sliding guides require constant greasing to

avoid early wear.
The machine is equipped with a system for the
automatic greasing of the cutting unit guides.
Every 4 hours check the grease level inside the

container by the cutting unit.
Should the grease level be too low, fill it up with NLGI 2
consistency grease.
Should the automatic greasing circuit break down,
grease the guides manually every 30 minutes of
operation.
CAUTION
Should the grease level be lower than the minimum or should some anomaly in the greasing
automatic circuit occur, the machine stops.
5.10. HYDRAULIC SYSTEM
5.10.1. HYDRAULIC CYLINDERS
Routine maintenance of the hydraulic cylinders is limited

to check the seal of the hose fittings and to make sure
that the bushing pins and the ball joints have been
greased.
As regards extraordinary maintenance all seals have to
be replaced when operating anomalies develop as a
result of excessive wear generating the hydraulic
cylinder anomalous working.
5.10.2. CRANE ROTATING JOINTS
The rotating joint needs extraordinary maintenance only

when the internal gaskets are worn.
Check regularly the seal between the pipe unions and
the rotating joint and verify the tightening of the
supporting brackets bolts.
5.10.3. HYDRAULIC SYSTEM
Check the pipe seals and tighten fittings at the first sign
of leakage.
This operation is especially important at the beginning
of the machine service life when oil leaks may develop
as a result of vibrations and parts bedding in.
The figures on the bottom and on the right are only

illustrative. Check the seal of all hydraulic pipes.
5.10.4. HYDRAULIC OIL
Check the oil level in the tank every 10 hours by means

of the level hose placed on the side of the tank (arrow
1).
If the oil level is near the MIN marking, refill with the oil
suggested in the 5.4 chart.
In case of a constant hydraulic oil loss, check the seals
of the cylinders and of the hydraulic system.
Change the hydraulic oil every 2000 hours (or at least

once a year) and clean the tank internally.
To change the hydraulic oil remove the tank filing cap
(arrow 2), remove the cap placed under the tank and
collect the oil in a suitable container. Change the
hydraulic oil when the machine is completely cooled.
As the hydraulic actuators contain plenty of oil, check

and change the oil when the cylinders have all been
completely closed. To this purpose let the cylinder rods
draw in to close the doors, the thrust cylinder and the
loading crane cylinders.
The hydraulic oil shall be disposed of according to the

law in force.
5.10.5. MAGNETIC ROD
Inside the machine oil tank one magnetic rod (arrow 3)

have been installed to catch the ferrous impurities in the
plant.
Clean the magnetic rod every 2000 hours (or at least
once a year) and clean the tank internally.
To remove the rod unscrew the nut installed on the oil
tank, take out the rod, clean it with a wiping cloth and
put it back in its seat.
5.11. FILTERS
5.11.1. HYDRAULIC OIL FILTERS
Oil filters must be regularly checked as clogged filters

reduces the machine performances and can also lead to
the collapse of the filter element with the consequent
contamination of the hydraulic system and serious
damage to the hydraulic components.
IMPORTANT: At the beginning of the machine service

life filters must be replaced more frequently.
Hydraulic system filters replacement:
• 1st replacement after 100 operating hours
• 2nd replacement after 500 operating hours
• Subsequently every 500 operating hours.
Shorter intervals between filter replacements will be
scheduled, if the machine works in very dusty areas.
IMPORTANT: the above mentioned filter replacement

shall be repeated from the beginning whenever
hydraulic system components are replaced as the
result of serious faults, such as seizure of pumps,
motors or cylinders, which cause big quantities of
impurities to enter the hydraulic system.
5.11.2. DIESEL ENGINE AIR FILTER
To check the diesel engine air filter loosen the knob

(see arrow in figure) and remove the filter cover.
Pull out the filter cartridge, shake it with your hand and
blow compressed air on it.
Also remove any dust particles from the cartridge
outside covering.
Follow the instructions of the diesel engine manual.
The air filter shall be checked every 100 operating
hours and replaced every 500 operating hours.
Shorter intervals between filter changes will be
scheduled, if the machine works in very dusty areas.
When the air filter is clogged the warning light Nr.4 on
the operator’s cab dashboard (see paragraph 3.3)
lights on. The filter has to be cleaned or replaced.
5.11.3. DIESEL ENGINE OIL LEVEL AND DIESEL ENGINE OIL FILTER
Check the engine oil every 10 working hours by means

