Dear Customer, thank you for having chosen our products.

In case of need
contact us at the following number:

FAX: 0039 0425 465 052

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

SPARE PARTS STORE: 0039 0425 932133-7
AFTER-SALES SERVICE: 0039 0425 932333-8
SALES DEPARTMENT: 0039 0425 932133-4
ACCOUNTING DEPARTMENT: 0039 0425 932133-0

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 Technik 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
1. GENERAL DESCRIPTION .................................................................................................................... 5
1.1 PRELIMINARY INFORMATION ................................................................................................................................................................. 5
1.2 FOREWORD ............................................................................................................................................................................................. 6
1.3 WARRANTY .............................................................................................................................................................................................. 6
1.4 LIABILITY .................................................................................................................................................................................................. 7
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 .................................................................................................................................... 8
1.5.3 GENERAL INSTRUCTIONS ........................................................................................................................................................... 9
1.5.4 DEFINITIONS ................................................................................................................................................................................. 9
1.5.5 UNIFIED SAFETY SYMBOLS ON THE MACHINE........................................................................................................................ 10
1.6 CHARACTERISTICS OF THE MACHINE ................................................................................................................................................ 11
1.6.1 DESCRIPTION OF THE MACHINE............................................................................................................................................... 11
1.6.2 OPERATOR TRAINING REQUIREMENTS ................................................................................................................................... 11
1.6.3 VIBRATION EXPOSURE .............................................................................................................................................................. 11
1.6.4 CONFORMITY TO STANDARDS ................................................................................................................................................. 12
1.6.5 MACHINE DIAGRAMS.................................................................................................................................................................. 13
1.6.6 DESCRIPTION OF OPERATION .................................................................................................................................................. 13
1.6.7 LIFTING DEVICE .......................................................................................................................................................................... 14
1.6.8 LIFTING DIAGRAM ....................................................................................................................................................................... 14
1.6.9 DIMENSIONS AND WEIGHTS...................................................................................................................................................... 15
2 SAFETY ............................................................................................................................................. 17
2.1 SAFETY STANDARDS ............................................................................................................................................................................ 17
2.2 SAFETY WARNINGS .............................................................................................................................................................................. 18
2.2.1 ACCIDENT PREVENTION ............................................................................................................................................................ 18
2.2.2 ENVIRONMENTAL CONDITIONS SUITABLE TO THE MACHINE ............................................................................................... 18
2.3 GENERAL SAFETY RULES .................................................................................................................................................................... 19
2.3.1 NOT ALLOWED PERFORMANCES ............................................................................................................................................. 19
2.3.2 ALLOWED PERFORMANCES ...................................................................................................................................................... 19
2.3.3 CARE AND MAINTENANCE ......................................................................................................................................................... 20
2.4 ESSENTIAL OPERATOR INSTRUCTIONS ............................................................................................................................................. 21
3 SPECIFIC CHARACTERISTICS .......................................................................................................... 22
3.1 TECHNICAL DATA .................................................................................................................................................................................. 22
3.2 CRANE MOVEMENTS ............................................................................................................................................................................ 24
3.3 INSTRUMENT SYSTEM.......................................................................................................................................................................... 25
3.4 MULTIFUNCTION DISPLAY.................................................................................................................................................................... 28
3.4.1 ALARMS ....................................................................................................................................................................................... 31
3.4.2 RADIO REMOTE CONTROL ........................................................................................................................................................ 32
3.4.3 ACOUSTIC AND LIGHT INDICATORS ......................................................................................................................................... 33
3.5 MACHINE IDENTIFICATION ................................................................................................................................................................... 34
3.6 MACHINE MAIN WORDINGS ................................................................................................................................................................. 35
3.7 MACHINE STARTING ............................................................................................................................................................................. 36
3.7.1 START-UP .................................................................................................................................................................................... 36
3.7.2 CHECKS AT THE START OF EACH WORKDAY ......................................................................................................................... 37
3.8 PROTECTION AND STORAGE............................................................................................................................................................... 37
3.8.1 MACHINE IDLE FOR A SHORT PERIOD ..................................................................................................................................... 37
3.8.2 MACHINE IDLE FOR A LONG PERIOD........................................................................................................................................ 37
3.8.3 MACHINE RESTARTING AFTER A LONG IDLE PERIOD ............................................................................................................ 38
3.9 ROAD CIRCULATION ............................................................................................................................................................................. 38
3.10 REFUELING ............................................................................................................................................................................................ 38
3.11 OPERATOR’S CAB ACCESS.................................................................................................................................................................. 39
3.12 LIFTING THE MACHINE ......................................................................................................................................................................... 39
3.13 COMPACTING UNIT AND SHEAR UNIT CONNECTION ........................................................................................................................ 39
3.14 COMPACTING CYLINDER POSITIONING.............................................................................................................................................. 44
3.15 GRAPPLE ASSEMBLY............................................................................................................................................................................ 45
1.1 MAGNETIC PLATE ASSEMBLY.............................................................................................................................................................. 46
4 USE OF THE MACHINE ...................................................................................................................... 47

Pag. 2 SB5000/700
 4.1 ENGINE START ...................................................................................................................................................................................... 48
4.1.1 COLD STARTING ......................................................................................................................................................................... 48
4.2 ENGINE STOP ........................................................................................................................................................................................ 49
4.3 MATERIAL TO BE COMPACTED............................................................................................................................................................ 49
4.4 CRANE HYDRAULIC CAB POSITIONING .............................................................................................................................................. 50
4.4.1 CAB LOWERING (TRANSPORT POSITION)................................................................................................................................ 50
4.4.2 CAB LIFTING (WORKING POSITION) .......................................................................................................................................... 50
4.5 TURRET ROTATION LIMITING DEVICE................................................................................................................................................. 51
4.5.1 ROTATION LIMITING DEVICE CUTTING OUT ............................................................................................................................ 51
4.6 TURRET ROTATION CHECK PIN........................................................................................................................................................... 52
4.7 AIR CONDITIONER (OPTIONAL)............................................................................................................................................................ 52
4.8 DRIVING PLACE ..................................................................................................................................................................................... 53
4.8.1 SAFETY PUSH BUTTON .............................................................................................................................................................. 53
4.8.2 RIGHT HANDLE ........................................................................................................................................................................... 53
4.8.3 LEFT HANDLE .............................................................................................................................................................................. 53
4.8.4 TELESCOPIC ARM CONTROL PUSH BUTTONS ........................................................................................................................ 54
4.8.5 BUCKET ROTATION CONTROL PUSH BUTTONS ...................................................................................................................... 54
4.9 MAGNETIC PLATE ................................................................................................................................................................................. 54
4.10 MACHINE STABILIZATION (OPTIONAL) ................................................................................................................................................ 54
4.10.1 CYLINDER LOWERING (WORKING POSITION ........................................................................................................................... 55
4.11 MATERIAL LOADING .............................................................................................................................................................................. 56
4.12 BULKHEAD POSITIONING ..................................................................................................................................................................... 56
4.13 BALING ................................................................................................................................................................................................... 57
4.14 MATERIAL CRUSHING ........................................................................................................................................................................... 58
4.14.1 COMPACTING FORCE SELECTION ............................................................................................................................................ 58
4.15 MATERIAL EXPULSION ......................................................................................................................................................................... 58
4.16 MATERIAL SHEARING (ONLY SB5000/700) .......................................................................................................................................... 58
4.17 AUTOMATIC BALING CYCLES............................................................................................................................................................... 59
4.17.1 BALING (AUTOMATIC CYCLE 0) ................................................................................................................................................. 59
4.17.2 BALING AND BALE’S EXPULSION (AUTOMATIC CYCLE 1)....................................................................................................... 59
4.17.3 PRE-BALING AND SHEARING (AUTOMATIC CYCLE 2) ............................................................................................................. 60
4.17.4 SHEARING (AUTOMATIC CYCLE 3) (ONLY SB5000/700) .......................................................................................................... 60
4.18 ADJUSTING THE LENGTH OF THE MATERIAL..................................................................................................................................... 60
5 MAINTENANCE................................................................................................................................. 62
5.1 FOREWORD ........................................................................................................................................................................................... 62
5.2 GENERAL MAINTENANCE PROCEDURE ............................................................................................................................................. 62
5.3 MAINTENANCE CHART ......................................................................................................................................................................... 63
5.4 HYDRAULIC OIL CHART ........................................................................................................................................................................ 63
5.5 LUBRICATING OIL CHART ..................................................................................................................................................................... 63
5.6 LUBRICATING GREASE CHART ............................................................................................................................................................ 63
5.7 GREASING.............................................................................................................................................................................................. 64
5.7.1 SHEAR AUTOMATIC GREASING SYSTEM ................................................................................................................................. 66
5.8 HYDRAULIC SYSTEM ............................................................................................................................................................................ 67
5.8.1 HYDRAULIC CYLINDERS ............................................................................................................................................................ 67
5.8.2 CRANE ROTATING JOINT ........................................................................................................................................................... 67
5.8.3 HYDRAULIC SYSTEM .................................................................................................................................................................. 67
5.8.4 HYDRAULIC OIL........................................................................................................................................................................... 68
5.8.5 MAGNETIC ROD .......................................................................................................................................................................... 69
5.9 FILTERS.................................................................................................................................................................................................. 69
5.9.1 HYDRAULIC OIL FILTER AND AIR BREATHER FILTERS ........................................................................................................... 69
5.10 GENERAL MECHANICS ......................................................................................................................................................................... 69
5.11 TELESCOPIC ARM SLIDING BLOCKS ................................................................................................................................................... 70
5.12 TURRET ROTATION REDUCTION GEAR .............................................................................................................................................. 70
5.13 BATTERIES............................................................................................................................................................................................. 71
5.14 FUSES .................................................................................................................................................................................................... 71
5.15 RADIATOR – HEAT EXCHANGER ......................................................................................................................................................... 71
5.16 CONTROL OF PRESSURE AND VALVE SETTING ................................................................................................................................ 72
5.16.1 MACHINE MOVEMENTS CIRCUIT............................................................................................................................................... 73
5.16.2 CRANE CIRCUIT .......................................................................................................................................................................... 73

SB5000/700 Pag. 3
 5.16.3 SERVOCONTROL CIRCUIT ......................................................................................................................................................... 73
5.17 BLOCKING SHEET AND SHEAR SLIDES (ONLY SB5000/700) ............................................................................................................. 74
5.18 SHEAR BLADES (ONLY SB5000/700) .................................................................................................................................................... 76
5.19 WELDING ON MACHINE ........................................................................................................................................................................ 77
6 EMERGENCY..................................................................................................................................... 78
6.1 EMERGENCY STOP ............................................................................................................................................................................... 78
6.2 DEAD MAN SAFETY SOLENOID VALVE................................................................................................................................................ 78
7 SCRAPPING AND DISPOSAL ............................................................................................................ 79
8 TROUBLESHOOTING ........................................................................................................................ 80
9 HYDRAULIC SYSTEM ........................................................................................................................ 82
9.1 COMPONENT LIST ................................................................................................................................................................................. 82
9.2 HYDRAULIC CIRCUIT............................................................................................................................................................................. 83
10 ELECTRIC SYSTEM ........................................................................................................................... 85
10.1 WIRE COLOUR CODES ......................................................................................................................................................................... 85

Pag. 4 SB5000/700
1. GENERAL DESCRIPTION

1.1 PRELIMINARY INFORMATION

This document is the use and maintenance manual of the machine in accordance with regulation
2006/42/EEC and subsequent amendments and integrations.
Do not destroy or alter this manual; integrate only with inserts.

Manual code: M-SB5000-02-03

Revision n°: 03
Compiling date: 07-02-18
Machine type: Scrap metal compacting machine
Model: SB5000/700

List of enclosures:
- CE declaration
- Diesel engine manual
- Radio remote control manual

CAUTION
DO NOT USE THE MACHINE BEFORE HAVING READ THIS
ENTIRE MANUAL

SB5000/700 Pag. 5
1.2 FOREWORD

These operating instructions together with the lift capacity tables the stabilizing 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 lifting 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 boom 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) during road transport, comply with all road traffic regulations (see the logbook of the truck which
will transport the machine).
9) obtain all the necessary information before starting the machine road traveling: distance, route,
level crossing height, bridge weight limits, etc.;
10) 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 Technik 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 Technik S.p.A.
Colmar Technik S.p.A. undertakes to repair or replace parts which it deems defective during the
warranty period.
The liability of Colmar Technik 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, and wear-out.
Spare parts not covered by warranty are engine oil filters, engine air filter, diesel filter, hydraulic oil filters,
and all hydraulic cylinders seals.
The equipment which has not been manufactured by Colmar Technik S.p.A. is warranted by their own
manufacturer.
The warranty expires by right in the following cases:
- when the Customer has not respected the contract payment clauses;

Pag. 6 SB5000/700
- 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 Technik S.p.A. has not
authorised or when the machine has been modified or repaired without Colmar Technik 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 Technik S.p.A.

For all cases not covered by the above and for all assistance, please contact Colmar Technik S.p.A.
directly by registered letter or fax, even in the event of arrangements agreed by telephone.
Colmar Technik S.p.A. accepts no liability for any delays in or failure to provide assistance.
Colmar Technik 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 Technik 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 Technik 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 Technik 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 Technik 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 metal scrap shear baler
COLMAR Model SB5000/700 (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;

SB5000/700 Pag. 7
- 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
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
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
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. SB5000/700.

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 Technik S.p.A. are forbidden.

Pag. 8 SB5000/700
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 signaler 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 = metal scrap shear baler COLMAR Mod. SB5000/700.

Assembled machine = the shear unit is connected to the baling unit.
Disjoined machine = the shear unit is not connected to the baling unit.
Equipment = lifting device (grapple).
Interface (rotator) = device used to connect the equipment to the telescopic 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 Technik 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 Technik 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.
Compactable and cutting material = See paragraph 4.4 of this manual.

To define the other terms used in this manual please refer to the standards UNI ISO 12100-1 and UNI
ISO 12100-2.

SB5000/700 Pag. 9
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

Sign showing that the
caution according to its
use and maintenance
color and always
manual has to be
accompanied by one of
consulted.
the following symbols.

Sign showing crushing Sign showing cutting

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

Sign showing burn

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

Sign showing hazard

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

Sign showing hanging Sign showing people

loads falling hazard. have to keep a safety
Do not stay in the distance from the
machine range of machine when it is
operation working.

Sign showing that only

mechanical devices
Sign showing it is
must be used to load
forbidden to get/climb
and unload the material
onto the machine.
inside the machine baler
NO CLIMBING box.

Pag. 10 SB5000/700
1.6 CHARACTERISTICS OF THE MACHINE

1.6.1 DESCRIPTION OF THE MACHINE

The shear baler for scrap metals COLMAR Model SB5000/700 have been designed to compact scrap
metals of medium-light size.
The whole machine construction consists of special high tensile steel.
The machine consists basically of:
- Compacting unit: it allows the scrap metal baling
- Shear 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.
- Loading crane and operator’s cab (they allow to load and unload the material inside the baler
box without using extra lifting equipment)
- Control board: it allows the hand or automatic control of all the machine functions and it
automatized the baling cycle of the material inside the baler box
- Radio remote control: it allows the hand and automatic control of the compacting cycle.
The material feeding baler box is 5000 mm [16’ 5”][ long, is made of very high tensile and abrasion-
resistant steel (HARDOX 450).
Both baler box closing doors, also made of special steel, are controlled by 2 pairs hydraulic cylinders.
The pusher of the material inside the baler box is performed through a hydraulic cylinder having a 170
Ton [187 Tons] pusher force.
The machine is equipped with a crane with the maximum lifting of 950 daN [2100 lbs] that allows the
loading and unloading of the material inside the baler box.
A shear unit is supplied together with the compacting unit. The shear unit allows to cut the compacted
material by means of a special steel blade operated by two hydraulic cylinders having a shear force of
700 Ton [772 Tons].
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.
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 servocontrol.
Colmar Technik 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 VIBRATION EXPOSURE

The machine has been projected and manufactured with anti-vibration devices, in order to reduce risks
caused by vibrations at a minimum level.
The total value of vibrations to which the system arm-hand is exposed is lower than 2,5 m/s2.
The total value of vibrations to which the body is exposed is lower than 0,5 m/s2.

SB5000/700 Pag. 11
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):
 2006/42/EEC Standard for Machine and subsequent modifications.
 Electromagnetic Compatibility (EMC) Directive 2004/108/EEC with the following amendments.
 Low Voltage Standard Directive 2006/95/EEC with the following amendments.

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 ISO 12100-1
 UNI EN ISO 12100-2
 UNI EN 294
 UNI EN 349
 UNI EN 414
 UNI EN 418
 UNI ISO 7731:2006
 UNI EN 954
 UNI EN 982
 UNI EN 1037
 UNI EN 1050
Safety of machinery – Basic concepts, general principles for design –
Part 1: Basic terminology, methodology.
Safety of machinery – Basic concepts, general principles for design –
Part 2: Technical principles.
Safety of machinery. Safety distances to prevent danger zones being
reached by the upper limbs.
Safety of machinery. Minimum gaps to avoid crushing of parts of the
human body.
Safety of machinery. Rules for the drafting and presentation of safety
standards.
Safety of machinery. Emergency stop equipement, functional
aspects. Principles for design.
Ergonomics – Danger signals for public and work areas. Auditory
danger signals.
Safety of machinery. Safety-related parts of control systems. General
principles for design.
Safety of machinery. Safety requirements for fluid power systems and
their components. Hydraulics.
Safety of machinery. Prevention of unexpected start-up.
Safety of machinery. Principles or risk assessment.

Pag. 12 SB5000/700
1.6.5 MACHINE DIAGRAMS

1.6.6 DESCRIPTION OF OPERATION

The material to be compacted is loaded inside the baler box (loading shall be performed using
EXCLUSIVELY mechanical devices).
A mechanical device 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).
Baling 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 compacting 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
compacting cylinder against the bulkhead. During the shearing cycle the bulkhead must be open.
When the material has been compacted, the thrust cube squashes the material through the operation of
a compacting hydraulic cylinder with 187 Tons [170 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 blocking sheet, a stopper driven by a hydraulic cylinder having a force of
47 Ton [52 Tons], then it is sheared with 700 ton [772 tons] by the shearing blade fitted at the end of the
shear cylinder.