of the staff (arrow 1). The level must be included
between the MIN and MAX markings.
If the oil level is near the MIN marking, refill with the oil
suggested in the 5.6 chart.
The engine oil shall be changed every 250 operating
hours.
− Change the oil when the engine is warmed up.
− Unscrew the cap on the oil pan.
− Remove the filling cap to let the oil freely flow.
− Screw the oil pan cap again and pour new oil
through the filling cap until the oil lever reaches the
MAX marking on the staff.
− Screw the filling cap again, start the engine for 5
minutes then stop it.
− Check the oil level and top up if necessary.
At the beginning of the machine service life the diesel engine oil filter must be replaced more frequently.
Diesel engine oil filter replacement:
• 1st replacement after 100 operating hours
• 2nd replacement after 500 operating hours
• Subsequently every 500 hours (every two oil changes).
Shorter intervals between filter replacements will be scheduled, if the machine works in very dusty areas.
The engine oil shall be disposed of according to the law in force.
NOTE: If the machine is equipped with hydraulic oil preheating device, the engine oil shall be changed with
running-in oil for rigorous climate The first change of the running-in oil shall be performed after the first twenty
operating hours with an 0W30 or 0W40 viscosity class oil.
5.11.4 DIESEL ENGINE GAS OIL FILTER
The fuel filters (arrow 3, figure above) shall be replaced every 500 operating hours.
Turn off the cock placed under the gas oil tank, unscrew the filter cartridges located on the engine block and
replace them with new ones of the same type. Turn the cock on and remove the air from the plant.
As different kinds of cartridges can be installed, follow the instructions of the diesel engine manual.
5.12. GENERAL MECHANICS
The mechanical parts that rotate reciprocally must be

periodically checked and lubricated.
It is also necessary to check the bolted connections for
loosened bolts.
To this purpose it shall be verified:
• the slew ring flanging both as to the frame and as to
the rotating turret (see arrow in the figure)
• the turret rotating joint supporting bracket
connection
• any other bolt, above all those of the components
subject to vibrations and movements.
5.13. TELESCOPIC ARM SLIDING BLOCKS
Check periodically the thickness of the telescopic arm

extension sliding block of the loading crane. The min.
thickness shall not be lower than 5 mm. Should the
thickness of the sliding blocks be lower than 5 mm.,
they must be replaced.
To replace the telescopic arm sliding blocks act as
follows:
1. Remove the cylinder connection pin from the rod
side.
2. Remove the setscrew (see arrows in the figure) on
the arm fixed section.
3. Withdraw the extractable part.
4. Replace the four sliding blocks.
5. Reassemble the arm extension.
5.14. TURRET ROTATION REDUCTION GEAR
Check the oil level in the turret rotation reduction gear

every 50 operating hours by unscrewing the plug 1 and
verifying if the oil is visible in the pipe. Top up the oil
level with the oil suggested in the 5.5 chart, if
necessary.
Change the oil in the reduction gear every 1000 hours

by unscrewing the plug 2 and let flow the exhausted oil
by unscrewing the plug 3.
Screw the plug 3 again after some minutes and add
new oil through the plug 1 until the height of the hole 2
has been reached.
The exhausted lubricating oil must be disposed of

according to the law in force.
5.15. COUPLING GEAR
Check the oil level in the coupling gear every 250

operating hours by unscrewing the plug you see in the
figure and verifying if the oil is visible. Top up the oil
level with the oil suggested in the 5.5 chart, if
necessary.
Change the oil in the coupling gear every 2000 hours

by unscrewing the plug placed on the bottom of the
coupling gear and let flow the exhausted oil.
Screw the plug again after some minutes and add new
oil through the upper plug until the level has been
reached.
The exhausted lubricating oil must be disposed of

according to the law in force
5.16. BATTERIES
Batteries are installed behind the compacting tank,

before the gas oil tank. The electrolyte level of each cell
shall be of about 6 mm. above the edge of the battery
plate.
If necessary, add distilled water up to the right level.
IMPORTANT:
− Check the electrolyte level only when the engine has
stopped.
− Do not use naked lights to light the cells up, as
batteries contain explosive gas.
− Before put back the cell caps, make sure they are
clean.
− If the temperature is below 0°C, start the engine for
some minutes after the level topping up.
− In case the battery has to be removed, first
disconnect the negative pole (–) and then the
positive pole (+); to restore it first connect the
positive pole (+) and then the negative pole (–).
− Unscrew the metallic bracket to remove the battery.
− Clean periodically clamps joints and grease them
with antioxidant.
5.17. FUSES
The fuse carrier is placed on the dashboard side in the