SB5000/700 Pag. 13
1.6.7 LIFTING DEVICE

When the machine is used as lifting device by means of tools such as buckets, grapples, etc, make sure
that the maximum lifting power listed in the table does 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 LIFTING DIAGRAM

ft m
35
10

30 9

25
7

6
20

15
4
950 daN 1100 daN 1650 daN 2200 daN
2100 lbs 2425 lbs 3635 lbs 4850 lbs
3
10

5
1

0 0

-1

-5

-2
8 7 6 5 4 3 2 1 0 m

25 20 15 10 5 0 ft

Pag. 14 SB5000/700
1.6.9 DIMENSIONS AND WEIGHTS

WITH
SHEAR
10872 Kg

10872 Kg

SB5000/700 Pag. 15
Dimensions and weight
Baler box length 5.000 mm
Weight of baling unit 29.800 Kg
Weight of shear unit 19.500 Kg

Pag. 16 SB5000/700
2 SAFETY

2.1 SAFETY STANDARDS

ACQUIRE A THOROUGH WEAR SAFETY CLOTHING

KNOWLEDGE OF THE MACHINE
Wear close-fitting clothing and use safety
The machine must only be used by qualified equipment 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 handles and to control board.
During maintenance operations, always rest the end of the telescopic arm 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, control board and radio remote
control

UNDER TEST

USE SAFETY EQUIPMENT TESTING THE MACHINE

Keep a first aid box and a fire extinguisher close
to the machine. Make sure that the fire
extinguisher is always fully charged and use it
according to the law in force.
Test the machine each day it is started following
the list of operations contained in this manual.
Start and operate the machine only from the
driver’s seat.
Only start the engine in ventilated areas. Before
starting the machine makes sure there are no
people in its range of action.

SB5000/700 Pag. 17
2.2 SAFETY WARNINGS

The machine has been designed and built in accordance with the current state of the art and regulations
governing the baler machine for scrap metals.
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. When using the machine on the
public highway, observe all applicable road traffic regulations.

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 pusher 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 [+ 77°F]
 Max. permissible temperature: + 40°C [+ 104°F]
 Min. permissible temperature: – 20°C [– 4°F]
 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 it self.

Special equipment of the machine is required if there are the following elements in the work
environment:
 Temperatures higher than + 40°C [+ 104°F]
 Temperatures lower than – 20°C [– 4°F]
 Condensate
 Brackish water
 Corrosive agents (acid or basic)
 Deflagration hazard in the environment
 Environments full of dust
 Radiations
 Insufficient lighting/illumination
Specific custom-made equipment are available, to allow the machine to operate under conditions
different from standard.

Pag. 18 SB5000/700
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 after it has been modified without the prior written consent of Colmar Technik
S.p.A.
 Using the arm as point of support for the machine positioning
 Loading by hand the material to be compacted in the baler box
 Compacting the material when the doors are open
 Compacting heavy members such as reduction gears, beams, etc, special steel parts or springs
 Pusher boxes and/or under-pressure tanks even if empty, or inert materials
 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, control board and radio
remote control
 Using the machine to lift or transport people
 Lifting loads over transit areas. Should this not be avoided, inform by means of warning signals about
the starting of operations
 Leaving the machine during its normal working

2.3.2 ALLOWED PERFORMANCES

 Using the machine as a scrap metal compacting and cutting machine observing the restrictions
stated in the chapter 4.4
 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 Technik S.p.A.
 Lifting loads observing the lifting power diagram and using the allowed equipment. Any other use of
the machine has to be considered unsuitable
 Loading/unloading the material in the baler box only by means of mechanical devices (self-propelled
crane or crane provided).

SB5000/700 Pag. 19
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 handles 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 people
 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 lifting power.

Pag. 20 SB5000/700
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 in 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. The machine shall be positioned on even, practically horizontal and consistent floor.
6. Do not use the machine when there are unsteady stacks or heaps of materials nearby that might collapse
onto the machine.
7. Before compacting the material make sure it does not contain explosives and/or inflammables (gas oil,
petrol, oil, etc.).
8. 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.
9. Only use mechanical means to load/unload the material in the tank.
10. Compact the material only after that the baler doors have been completely closed, eventually insisting for
some seconds on the commands for the closing of doors.
11. When the compacted/sheared 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 [65 ft] from the machine. Close the work area with opportune
barriers.
12. 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).
13. Stop the engine (in case of electric motor, rotate the main switch to “0” position) 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.
14. Stop the engine (in case of electric motor, rotate the main switch to “0” position) before performing any
maintenance operation.
15. Put no object in the operator’s cab; put the maintenance tools back in their special compartment.
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 arm.
18. Do not use the machine and the equipment to lift or transport people.
19. Never lift loads higher than the machine lifting capacity (max. lifting capacity 950 daN [2100 Lbs]).
20. Do not perform non-vertical lifting manoeuvers and towing.
21. Don't use the machine with the cabin doors open.
22. The lifting of different kinds of load shall be performed only by means of equipment suitable to the
use.
23. Do not use the arm as point of support for the machine positioning.
24. When leaving the driving position switch the engine off, let the equipment down and rest it on the
extremity of the tank.
25. Do not lift 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.
26. When working with the grapple make sure that the people by the work area keep a safe distance of at
least 20 m [65 ft] from the machine.
27. The manoeuvers concerning the turret rotation and the arm movement are proportional. In proximity
to the max. lifting capacity reduce the movement speed.
28. In case of transport on trucks the check pin has to be inserted to lock the turret rotation.
NOTE: The words in bold type refers to the machine equipped with loading crane.

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.

SB5000/700 Pag. 21
3 SPECIFIC CHARACTERISTICS

3.1 TECHNICAL DATA

Dimensions and quantities of baled material

Length Variable, depending on the type of material
Width 860 mm[34’’]
Height 640 mm [25’’]
Quantity of compacted material 10-12 Ton/h [11-13 Tons/h]
Dimensions of sheared material
Length Variable
Cutting blade width 900 mm [35.43’’]
Quantity of compacted material 10-12 Ton/h [11-13 Tons/h]
Materials
Structure Steel HARDOX 450 – S355 J2G3
Baler box Abrasion resistant steel HARDOX 450
Cylinders force
Compacting cylinder 170 Ton [187 Tons]
Doors cylinders 173 Ton [191 Tons]
Diesel engine
Make JOHN DEERE
Model CD6068HF485
Cycle Turbo charged, air to air charge cooled
Cylinders 6 in line
N° of stroke 4
Injection Direct injection
Bore x stroke 106 mm x 127 mm
3
Displacement 6800 cm
Max power 187 kW
Rated 2200 revs/min.
Torque 811 Nm
Fuel Diesel
Cooling system Pressurized water
Electrical system
Operating voltage 24 V
Alternator 100 A
Starter 7 kW
12 V batteries in series 2x100 Ah
Hydraulic system
N°1 variable displacement piston pump (baler and shear movements)
Max flow rate 190lt/min
Max working pressure 280 Bar
N°1 gear pump (baler and shear movements)
Max flow rate 360 lt/min
Max working pressure 120 Bar
N°1 gear pump (cooling)
Max flow rate 160 lt/min
Max working pressure 5 Bar
N°1 piston pump Rexroth (crane movements)
Max flow rate 60 lt/min
Max working pressure 220 Bar
N°1 gear pump (30 bar, air conditioning, magnet)
Max flow rate 60 lt/min
Max working pressure 30 Bar
N°1 gear pump (cooling hydraulic motor)
Max flow rate 20 lt/min
Max working pressure 80 Bar

Pag. 22 SB5000/700
Loading crane
Loading arm with rotation obtained by means of a radial piston hydraulic engine with one-stage epicycloidal reduction gear
having a pinion gear acting on an external teeth fifth wheel.
Fifth wheel diameter 620 mm [24.4’’]
Max. range 7.000 mm [22’ 11’’]
Non-continuous rotation 270°
Max lifting with standard grapple 950 daN [2,100 lbs]
Grapple volume 280 lt [74 gal]
Overall weight of the crane with grapple 2.000 Kg [4,410 lbs]
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-assisted controls
handles.
Height 1.600 mm [5’ 3’’]
Length 1.200 mm [3’ 11’’]
Width 900 mm [2’ 11’’]
Fuel and fluid capacities
Hydraulic oil tank capacity 850 lt. [224 gal]
Hydraulic circuit total capacity 1.000 lt. [264 gal]
Diesel 200 lt. [53 gal]
Diesel engine coolant 35 lt. [9 gal]
Diesel engine oil 15 lt. [4 gal]
Rotation reduction gear oil 3 lt. [1 gal]

SB5000/700 Pag. 23
3.2 CRANE MOVEMENTS

Pag. 24 SB5000/700
3.3 INSTRUMENT SYSTEM

CONTROL BOARD

30

SB5000/700 Pag. 25
 DASHBOARD

Pag. 26 SB5000/700
 PUSH
N. GREEN LED YELLOW LED RED LED FUNCTION
BUTTON
PRESSED
ON BLINK ON BLINK ON BLINK PRESSED FOR 1
SECOND
Slowdown Solenoid
Limit switch Limit switch Solenoid
1 limit switch valve Open door 1
activated error valve error
activated activated
Slowdown Solenoid Limit switch Solenoid
Limit switch error valve error
2 limit switch valve Open door 2
activated
activated activated
Solenoid Limit switch Solenoid
Limit switch valve error valve error
3 Pusher backward
activated activated
Solenoid
Limit switch valve Mobile bulckhead
4
activated activated up
Solenoid
Limit switch valve
5 Blocking sheet up
activated activated
Solenoid Limit switch Solenoid
Limit switch valve error valve error
6 Close door 1
activated activated
Solenoid Limit switch Solenoid
Limit switch valve error valve error
7 Close door 2
activated activated
Solenoid Solenoid
8 valve valve error Pusher forward
activated
Solenoid
Limit switch valve Mobile bulckhead
9
activated activated down
Solenoid
Limit switch valve Blocking sheet
10
activated activated down
Solenoid
Limit switch valve
11 Shear up
activated activated
Increase
Select engine rpm - Select
12 Rpm increasing
variable 1 Select variable 3
variable 2
Kayboard SCP function over 5 Alarms
13 New alarms Old alarms emergency
enabled seconds reset
Over 3 seconds,
change the
Cabin lights
14 Arm lights on keyboards lights All lights off
on
with push buttons
12(+) e 17(-)
Buzzer Siren Claxon
15 Claxon
enabled enabled enabled
Solenoid
Limit switch valve
16 Shear down
activated activated
Decrease
Select engine rpm - Select
17 Rpm decreasing
variable 1 Select variable 3
variable 2
Automatic Automatic
Cycle in Cycle
18 cycle Cycle active cycle not Start / Stop cycle
pause selection
enabled enabled
Engine Stop the
Engine start and
19 Engine on Fuel reserve preheating Engine stop engine
claxon activation
plugs starting
Over 5
Automatic Automatic second in
Automatic cycle in M Automatic cycle in H Automatic order to
Automatic
cycle in L cycle + Setup 2 cycle + Setup 3 cycle + Select compacting activate
20
expulsion in Crane expulsion in Automatic expulsion in force L-M-H setup 1,2,3
Setup1 L M H with push
always acceleration
enabled not enabled buttons 12
e 17.

SB5000/700 Pag. 27
21 Multifunction display

22 Main switch

23 Emergency push button

24 Alarms control

25 Dashboard main switch

26 Rotation lights

27 Windshear wiper

28 Magnet on-off switch

29 Magnet magnetize-demagnetize switch

30 Engine display (see Murphy User Manual)

3.4 MULTIFUNCTION DISPLAY

Start-up
This page is show for 5 seconds after the engine
startup.
Use the multidirectional pad in order to change
page.

Main menu
From this page use the arrows in order to select
the page to show

Pag. 28 SB5000/700
 This message remember to the operator to have
the baler ejection way free for the discharge of
material. In order to proceed is necessary confirm
with YES push button.

Engine page
In this page are show:
 Engine RPM
 Fuel level
 Coolant temperature
 Hour-meter
 Engine oil pressure
 Battery volt
 Air filter clogged lamp
 Engine preheating plugs lamp

Automatic cycle page

Use the arrows in order to select the automatic
cycle and the compacting force.

Cycle option page

Use the arrows in order to select the compacting
force or the bale length.

SB5000/700 Pag. 29
 Pressure gauge page
In this page are show the hydraulic circuit
pressure.

Transducers page
In this page are show the values of
pressure/temperature transducers installed on
the machine.

Alarms page
In this page are show all the alarms indicates a
paragraph 3.4.1.

Configuration page
From this page is possible change the language
and display brightness.

Pag. 30 SB5000/700
3.4.1 ALARMS
001 EMERGENCY
002 Engine Oil Pressure disconnected
003 Engine Water Temp.disconnected
004 Alternator D+ Fault
005 Alternator W Fault
006 Overflow Total Hourmeter
007 Overflow Partial Hourmeter
008 Air Filter Clogged
009 Switch Door 1 Open
010 Switch Door 1 Closed
011 Switch Door 2 Open
012 Switch Door 2 Closed
013 Switch Pusher Back
014 Pusher Forward
015 Switch Bulkhead High
016 Switch Bulkhead Low
017 Switch Door 1 Slow
018 Swicth Door 2 Slow
033 Manipulator Ps disconnected
057 Cabinet Keyboard Fault
058 Cabinet Display Fault
059 PLC Baler Box 1 Fault
060 PLC Engine Skid Fault
061 Dashboard Keyboard Fault
062 PLC Cabine Fault
063 Dashboard Display Fault
065 Baler 30bar Ps w.broken
066 Baler 30bar Ps s.circuit
067 Baler 30bar Ps overload
068 Baler 30bar Ps LOW pressure
069 Baler 30bar Ps HIGH pressure
070 Hydraulic Block Ps w.broken
071 Hydraulic Block Ps short circuit
072 Hydraulic Block Ps overload
073 Hydraulic Block LOW pressure
074 Hydraulic Block HIGH pressure
075 Feet-Crane Ps w.broken
076 Feet-Crane Ps s.circuit
077 Feet-Crane Ps overload
078 Feet-Crane Ps LOW pressure
SB5000/700
093 Open Door 2 valve w.broken
094 Open Door 2 valve s.circuit
095 Open Door 2 valve no voltage
096 Pusher Forward valve w.broken
097 Pusher Forward valve s.circuit
098 Pusher Forward valve no voltage
099 Pusher Backward valve w.broken
100 Pusher Backward valve s.circuit
101 Pusher Backward valve no voltage
102 Bulkhead Up valve w.broken
103 Bulkhead Up valve s.circuit
104 Bulkhead Up valve no voltage
105 Bulkhead Down valve w.broken
106 Bulkhead Down valve s.circuit
107 Bulkhead Down valve no voltage
128 Plc Electric Cabinet Fault
129 Oil Temp.Sensor disconnected
130 Oil Temp Sensor s.circuit
131 Oil Temp Sensor overload
132 Hydraulic Oil LOW Temp.
133 Hydraulic Oil HIGH Temp.
134 Fuel LOW Level
135 Hydraulic Oil MIN Level
136 OIL Filter 1 Clogged
137 OIL Filter 2 Clogged
138 Conditioner valve w.broken
139 Conditioner valve s.circuit
140 Conditioner valve overload
141 Conditioner valve disconnected
142 Conditioner valve no voltage
143 Oil Radiator valve w.broken
144 Oil Radiator valve s.circuit
145 Oil Radiator valve overload
146 Oil Radiator valve disconnected
147 Oil Radiator valve no voltage
148 OUT02 Wire Broken
149 OUT02 Short Circuit
150 OUT02 Without Voltage
151 OUT03 Wire Broken
152 OUT03 Short Cicuit
Pag. 31
 079 Feet-Crane Ps HIGH pressure 153 OUT03 Without Voltage
080 Close Door 1 valve w.broken 154 OUT08 Wire Broken
081 Close Door 1 valve s.circuit 155 OUT08 Short Circuit
082 Close Door 1 valve overload 156 OUT08 Without Voltage
083 Close Door 1 valve disconnected 157 OUT09 Wire Broken
084 Close Door 1 valve no voltage 158 OUT09 Short Circuit
085 Open Door 1 valve w.broken 159 OUT09 Without Voltage
086 Open Door 1 valve s.circuit 160 OUT10 Wire Broken
087 Open Door 1 valve overload 161 OUT10 Short Circuit
088 Open Door 1 valve disconnected 162 OUT10 Wire Broken
089 Open Door 1 valve no voltage 163 OUT11 Wire Broken
090 Close Door 2 valve w.broken 164 OUT11 Short Circuit
091 Close Door 2 valve s.circuit 165 OUT11 Without Voltage
092 Close Door 2 valve no voltage 192 Plc Electric Cabinet Fault

3.4.2 RADIO REMOTE CONTROL

F1 Remote control enable push button G6 Close door 1

F2 Open door 2 G7 Upwards shear
F3 Increase engine speed G8 Free
F4 Downwards blocking sheet G9 Start automatic cycle
F5 Start diesel engine G10 Stop automatic cycle
F6 Open door 1 G11 Forward compacting cylinder
F7 Downwards shear G12 Backward compacting cylinder
G2 Close door 2 G13 Open bulkhead
G3 Decrease engine speed G14 Close bulkhead
G4 Upwards blocking sheet Stop relay Emergency shutdown push-button
G5 Stop diesel engine 0/1 Remote control enable key
NOTE: Refer to the radio remote control manual

Pag. 32 SB5000/700
3.4.3 ACOUSTIC AND LIGHT INDICATORS

The machine is provided with acoustic and light

indicators for identification of working phases
during the automatic cutting cycle.
The baler unit is equipped with a three lamps. The
shear unit is equipped with a column composed of
three lamps and one acoustic buzzer (positions
indicated by the arrow in the right figure).
The function and signalling logic is described as
follows:

Baler unit:
Red lamp: Compacting cylinder forward and
backward
Orange lamp: Compacting cylinder and doors 1,2 in
max pressure (max circuit pressure)
Green lamp: Compacting cylinder completely
backward
Buzzer: Before opening doors (only in
automatic cycle)
Horn: Doors 1,2 close

Shear unit:
Red lamp: Shear lowered

Orange lamp: Automatic grease system breakdown

Green lamp: Shear raise

Buzzer: End shear automatic cycle

SB5000/700 Pag. 33
3.5 MACHINE IDENTIFICATION

The serial number of the machine is marked on a

metal plate (see figures).
The serial number of the diesel engine is marked
on a metal plate on the engine block.