operator’s cab, or on the control board. To approach the
fuses just remove the safety plastic cover and, if
necessary, replace the burnt-out fuse.
In case of short circuit do not replace any fuse before
having verified the reasons and having repaired the
fault.
Fuse carrier
Relays colours:
RED: 10 A; YELLOW: 20 A; GREEN: 30 A
5.18. RADIATOR
Check the coolant every 10 operating hours, only when

the engine is cooled. The coolant level must be at about
12 mm. under the filler.
If necessary, add distilled water or coolant according to
what stated in the chart 5.8.
In case of a constant coolant loss, check the seals of
the radiator-engine and of the radiant unit.
IMPORTANT:
The cooling system is a pressurized circuit; therefore if
you remove the plug when the engine is warmed up pay
attention and protect your hands with gloves or
insulating materials.
Filler
Change the coolant every 2000 operating hours.
− Remove the filler and unscrew the plug you see in
the lower figure. Change the coolant when the
engine is tepid.
− Let flow all the coolant and screw again the plug
placed under the radiator.
− Pour a detergent anti-incrustator liquid available on
the market.
− Start the engine at mean rpm for about 15 minutes.
− Let flow the detergent anti-incrustator solution by
unscrewing the plug you see in the figure and at the
same time fill with running water for at least 40
minutes.
− Stop the engine, let all the water off, screw the plug
again and fill with coolant according to what stated in
the chart 5.8.
− Start the engine and check the level after some
Emptying cap
minutes; if necessary, top up to reach the min.
required level.
Clean the radiator periodically by means of a compressed air jet or wash with water.
IMPORTANT:
− Do not use products containing even little quantities of oily substances as they facilitate dust adhesion which
damages the heat exchange.
− Clean the heat exchanger whenever it gets dirty with oil, grease, gas oil or oily or fatty substances.
− Some machine versions, which can be operative even in case of particularly low temperatures, make use of a
cooler having a high percentage of coolant. If the machine has to be used in milder climates, the coolant must
be replaced with a coolant containing a proper mixture (refer to chart 5.8).
5.19. PRESSURE BAR AND SHEAR SLIDES
Check the pressure bar and shear slides wearing every 50 hours by lifting up the sheet protecting the material exit
hole, by fixing it with the proper safety chain and by inserting a thickness gauge between the mobile slide (see
black elements in pictures here below) and the fixed slide (see thick profile in pictures here below).
The side clearance between the fixed and mobile slides (arrow A in following pictures) should not exceed 0,4/0,5
mm.
The front clearance between the fixed and mobile slides (arrow B and C in following pictures) should not exceed
0,3/0,4 mm. The clearance must be measured in three different moments: when shear and pressure bar are
completely up, at half stroke and at the end of stroke.
DANGER
To check the shear and pressure bar clearance it is COMPULSORY to switch the engine off
and take the ignition key off the control panel.
In the next lines, reference is made to the adjustment of the

pressure bar and shear slides.
Shear
In case the front clearance (arrows A and B) exceeds the

values indicated, adjust the shear slides following the
instructions here below.
• Unscrew the screws D in order to help the wedge
slide movement
• Screw up the screws E in order to let the wedge slide
move forward
• Screw up the screws D and then the screws E with a 130
Kgm tightening torque
• Check the screws F tightening (130 Kgm tightening
torque)
• Check again the front clearance and verify it is within the
allowed tolerances, otherwise adjust the slides twice.
In case the side clearance (arrow A) exceeds the values

indicated, adjust the slides by inserting some shims at back of
the slide itself.
It is necessary to take the blade holder from its seat and shim
the slide till the clearance has recovered a tolerable value.
For this operation, please contact Colmar S.p.A.
CAUTION
The slides adjustment must be done on both sides

of the shear (left and right).
Pressure bar
In case the side clearance exceeds the values indicated,

adjust the slides by inserting some shims at back of the slide
itself.
It is necessary to take the blade holder from its seat and shim
the slide till the clearance has recovered a tolerable value.
For this operation, please contact Colmar S.p.A.
NOTE: The slides adjustment must be done on both sides of