CE Plate

Pag. 34 SB5000/700
3.6 MACHINE MAIN WORDINGS

MAX LIFTING

SB5000/700

CAUTION:
MOVING REMOTE-
PARTS CONTROLLED
MACHINE

HIGH
TEMPERATURE NO CLIMBING

SB5000/700 Pag. 35
3.7 MACHINE STARTING

3.7.1 START-UP

At start up perform what follows:

1. Make sure that the machine has its own:
- CE declaration
- Diesel engine manual
- Radio remote control manual
- Grapple 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 radio remote control batteries
6. Check of the machine to verify if there are leaks in the following components and plants:
- Hydraulic system
- Door closing cylinders
- Compacting cylinder
- Bulkhead cylinder
- Outriggers cylinders
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
15. Verify the state of painting
16. Check the tightening of the compacting cylinder collar
17. Perform an idling test under all the expected working conditions
18. Verify the good working of the lighting installation
19. After the tests have been performed verify if there are leaks
20. Work after adapted period of heating

The machine will be delivered with the correct lubricant level in the engine and in the turret rotation
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.

CAUTION
Before starting the machine the operator in charge
has to read this manual thoroughly

Pag. 36 SB5000/700
3.7.2 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
8. Verify the state of painting
9. Verify the grease level and the efficiency of greasing system
10. Check the tightening of the compacting cylinder collar
11. Verify the power level of the radio remote control batteries
12. Verify the battery power level and connection
13. Verify the hydraulic oil and fuel level
14. Verify the absence of accumulation of the compacting cycle residuals or dust by the compacting
cylinder head
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 is not satisfying calling
Colmar After Sales Service.

3.8 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.

3.8.1 MACHINE IDLE FOR A SHORT PERIOD

1. Rest the machine in a safe position (doors 1,2 close, compacting cylinder in transport configuration
and mobile bulkhead close, blocking sheet and shear completely lowered, arms in a safe position,
tool on the tank of the machine, if the machine has been installed on a truck, wheel chocks, if
necessary).
2. Lock the operator’s cab, remove the key and keep it in a safe place.
3. Disconnect the battery disconnecting device located below the control board
4. Insert the turret rotation check pin.
5. Clean the machine and lubricate all units provided with lubricator.

3.8.2 MACHINE IDLE FOR A LONG PERIOD

As above, moreover:
1. Change the engine oil, the hydraulic oil, the reduction gear oil and replace the filters.
2. Clean the diesel engine air filter.
3. Protect the silencer to avoid the penetration of foreign matters.
4. Spray the entire machine with protective oil.
5. Store the machine in a sheltered, well-aired, and dry and without dust place, if possible, otherwise
protect it against the weather with a plastic sheet.
6. Keep the radio remote control in a safe place.
7. Grease the battery electrodes to protect them against corrosion.
8. Recharge batteries once a month.
9. 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
antifreeze.

SB5000/700 Pag. 37
3.8.3 MACHINE RESTARTING AFTER A LONG IDLE PERIOD

1. Clean the machine carefully.

2. Remove the silencer protection.
3. Locate the batteries and check the electrolyte level and the battery power level.
4. Verify the level of the fuel, hydraulic oil, engine oil and turret rotation reduction gear oil.
5. Lubricate all machine member that require greasing (see paragraph 5.9)
6. Start the engine and let it idle for some minutes.
7. Verify the good working of the emergency and safety devices.
8. Verify the efficiency of the machine controls and warning lamps.

3.9 ROAD CIRCULATION

The machine consists of two main units: the compacting unit and the cutting unit; the units can be
disjoined to allow the machine transport and/or handling.
The machine can be mounted fixed on truck. The compacting and the cutting units have to be split up to
transport the machine onto a truck.
If the machine is transported on a truck prearranged for this transport device, strictly adhere to the
specifications given in the registration of the truck and to all applicable standards, regulations, and laws
as regards road traffic.

CAUTION
Verify that the dimensions and weights of the whole machine comply with the laws in
force as regards road traffic

3.10 REFUELING

The diesel tank must 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.

Pag. 38 SB5000/700
3.11 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.
always clean seizes and the steps of access in cab
from traces of oil, etc in order to avoid to slip

3.12 LIFTING THE MACHINE

On some points on the machine, as illustrated in

the figure (marked with stickers), there are holes for
hooking and lifting the machine.
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.

3.13 COMPACTING UNIT AND SHEAR UNIT CONNECTION

The machine consists of two main units: the compacting unit and the shear unit; the units can be
disjoined to allow the machine transport and/or handling.
Hereafter the machine is referred to as complete when the shear unit is connected to the compacting
one and as disjoined when the shear unit is detached from the compacting one.
IMPORTANT
The machine has to be set up according to Colmar Technik S.p.A. specifications.
It is advisable to dig a hole in front of the sheared material exit whose dimensions are
at least 1 mt (40”) deep, 2 mt (80”) wide and 2 mt (80”) long. This will facilitate the exit
of the sheared material.
CAUTION
The machine in working configuration shall rest on a solid and horizontal ground.
No shim shall be inserted to increase the machine height.
If the machine is delivered fixed on a truck, extend and lower to the ground the
outriggers.
Position the machine so that both the exhaust gas and the hot air coming out of the
radiator grids can disperse freely.
Working configurations different from the above mentioned are not allowed without
written authorisation of Colmar Technik S.p.A.

SB5000/700 Pag. 39
 IMPORTANT
The machine can work both when it is complete and when it is disjoined.
When the machine is complete scrap metal can be compacted and cut; when the
machine is disjoined, the compacting unit can only compact the material.
The shear unit detached from the compacting one cannot work.

In order to use the shear unit installed on the ground follow this steps:
1. Stop the machine and remove the switch
key from the board
2. Remove the hoses for the rear stabilizers
and the two pins.
3. Remove the rear bumber from the truck.

Pag. 40 SB5000/700
 4. Move the truck backward in order to centre
the 4 holes for the pins A and B and inser
them. In order to centre vertically the holes
use the air suspensions of the truck. B

5. Disconnect the electrical plug on the baler

unit and connect it on the shear unit
6. Connect the hydraulic oil pipes which feed
the shear unit and connect the all the
hoses with quick couplings. Two on the top
of the blocking sheet and one for the
greasing system.
7. Open the valves on hydraulic oil pipes
which feed the shear unit.
8. In order to disconnect the shear unit, close
the valves, disconnect all hoses and
electrical plug, and perform the point 1-4 in
reverse order.

In order to install the shear unit on the truck, after performed the steps above, follow this steps:

SB5000/700 Pag. 41
1. Connect the four hoses with quick coupling (two
each side of the machine) to the shear
stabilizers.
2. Oper the four stabilizers of the machine (two on
the shear and two on the baler). Insert the pins
once opened.
3. Remove the screws that fixing the shear unit to
the floor/base.
4. Use the truck air suspensions in order to lift the
baler and the shear of some centimeters.
5. Move the truck forward for at least 2 meters.
6. Strat the machine and lower the four stabilizers
until the ground.
7. Switch off the machine.
8. Close the valves on the hydraulic oil tank and
remove the two pipe extensions and connect
directly the hoses (see picture).
9. Remove all the screw rods that fixing the
machine to the truck.
10. Now use the truck air suspensions in order to
lower the truck of some centimeters. Se the
machine and truck are separated.
11. Move the truck backward and straight for1.5
meters.
12. Use the truck air suspensions in order to lift the
truck and fix the machine to the truck with the
screw rods.
13. Switch on the machine a raise all stabilizators.
Rotate it of 90°.
14. Install the the rear bumber on the truck.

Position of the screw rods between machine and truck.

Pag. 42 SB5000/700
 Travel configuration
In order to remove the shear from the truck foww the steps above in reverse order

SB5000/700 Pag. 43
3.14 COMPACTING CYLINDER POSITIONING

The compacting cylinder rests in a tubular support.

The baling power is discharged on the front side of the support.
Keep clean the thrust cube housing from the compacting cycle residuals to assure the proper rest of the
support of the compacting cylinder head and its relative tubular support.

Avoid the accumulation of the compacting cycle residuals or dust by the compacting cylinder head
(circled in the figure above).
If necessary clean the area by the compacting cylinder head before performing any machine manoeuvre.

DANGER
Clean the area by the compacting cylinder head ONLY when the diesel engine has
come to a complete stop.

Pag. 44 SB5000/700
3.15 GRAPPLE ASSEMBLY

To mount the grapple on the machine, contact the authorized personnel and follow the indications here
below:

Be sure that the grapple has the CE mark.

The equipment must be on flat and compacted ground on a
stable position.

Approach the telescopic arm extremity to the equipment.

Stop the diesel engine.

Connect the two parts with the fitted pin by hammering it in
for all its length.

Fasten the pin with the standard bolt.

Connect the hydraulic hoses taking care to gather and

throw the spilled hydraulic oil away as prescribed by the
regulations in force.

SB5000/700 Pag. 45
 DANGER
Shock and crush danger: pay attention during lifting and transport operations. be
sure that there are no persons in danger of grapple fall.

CAUTION
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.

1.1 MAGNETIC PLATE ASSEMBLY

To mount the magnetic plate on the machine, contact the authorized personnel and follow the indications
here below:

Be sure that the plate has the mark CE. Install on the machine the fork with lifting hook
The magnetic plate must be on flat and compacted following the instructions at previous point.
ground in stable position. Approach the arm extremity to the equipment.

Switch off the engine and lock the cab door. Join the Connect the electrical cable of the magnetic
plate eyelets with certificated steel cable. plate to the plug located on the arm extremity.
DANGER
Fulguration danger. Be sure that the upstream electric system is off while
connecting the plug.
Shock and crush danger: pay attention during lifting and transport operations. be
sure that there are no persons in danger of plate fall.

Pag. 46 SB5000/700
4 USE OF THE MACHINE

CAUTION
DO NOT USE THE MACHINE BEFORE HAVING READ THIS
ENTIRE MANUAL.

CAUTION
If the machine is operated by radio 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.

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 SHUT
DOWN PUSH BUTTON (red emergency push button on yellow background) located
on the control board, on the radio remote control, on the dashboard and on the shear
(see chapter 6).

CAUTION
In case of emergency stop of the machine by means radio remote control, to re-enable
it is necessary turn off than turn on.

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 and SCP except).
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
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.

SB5000/700 Pag. 47
4.1 ENGINE START

The diesel engine can be started without distinction

from the dashboard in the operator’s cab, from the
control board or from the remote control (see
paragraph 3.3).

To feed the machine electrical system it is

necessary to activate 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° clockwise until it retracts of
approximately 2 cm [1’’].
To bring the battery disconnecting device out of action turn the lever of 90° counter clockwise until it
protudes of approximately 2 cm [1’’].

To start the engine from the control board:

Turn the main switch 22, than press the start diesel engine button 19. The engine starts after 4 seconds.
To start the engine from the radio remote control:
Turn the main switch 22 (on the control board), turn the a on left side of the radio remote control in 1
position then press the remote control enable push button F1 on left side of the radio remote control,
than press start diesel engine F5. The engine starts after 4 seconds.
To start the engine from the dashboard:
Turn the main switch 18 (on the control board), turn the main switch 22 (on the dashboard) then press
the start diesel engine button 19. The engine starts after 4 seconds.

NOTE: Before repeating the engine starting, make sure that both the engine and the starter are off.
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 on the dashboard:
1. To govern the engine revolutions from the control board or the dashboard, use the
push buttons 12 and 17.
2. To govern the engine revolutions from the radio remote control push the lever F3
G3 upwards or downwards.

4.1.1 COLD STARTING

Before using the machine, let the pumps idle for 15 minutes with diesel engine at mean rpm.

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 20 m [65’].

Pag. 48 SB5000/700
4.2 ENGINE STOP

The machine diesel engine can be stopped from the control board or from the remote control the diesel
engine can’t be stopped from the dashboard in the operator’s cab.
To stop the engine from the control board:
- Turn the main switch 22
To stop the engine from radio remote control:
- Move the lever in G5 position
To stop the engine in emergency cases:
- Press any emergency shut down push button (red emergency push button on yellow background)
on the dashboard or on the control board 23, on the right side of the radio remote control (STOP
RELAY) and on the shear unit. Moreover refer to chapter 6 of this manual.

4.3 MATERIAL TO 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:

 Unitized body frame car housing All materials not explicitly mentioned in “Materials
 Household appliances which can be compacted” and especially:
 Light scrap metals  Side member frame car housing
 Light scrap (classification CECA cat. 50, 50/SC,  Electrical and explosion engines
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 [0,12’’].
 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

CAUTION
Colmar Technik S.p.A. shall not be liable for any damage to the machine caused by
the compacting of materials which MUST NOT be compacted.

SB5000/700 Pag. 49
4.4 CRANE HYDRAULIC CAB POSITIONING

The crane hydraulic cab can be rotated to reduce

the height of the machine.
The rotation, which allows the cab tipping, is made
by means of a hydraulic cylinder.
This has to be made to observe the overall
dimensions stated in the rule of the road as for
transport.

NOTE: the following instructions are necessary to

perform the tipping of the crane’s cab. If some of
them have already been done, go to the next point.

Security screw

4.4.1 CAB LOWERING (TRANSPORT POSITION)

To let the crane’s cab down follow these instructions:

1. Remove any object from the crane’s cab
2. Stop the machine diesel engine
3. Lock the door
4. Find the distributor which feeds the hydraulic oil
to the bulkhead / cab tipping cylinder (see in the
right photo).
5. Unhook the cab basement chain from the lock
welded on the machine steel structure.
6. Link the two female quick coupling with the
male quick coupling ones welded on the cab
tipping cylinder. The hose connecting sequence
is irrelevant: if the hoses are inverted the
cylinder movement is inverted, too.
7. Start the machine diesel engine by means of the starting board control.
8. Pull the lever placed on the distributor. Keep the lever pulled until the cab has been completely
lowered.
9. Stop the machine diesel engine.
10. Insert the turret rotation check pin.
11. Hook the cab basement chain from the lock welded on the machine steel structure and stretches it
acting on the screw coupling.
12. Insert the security screw between the front cabin protection and the baler.
13. Hang the hydraulic hoses which link the cab (wrapped in the blue gaiter) to the hook welded on the
machine steel structure.

4.4.2 CAB LIFTING (WORKING POSITION)

NOTE: the following instructions are necessary to perform the tipping of the crane’s cab. If some of them
have already been done, go to the next point.

To lift the crane’s cab follows these instructions:

Pag. 50 SB5000/700
1. Find the distributor which feeds the hydraulic oil to the bulkhead /cab tipping cylinder.
2. Loose the chain screw coupling and remove it from the cab basement to the lock welded on the
machine steel structure.
3. Remove the security screw between the front cabin protection and the baler.
4. Link the two female quick coupling with the male quick coupling ones welded on the cab tipping
cylinder. The hose connecting sequence is irrelevant: if the hoses are inverted the cylinder
movement is inverted, too.
5. Start the machine diesel engine.
6. Pull the lever. Keep the lever pulled until the cab has been completely lifted.
7. Stop the machine diesel engine.
8. Hook the cab basement chain from the lock welded on the machine steel structure.
9. Remove the turret rotation check pin.
10. Release pressure in the hoses by pulling repeatedly the lever.
11. Disconnect the two female quick coupling with the male quick coupling ones welded on the cab
tipping cylinder.

CAUTION
The last point avoids the shearing of the hydraulic hoses during the turret rotation.

4.5 TURRET ROTATION LIMITING DEVICE

By the loading crane fifth wheel 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 baler box doors, if these are open.
Any turret rotation performed by the operator,
which can cause impacts, will be locked.

4.5.1 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.

SB5000/700 Pag. 51
 CAUTION
If the rotation limiting device is cut out, no protection will avoid possible impacts
between the lifting device and the baler box doors, should these be open.
Therefore turn the turret very carefully.

4.6 TURRET ROTATION CHECK PIN

During the transport of the machine insert the

check pin placed on the circle of the loading crane
fifth wheel to lock the rotating turret in a fixed
position.
The lower fixed locator shall correspond to the
mobile upper one.
During working remove the pin.

4.7 AIR CONDITIONER (OPTIONAL)

If the crane is equipped with a manual air

conditioner, it concurs to cool and to heat the air
inside the cabin. The air conditioner work only
when the diesel engine is on.
Is possible change the air direction moving the
aerators.
Start the engine and select the fan speed and the
temperature with panel on the left armrest.

Pag. 52 SB5000/700
4.8 DRIVING PLACE

4.8.1 SAFETY PUSH BUTTON

To perform any manoeuvre of the loading crane, press the push button
placed at the top of the handles. 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 65
ft.

4.8.2 RIGHT HANDLE

The right handle governs the grapple

open/close and the boom up/down.
The following movements can be
carried out:
A Grapple open
B Grapple close
C Boom down
D Boom up

4.8.3 LEFT HANDLE

The left handle governs the turret swing

and the arm up/down.
The following movements can be
carried out:
E The turret swing rightwards
F The turret swing leftwards
G Arm down
H Arm up
NOTE: The manoeuvres concerning the turret swing and the arm up/down are proportional. Reduce the
movement speed in the proximity of the max. lifting.

SB5000/700 Pag. 53
4.8.4 TELESCOPIC ARM CONTROL PUSH
BUTTONS

The push-buttons placed on the right handle

govern the positioning of the crane telescopic arm.

4.8.5 BUCKET ROTATION CONTROL PUSH

BUTTONS

The push-buttons placed on the left handle govern

the clockwise or counter clockwise rotation of the
grapple at the end of the telescopic arm to orient
the load.

4.9 MAGNETIC PLATE

In order to activate the magnetic plate generator use the switch no. 28 on the dashboard.
In order to magnetize-demagnetize the magnetic plate use the switch no.29 on the dashboard.

4.10 MACHINE STABILIZATION (OPTIONAL)

When working the machine must be stabilized by

lowering the two cylinders placed under of the
crane and at the end of the baler/shear.
During the machine transport the cylinders shall be
retracted and the two under the crane turned
internally.
To lower and lift the cylinders act as follows.

DANGER
To stabilize the machine it is necessary to avoid the machine overturning when the
tank doors are open.

Pag. 54 SB5000/700
 4.10.1 CYLINDER LOWERING (WORKING
POSITION

- Remove the pin of the extraction block placed

on the inner side of the cross member by
turning it of 90° then extract it.
- Manually extend the part of the cross member
outwards until the hole on the cross member
and the hole on the extractable part overlap.
- Put the pin back onto the inner side of the
cross member.
- Open the valves placed on the stabilizer
- Start the machine diesel engine.
- Pull the lever until the all stabilizer have been
completely lowered
- Close the valves placed on the stabilizer.
- Stop the machine diesel engine.