the shear (left and right).
CAUTION
The excessive and/or incorrect adjustment of the

pressure bar and shear slides clearance can
damage the operation hydraulic cylinders.
5.20. SHEAR BLADES
The shear blades wearing must be checked every 100

working hours.
In case the blades are excessively worn out, it is
necessary either to rotate or to replace them.
Every blade can be rotate just once, then it must be
replaced.
In case the wearing is excessive and the blades have
been rotated, the blade holder can be damaged
because it is made up with tendered material.
The shear blades must be replaced every 250 working
hours.
Depending on the dimensions of the material to be
sheared, it is necessary to adjust the clearance between
the lower fixed blade and the upper mobile one.
The picture on the right displays the following elements:
A. Pressure bar slides
B. Lower fixed blade
C. Upper mobile blade
D. Shear slides.
In order to check the clearance, bring close the upper

(C) and lower (B) blades and measure the clearance by
a thickness gauge.
The larger the dimension of the material to shear (thick
sheets), the larger the clearance (maximum 2 mm).
The smaller the dimension of the material to shear (thick
sheets), the smaller the clearance (minimum 0,5 mm).
In order to adjust the clearance between the fixed and
the mobile blade, it is necessary either to insert or to
remove some shims at the back of the fixed blade. This
operation can be carried out by removing the fixed
blade, inserting or removing the shims and refitting the
blade.
When delivered, the machine is fitted with clearance of
0,5 mm between the fixed and mobile blade therefore it
is fit to shear thin material.
DANGER
To check the shear blades wearing it is COMPULSORY to switch the engine off and take the
ignition key off the control panel.
CAUTION
Either turn or replace the shear blades every 250 working hours.
Before turning the blades, make sure their edges are not damaged in order to avoid structure
deformations and subsequent breakdowns. In case of splinterings or breakdowns, restore the
surface by means of welding with special electrodes, and then level.
CHAPTER 6 - SCRAPPING AND DISPOSAL

When the machine has reached the end of its service life, the owner shall arrange for the scrapping and disposal of
the machine itself in accordance with the applicable regulations and by means of authorised disposal contractors
for the different components.
We also remind that all used oil, batteries, rubber hoses, tyres and any other machine parts requiring separate
disposal shall always be disposed of in accordance with applicable regulations by authorised contractors.
CHAPTER 7 - EMERGENCY
7.1. EMERGENCY STOP
In case of emergency the engine can be stopped (locking all the machine and the loading crane movements) from
outside by operating the red push button on a yellow background placed on the dashboard in the cab (paragraph
3.3).
7.2. DEAD MAN SAFETY SOLENOID VALVE
The solenoid valve for the loading crane movement

consent can be cut out only in case of emergency.
The solenoid valve allows the loading crane
manoeuvring only when one of the push buttons placed
under the head of the manipulator is hold down ("dead
man" safety).
The solenoid valve, see arrow in the figure, is placed on
the loading crane distributor, which is located on the
slew ring.
In case of solenoid valve fault or of emergency
manoeuvres, cut out the solenoid valve by completely
unscrewing the knob showed by the arrow in the figure.
In this case the turret rotation, the main and secondary
arm and the bucket manoeuvring can be performed also
without the push buttons placed under the head of the
manipulator.
CAUTION
In normal working conditions the solenoid valve shall be cut in, as it is a safety device provided
by the law in force concerning the safety of the machine. The solenoid valve shall be cut out
only in case of fault or of emergency manoeuvres. Colmar S.p.A. accepts no liability for any
damage and/or accident arising from the imprudent or wrong manoeuvring.
WARNING
In the following operations, the operator can be in potential danger. To minimize

accident risks, it is necessary not to panic, to maintain calm and to follow carefully the
several phases to overcome the emergency
7.3. FIRE
In case of fire, inside the cab there is a CO2 fire extinguisher to be used according to the relative regulations in
force. In case of fire of the machine or that the machine is near a fire, get immediately out of the cab, give the
warning and contact the fire men.
CAUTION
It is strongly advisable to install a fire extinguisher

inside the machine cab or immediately near it.
7.4. OPERATOR’S EXTRACTION FROM THE CAB IN CASE OF ILLNESS
In case the operator is ill and it is impossible for him to get out from the cab by himself, it is necessary to intervene
immediately following these phases:
1. Join the cab with stable and safe structures or, if it is impossible to operate in safe conditions, contact the
medical or emergency personnel.
2. Open the cab door.
3. Lift the operator from the seat and extract him from the cab paying attention not to worsen his conditions. In
case of doubt or serious illness, contact the medical personnel.
4. Rest the operator on the ground and follow the most important directions of first aid.
5. If not already done, contact the medical personnel.
CHAPTER 8 - TROUBLESHOOTING
Problem Cause Solution

− Hydraulic oil level in the tank is to low. − Top up with hydraulic oil of the same type.
− Wrong assembly of hydraulic pump. − Check assembly.
− Engine/pump coupling not correct. − Check assembly.
The machine, with diesel
engine powered-on, does not − Distributor pressure relief valve jammed or − Disassemble and clean the pressure relief
run worn. valve or replace.
− Worn pump. − Replace pump.
− Hydraulic oil pre heating device not warmed up − Wait until the hydraulic oil is warmed up
(optional)
− Hydraulic oil viscosity is too high. − Use recommended hydraulic oil
− Hydraulic oil level in the tank is too low. − Top up with hydraulic oil of the same type.
Noisy pump
− Suction pipe clogged or crushed. − Check duct for integrity
− A flange on the suction pipe lets air in. − Check seals and replace gasket.
− Too low hydraulic oil level in the tank. − Top up with hydraulic oil of the same type.
− Clean exchanger fins and/or check for
− Dirty or clogged exchanger. internal obstructions.
Extreme hydraulic oil heating. − Replace fuse.
− Electric fan protection fuse fault. − Add cooling water in the radiator.
− Little cooling water in the radiator. − Replace electric fan.
− Electric fan fault.
− The pressure relief valve on the distributor − Recalibrate the valve. Disassemble and
related to the circuit section showing the clean the valve, then assemble with new
Slow operation of some
problem is not calibrated or its shutter is open metal packings. Replace valve.
hydraulic functions.
due to impurities.
− Worn pump. − Replace pump
− Oil slip between the two cylinder chambers − Replace the cylinder gaskets.
with consequent non-lifting of the load.
Irregular operation of the oil-
− Loosen piston/rod connection. − Check rod/piston connection.
hydraulic cylinder.
− Pressure relief valve on the distributor jammed − Disassemble and clean or replace the
or worn. pressure relief valve.
− Jammed cursor. − Replace distributor element.
− Slips inside the distributor. − Replace distributor element.
− Elements with worn gaskets show signs of oil − Replace gaskets.
Irregular operation of the leaks.
distributor. − Cursor return springs worn. − Replace return springs.
− Insufficient pilot pressure. − Check servo control circuit.
− High hydraulic oil temperature. − Check conditions of heat exchanger.
− No tension to the pilot solenoid valve. − Check tension.
− The pressure relief valve on the distributor − Disassemble and clean the pressure relief
jammed or worn. valve or replace.
− Pressure relief valve on the distributor too − Calibrate the valve.
low calibrated.
Irregular turret rotation − Antishock valve jammed or dirty. − Replace the valve.
− Flow control valve not calibrated. − Calibrate the valve.
− Motor pinion-crown gear too much slack. − Replace the motor.
− Worn slew ring. − Replace.
− Worn reduction gear. − Replace.
− Too much material loaded inside the tank. − Load the tank as stated by this manual.
The doors open when the − Secondary valves on the machine feeding − Calibrate the valves .
thrust cylinder is operated distributor not calibrated.
− Piston locking valves not calibrated or worn. − Calibrate or replace the valves.
Hydraulic oil inside the − Oil seal on pumps/motors out of seat owing − Check hydraulic circuit and replace worn
components to high pressure in the casing. pump/motor.
− Low pilot pressure − Check hydraulic circuit
− Faulty servo control − Replace
Servo controls are not working
− Faulty solenoid valve − Replace
− Faulty electrical connections − Check electric circuit
Solenoid valves are not − No tension − Check hydraulic system
working
− Discharged battery − Charge batteries
− Microswitches cutting out the remote control − Check the microswitches operation
Remote control is not working
are non operative
− The machine is too far. − Approach the machine.
− Hydraulic oil feed cocks between compacting − Turn the cocks on
The cutting unit does not and cutting units are turned off
work − Electric outlet between compacting and cutting − Check connections between outlets.
units not connected.
Early shear sliding guides − Not enough frequent and/or abundant − Check frequently and abundantly the shear
wear greasing. sliding guides.
CHAPTER 9 - HYDRAULIC SYSTEM