In case of transport close the two stabilizers under

OPEN
the crane and remove the other two stabilizer.

CLOSE

SB5000/700 Pag. 55
4.11 MATERIAL LOADING

DANGER
The material to be compacted shall be loaded into the baler box ONLY by
means of MECHANICAL DEVICES (self propelled crane or crane provided)
complying with the use instructions contained in the relevant manual.

Before loading the baler box be sure that the

mobile bulkhead is closed
Doors 1 and 2 shall be completely open during
material loading.

The material loaded must comply with the carrying

capacity of the machine.

The level of the material loaded into the baler box

shall never exceed the height of the baler box
restraining sheet (see figure).

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 SHUT
DOWN PUSH BUTTON (red emergency push button on yellow background) located
on the control board, on the radio remote control, on the dashboard (see chapter 6)
and on the shear unit.

CAUTION
Avoid crushing inside the machine baler box by using the holding device of the lifting
equipment used to load the material.

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.

4.12 BULKHEAD POSITIONING

The bulkhead can be open/close from the control board, from the radio remote control and from
dashboard.
To open/close the bulkhead from the control board/dashboard:
- Use push buttons 4 (up) or 9 (down)
To open/close the bulkhead from the radio remote control:
- Move the lever G13 G14 up/down

The bulkhead must be close when the material must be compacted.

Pag. 56 SB5000/700
4.13 BALING

The material can be compacted from the control

board, the radio remote control and the dashboard:
To compact the material from the
control board/dashboard:
- Close the door 1, use pushbutton 6.
- Close the door 2, use pushbutton 7.
To compact the material from the radio
remote control:
- Close the door 1, move the lever in G6
position
- Close the door 2, move the lever in G2
position

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 baling the doors 1 and 2 shall
be completely closed and the angle between the
doors must be 90°. If necessary, insist on the
controls to be sure the doors are closed.
In the right below figure you can see the
dimensions of the compacted material.
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) before any machine
maneuver (refer to paragraph 3.13.)

DANGER
Before compacting, make sure that the tanks of materials loaded into the baler box
(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 baler box.

SB5000/700 Pag. 57
 IMPORTANT
If the orange rotating light lights up during doors 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.

4.14 MATERIAL CRUSHING

To complete the material baler box it is necessary to operate the compacting cylinder.
The compacting cylinder can be moved from the control board, the radio remote control and the
dashboard:
To crushing the material from the control board/dashboard:
- Move the compacting cylinder forward, use pushbutton 8.
To crushing the material from the radio remote control:
- Move the compacting cylinder forward, move the lever in G11 position
Before move the compacting cylinder make sure that the bulkhead is close.

CAUTION
The compacting cylinder can be operated 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.

4.14.1 COMPACTING FORCE SELECTION

From the display 21 on the control board/dashboard is possible to select the compacting force. 3
degrees of compacting force are available Low-Medium-High.

4.15 MATERIAL EXPULSION

Before ejecting the compacted material retract the compacting cylinder of 10-20 cm [0,4-0,8’’] to reduce
pressure on the bulkhead and open little door 1 to reduce the pressure on the doors:
To reduce the pressure on the bulkhead from the control board/dashboard:
- Move backward the compacting cylinder, use the pushbutton 3.
To reduce the pressure on the bulkhead from the radio remote control:
- Move the compacting cylinder backward, move the lever in G12 position
Before ejecting the compacted material make sure that the bulkhead is opened, the blocking sheet and
shear have been raised.
To ejecting the material from the control board/dashboard:
- Move the compacting cylinder forward, use the pushbutton 8.
To ejecting the material from the radio remote control:
- Move the compacting cylinder forward, move the lever in G11 position

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 radio remote control.

4.16 MATERIAL SHEARING (ONLY SB5000/700)

The material shearing can only be carried out if doors 1 and 2 are completely closed. The machine is
equipped with a lot of micro-switches that assure a safe material shearing.

Pag. 58 SB5000/700
To stabilize the material from the control board/dashboard:
- Move lower the blocking sheet, use pushbutton 10.
To stabilize the material from the radio remote control:
- Move lower the blocking sheet, turn the lever in F4 position
To shear the material from the control board/dashboard:
- Move lower the shear, use pushbutton 16
To shear the material from the radio remote control:
- Move lower the shear, turn the lever in F7 position

4.17 AUTOMATIC BALING CYCLES

The automatic mode can be activate from the display 21 on the control board/dashboard choosing
between four cycles and 3 degree of compacting force
- Cycle 0 Baling
- Cycle 1 Baling and bale’s expulsion
- Cycle 2 Pre-baling and shearing
- Cycle 3 shearing
The selection of cycle can be made acting on the display.
To activate the automatic mode from the control board/dashboard:
- Push the START CYCLE button 18
To stop the automatic mode from the control board:
- Push the STOP CYCLE button 18
To activate the automatic mode from the radio remote control:
- Move the lever in G9 position
To stop the automatic mode from the radio remote control:
- Move the lever in G10 position
To stop the automatic mode in emergency cases:
- Press any emergency shut down push button (red emergency push button on yellow background)
on the control board/dashboard 23, and on the right side of the radio remote control (STOP
RELAY) or around the machine. Moreover refer to chapter 6 of this manual.

4.17.1 BALING (AUTOMATIC CYCLE 0)

To activate the automatic cycle doors 1, 2 and bulkhead must be closed and the compacting cylinder
completely backward. When these conditions are verified on the control board ignites the luminous push-
button start cycle 18. During the automatic cycle the luminous push-button start cycle 18 will flash.
The cycle sequence is:
1. The compacting cylinder move forward until that it does not catch up the pressure set up based on
the degree of compacting force selected (L-M-H)
2. The compacting cylinder move backward
3. Doors 1 and 2 opens

4.17.2 BALING AND BALE’S EXPULSION (AUTOMATIC CYCLE 1)

To activate the automatic cycle doors 1, 2 and bulkhead must be closed, compacting cylinder completely
backward, blocking sheet and shear upwards When these conditions are verified on the control board
ignites the luminous push-button start cycle 18. During the automatic cycle the luminous push-button
start cycle 18 will flash.
The cycle sequence is:
1. The compacting cylinder move forward until that it does not catch up the pressure set up based on
the degree of compacting force selected (L-M-H)

SB5000/700 Pag. 59
2. The compacting cylinder move backward for about 10-20 cm [0,4-0,8’’] to reduce pressure on the
bulkhead and open little door 1 to reduce the pressure on the doors
3. The bulkhead open
4. The compacting cylinder move forward pushing outside the compacted material
5. The compacting cylinder move backward
6. Doors 1 and 2 opens and bulkhead close

4.17.3 PRE-BALING AND SHEARING (AUTOMATIC CYCLE 2)

To activate the automatic cycle doors 1, 2 and bulkhead must be closed, compacting cylinder completely
backward, blocking sheet and shear upwards When these conditions are verified on the control board
ignites the luminous push-button start cycle 18. During the automatic cycle the luminous push-button
start cycle 18 will flash.
The cycle sequence is:
1. The compacting cylinder move forward in regenerative mode until that it does not catch up the set
up pressure
2. The compacting cylinder move backward for about 10-20 cm [0,4-0,8’’] to reduce pressure on the
bulkhead and open little door 1 to reduce the pressure on the doors
3. The bulkhead open
4. The compacting cylinder move forward pushing outside the pre-compacted material of the length
set up from the timer
5. The blocking sheet move downward
6. The shear move downward
7. The blocking sheet move upward
8. The shear move upward
Note: Steps 4,5,6,7,8 repeat until the compacting cylinder has arrived at end of stroke
9. The compacting cylinder move backward
10. Doors 1 and 2 opens and bulkhead close

4.17.4 SHEARING (AUTOMATIC CYCLE 3) (ONLY SB5000/700)

To activate the automatic cycle doors 1, 2 and bulkhead must be open, blocking sheet and shear
upwards When these conditions are verified on the control board ignites the luminous push-button start
cycle 18. During the automatic cycle the luminous push-button start cycle 18 will flash.
The cycle sequence is:
1. The compacting cylinder move forward pushing outside the material of the length set up from the
timer
2. The blocking sheet move downward
3. The shear move downward
4. The blocking sheet move upward
5. The shear move upward
Note: Steps 1,2,3,4,5 repeat until the compacting cylinder has arrived at end of stroke
6. The compacting cylinder move backward
7. Doors 1 and 2 opens and bulkhead close

4.18 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 on the display 21 on the control board/dashboard.

Pag. 60 SB5000/700
 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 compacting 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 Technik S.p.A. is not responsible for any accident and/or problems
caused by tampering with the calibration values.

SB5000/700 Pag. 61
5 MAINTENANCE

CAUTION
Maintenance must be exclusively carried out by Colmar 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 Service

5.2 GENERAL MAINTENANCE PROCEDURE

 All the maintenance operations must be carried with engine switch off and main switch disconnect to
the control board, to the dashboard and to the radio remote control
 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
enter the lubricant.
 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.