9.1. COMPONENT LIST
1 Steel structure 50 Adapter DN32 CETOP 08

2 Pressure relief valve 51 Modular valve CETOP 03
3 Cover DIN 40 52 Solenoid valve CETOP 08
4 Cover DIN 50 53 Adapter DN32 CETOP 08
5 Cut refusal pressure switch 54 Pressure switch - max. pressure
6 Control coupling 55 Diesel engine
7 Pressure switch 56 Coupling gear
8 Cover DIN 40 57 Coupling gear
9 Pressure relief valve 58 Gear pump
10 Control coupling 59 Piston pump
11 Pressure switch 60 Gear pump
12 Cover DIN 40 61 Gear pump
13 Pressure switch - pressure bar max.pressure 62 Gear pump
14 Control coupling 63 Suction filter
15 Control coupling 64 Solenoid valve
16 Solenoid valve CETOP 03 65 Gear engine
17 Modular valve CETOP 03 66 Heat exchanger
18 Solenoid valve CETOP 08 67 Filter
19 Non-return valve 68 Pump cut off cocks
20 Valve DIN 50 69 Pump cut off cocks
21 Solenoid valve CETOP 08 70 Manually operated distributor
22 Valve DIN 40 71 Hydraulic bulkhead cylinder
23 Valve DIN 50 72 Locking valves
24 Solenoid valve CETOP 03 80 Shear cylinders D400 d200 stroke 900
25 Valve DIN 40 81 Pressure bar cylinder D200 d130 stroke 865
26 Non-return valve 82 Overcenter valve
27 Selector valve 83 Second wall cylinders D210 d150 stroke 590
28 Valve DIN 40 84 First wall cylinders D210 d150 stroke 590
29 Valve DIN 40 85 Thrust cylinder D250 d180 stroke 5080
30 Steel structure 86 Rotating hydraulic joint
31 Solenoid valve 87 Gear pump
32 Pressure relief valve 88 Dead man solenoid valves
33 Exclusion valve 89 Right manipulator
34 Solenoid valve 90 Left manipulator
35 Exclusion valve 91 Solenoid valves NC
36 Pressure relief valve 92 Crane feeding 6-sections distributor
37 Non-return valve 93 Locking valve
38 Pressure relief valve 94 Crane main cylinder
39 Pressure relief valve 95 Crane secondary cylinder
40 Quick coupling 96 Turret rotation engine
41 Pressure switch - backward compacting cylinder 97 Flow control valve
42 Cover 98 Rotation control valve
43 Valve 99 Double-acting locking valve
44 Steel adjusting block 100 Crane telescopic cylinder
45 Modular valve CETOP 03 101 Relief valve
46 Adapter DN32 CETOP 08 102 Rotating system hydraulic engine
47 Solenoid valve CETOP 08 103 Orange peel bucket cylinder
48 Modular valve CETOP 03 104 Accumulator servocontrol
49 Solenoid valve CETOP 08
9.2. HYDRAULIC PLAN
84
85
80 81 82 82
83
150 BAR
8 9 10 11 12
41 40
200 BAR
A A1 B1 MB1 B MB 200 BAR MA A B MB MA1 A1 B1 MB1 MC C D MD

42
110 BAR 13
7
MA 25 28 29 14
6 MC
C 38 39
5 24 26 43
260 BAR 46
a 15 33 34
MD
S13 27
120 BAR
D
52 49
23 51 48
4 16 44
36 45
21 18 S2
37
19
a b a b a b a b
240 BAR 220 BAR 280 BAR
S9 S10 S11 S12 S3 S4 S5 S6 S7 S8
22 S14 S15 Ø1.2 Ø1.2 Ø1.2
3
a b 35
P2
Ø1.2
S1
20
32 31 53 50 47
T Y P2 X MP P P1 MP1 T2 T1 X T
1 30
54
200 BAR
A1 A/B R U
56
59
55
70
100 bar X3
S T1
132 kW
1800 rpm
57 200 90 32
72
63
6 16 5 bar
66
200 bar
65
71 69 68
87 58 60 61 62 67
64
104
CHAPTER 10 - ANNOTATION
HEAD OFFICE
Via Statale 16, 3 - 45031 Arquà Polesine (RO) - ITALY
Phone 0039 0425 / 932 133
Fax 0039 0425 / 465 052
http://www.colmarspa.com e-mail: [email protected]
SPARE PARTS DEPT.

Phone 0039 0425 / 452 081
Fax 0039 0425 / 465 228
Contact name Mrs Luisa Zanella (e-mail: [email protected])
AFTER-SALE SERVICE
Phone 0039 0425 / 932 313
Fax 0039 0425 / 465 228
Contact name Mr Simone Castiglieri (e-mail: [email protected])
EXPORT DEPT.
V.le dei Colli Euganei, 88 - Flat 5-6 - 35041 Battaglia Terme (PD) - ITALY
Phone 0039 049 / 910 1349
Fax 0039 049 / 911 4163

Руководство по эксплуатации PT6260-800R

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Руководство по эксплуатации PT6260-800R

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What is the purpose of this manual?

What is the purpose of this manual?

What are the main components of the hydraulic system described in the manual?

What are the main components of the hydraulic system described in the manual?

SCRAP METAL COMPACTING AND

CUTTING UNIT WITH LOADING CRANE

USE AND MAINTENANCE INSTRUCTION MANUAL

TELEFAX: 0039 0425 465 052

You find here our telephone numbers to get a quicker service:

Machine model: ............................................................................................................................................

Machine serial number: ................................................................................................................................

Engine serial number:...................................................................................................................................

Year of manufacturing: .................................................................................................................................

Date of purchase: .........................................................................................................................................

CHAPTER 3 - SPECIFIC CHARACTERISTICS ................................................................................................................. 18

CHAPTER 4 - USE OF THE MACHINE.............................................................................................................................. 32

4.7. Material loading ............................................................................................................................................................ 37

CHAPTER 5 - MAINTENANCE .......................................................................................................................................... 45

CHAPTER 6 - SCRAPPING AND DISPOSAL ................................................................................................................... 60

CHAPTER 8 - TROUBLESHOOTING ................................................................................................................................ 63

CHAPTER 9 - HYDRAULIC SYSTEM ................................................................................................................................ 64

CHAPTER 10 - ANNOTATION ........................................................................................................................................... 66

CHAPTER 1 - GENERAL DESCRIPTION

Manual code: M-PT6260-02-06

DO NOT USE THE MACHINE BEFORE

Use exclusively original spare parts for maintenance and repairs.

1.5. SAFETY INSTRUCTIONS

1.5.1. INSTRUCTIONS FOR USE AND CONSERVATION OF THE MANUAL

Pay attention to the following warnings and to their meaning.

1.5.2. PURPOSE AND LIMITS OF THE MANUAL

1.5.3. GENERAL INSTRUCTIONS

Machine = machine Colmar Mod. PT6260 - 800 R.

1.5.5. UNIFIED SAFETY SYMBOLS ON THE MACHINE

Should the adhesive warning signs (above mentioned) become illegible,

Sign showing crushing Sign showing cutting

Sign showing burn hazard

Sign showing entangling Sign showing hazard

Sign showing hanging Sign showing people have

Sign showing that only LOAD/UNLOAD

1.6. CHARACTERISTICS OF THE MACHINE

1.6.1. DESCRIPTION OF THE MACHINE

1.6.2. OPERATOR TRAINING REQUIREMENTS

1.6.4. CONFORMITY TO STANDARDS

1.6.5. WORK DIAGRAM

1.6.6. DESCRIPTION OF OPERATION

1.6.7. HOISTING DEVICE

1.6.8. HOISTING POWER DIAGRAM

Hoisting power diagram

1.7. MACHINE DIAGRAMS

Weight of compacting unit 40.000 Kg

Weight of cutting unit 21.000 Kg

Weight of shear-baler with complete equipment 61.000 Kg

ACQUIRE A THOROUGH KNOWLEDGE OF THE WEAR SAFETY CLOTHING

USE SAFETY EQUIPMENT TESTING THE MACHINE

2.2. SAFETY WARNINGS

2.2.1. ACCIDENT PREVENTION

2.2.2. ENVIRONMENTAL CONDITIONS SUITABLE TO THE MACHINE

It is forbidden to use the standard configuration machine under environmental conditions

2.3. GENERAL SAFETY RULES