Pag. 62 SB5000/700
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 control panel). Approximately 10
hours correspond to a workday, 50 hours to a week, 250 hours to a month and 2000 hours to a year.
Machine maintenance chart:
HOURS OPERATION LUBRICANT
Check hydraulic oil level Classification ISO HV 46
Pins greasing Consistency NLGI 2
10 Pusher cylinder greasing Consistency NLGI 2
Blocking sheet slides greasing [SHEAR] Consistency NLGI 2
Check grease level of automatic greasing system tank Consistency NLGI 2
Check hydraulic system filter cartridge
Check bolts tightening
Check fittings tightening
50
Pinion, slew bearing, telescopic arm pins, articulated joints and sliding
Consistency NLGI 2
blocks greasing [CRANE]
Check blocking sheet and shear slides [SHEAR]
Check hydraulic system slips
First change of hydraulic oil filter cartridge
100
External cleaning of the heat exchanger
Check shear blades [SHEAR]
Shear blades change [SHEAR]
250
Check coupling gear oil level Viscosity class ISO VG 150
Clan magnetic rod
500 Change hydraulic oil tank breather filter
Change hydraulic oil filter cartridge
Change coupling gear oil Viscosity class ISO VG 150
1000
Check turret rotation reduction gear oil [CRANE] Viscosity class ISO VG 150
2000 Change of hydraulic oil and cleaning of tank Classification ISO HV 46
2500 Change turret rotation reduction gear oil [CRANE] Viscosity class ISO VG 150
Rev. 04 22-09-09

See the engine manual for the engine maintenance chart.

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.

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 [113°F] ).

5.6 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.

SB5000/700 Pag. 63
5.7 GREASING

According to the maintenance chart, all elements provided with lubricator shall be greased with NLGI 2
consistency grease.
If the machine is used in heavy-duty conditions, grease the elements more frequently.
The lubricators are identified by colored 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 colored 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 (boom, arm and telescopic arm)
and of the grapple, and on the cab tipping cylinder.

Pag. 64 SB5000/700
Fifth wheel tooting greasing:
Before greasing the loading crane fifth wheel
tooting, remove by means of a spatula the old
grease which gathers on the rims of the pinion gear
and of the fifth wheel tooting, and then smear the
fifth wheel tooting with new grease by means of a
spatula or a brush.
After having greased the fifth wheel tooting rotate
sometimes the turret to distribute the new grease
on the whole tooting circumference.

Telescopic arm greasing:

Before greasing the telescopic arm, remove by
means of a spatula the old grease which gathers
on the rims of the telescopic arm itself, then smear
the telescopic arm with new grease by means of a
spatula or a brush.
After having greased the sliding blocks, draw the
telescopic arm in and out many times to distribute
the new grease on the whole length of the sliding
blocks guide.

Compacting cylinder greasing:

The compacting cylinder outer liner shall be
greased by means of a brush.
To grease act as follows:
- Place the machine in working configuration
(paragraph 3.14.2);
- Grease by means of a brush and smear the
liner for about 1m [3’4’’] starting from the collar
towards the external part of the machine with
NLGI 2 consistency grease;
Place the machine in transport configuration (draw
the compacting cylinder inside the baler box) as
described at paragraph 3.14.2.
Mobile bulkhead greasing:
Use the lubricators on the picture in order to grease
the mobile bulkhead guides.

SB5000/700 Pag. 65
5.7.1 SHEAR AUTOMATIC GREASING
SYSTEM

The shear sliding guides and the blocking sheet

sliding guides require constant greasing to avoid
early wear.
The machine is equipped with a system for the TANK
automatic greasing of the cutting unit guides and RELIEF VALVE
blocking sheet guides.
When the machine work in automatic cycles 2 or 3
or when the shear is used in manual mode the
automatic greasing system provide to send a fixed
quantity of grease in all greaser points.

The automatic greasing system is provided of a DISCHARGE

cycle sensor that checks up on the effective GREASE
lubrication of all greasing points.
RECHARGE
If the sensor doesn’t signal the grease transit, send TANK
a breakdown signal, turning on the orange light on
the column and turning off the engine.

To reset the breakdown check the grease level on

the tank and add NLGI 2 consistency grease if
necessary from the recharge point.

CAUTION
Add grease only by recharge tank point, where a
filter provides to clean it.
DON’T RECHARGE FROM THE OVERHEAD
SIDE OF TANK

If the grease circuit empties him, use the recharge

circuit point to provide to fill it.
If circuit is clogging a relief valve provide to
discharge grease through a hose.

Pag. 66 SB5000/700
5.8 HYDRAULIC SYSTEM

5.8.1 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.

5.8.2 CRANE ROTATING JOINT

The rotating joint needs extraordinary maintenance

only when the internal gaskets are worn.
Check regularly the seal between the hose unions
and the rotating joint and verify the tightening of
the supporting brackets bolts.

5.8.3 HYDRAULIC SYSTEM

Check the hose 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 figure in side is for example. Check all
connections sealing.

SB5000/700 Pag. 67
5.8.4 HYDRAULIC OIL

Check the oil level in the tank, in according to the

maintenance chart, by means of the level gauge
placed under the filling cap (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, in according to the

maintenance chart, and clean the tank internally.
Oil level

To change the hydraulic oil remove the tank filing

cap, 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 compacting cylinder and the
loading crane cylinders.
Tank filing cap

The hydraulic oil shall be disposed of according to

the law in force.

Pag. 68 SB5000/700
5.8.5 MAGNETIC ROD

Inside the machine oil tank one magnetic rod have

been installed to catch the ferrous impurities in the
plant.
Clean the magnetic rods, in according to the
maintenance chart, and clean the tank internally.
To remove the rod unscrew the nut installed askew
on the oil tank top, take out the rod, clean it with a
wiping cloth and put it back in its seat.

Magnetic rod

5.9 FILTERS

5.9.1 HYDRAULIC OIL FILTER AND AIR BREATHER FILTERS

Oil filters must be regularly checked as clogged Air breather

filter reduces the machine performances and can filters
also lead to the collapse of the filter element with
the consequent contamination of the hydraulic
system and serious damage to the hydraulic
components. Hydraulic oil
filters
IMPORTANT: At the beginning of the machine
service life filter must be replaced more frequently.
Replace the hydraulic system filter in according to
the maintenance chart.
Shorter intervals between filter replacements will be
scheduled, if the machine works in very dusty
areas.

Moreover replace the air breather filters in

according to the maintenance chart.

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.

5.10 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 fifth wheel 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.

SB5000/700 Pag. 69
5.11 TELESCOPIC ARM SLIDING BLOCKS

Check periodically the thickness of the telescopic

arm sliding block of the loading crane. The min.
thickness shall not be lower than 5 mm [0,2’’].
Should the thickness of the sliding blocks be lower
than 5 mm [0,2’’], 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 telescopic arm.

5.12 TURRET ROTATION REDUCTION

GEAR

Check the oil level in the turret rotation reduction

gear, in according to the maintenance chart, 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, in according

to the maintenance chart, 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.

Pag. 70 SB5000/700
5.13 BATTERIES

Batteries are installed behind the hydraulic 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 Batteries
positive pole (+) and then the negative pole (–).
 Unscrew the metallic bracket to remove the
battery.
 Clean periodically clamps joints and grease
them with antioxidant.

5.14 FUSES

In case of short circuit do not replace any fuse before having verified the reasons and having repaired
the fault. The fuse are in the control board and on the right of the dashboard.

5.15 RADIATOR – HEAT EXCHANGER

Check the coolant, in according to the maintenance

chart, only when the engine is cooled.
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. 1
2
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.
Change the coolant in according to the maintenance chart.
 Remove the filler(1) on the expansion vase and unscrew the plug (2) under the radiator. Change the
coolant when the engine is tepid.
 Let flow all the coolant and screw again the plug placed under the radiator (2)
 Pour a detergent anti-incrustation liquid available on the market.
 Start the engine at mean rpm for about 15 minutes.
 Let flow the detergent anti-incrustation solution by unscrewing the plug (2) and at the same time fill
with running water for at least 40 minutes.

SB5000/700 Pag. 71
 Stop the engine, let all the water off, screw the plug (2) again and fill with coolant according to what
stated in the chart 5.8.
Start the engine and check the level after some minutes; if necessary, top up to reach the min. required
level.
Clean the radiator-heat exchanger 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).

5.16 CONTROL OF PRESSURE AND VALVE SETTING

CAUTION
The valve setting stated in this chapter shall be performed only by authorised
workshops or by qualified personnel of Colmar Technik S.p.A., prior consent of the
company.

The here described measurements shall be made with a manometer of at least 400 bar full-scale and
complete with a rubber hose with 16x2 female quick coupling.
The symbol identifies pressure tubes in the hydraulic plan herewith enclosed.
All the pressures of the machine to exclusion of the servocontrol pressure and the pressure on the crane
are measurable from the pressure coupling indicated in figure.

Pag. 72 SB5000/700
5.16.1 MACHINE MOVEMENTS CIRCUIT

Connect the manometer to the measure coupling

indicated in figure, then move a cylinder to the end of
stroke (for example the door 1 or 2 cylinder or the
compacting cylinder) and read the pressure value on
the manometer.
Max allowed pressure 240 bars.
NOTE: To perform this pressure measurement the
diesel engine shall be at peak rpm (1800 rev/min.).

5.16.2 CRANE CIRCUIT

Connect the manometer to the measure coupling

indicated in figure then read the pressure value on the
manometer.
Max allowed pressure 220 bars.

5.16.3 SERVOCONTROL CIRCUIT

Connect the manometer to the measure coupling

indicated in figure then read the pressure value on the
manometer.
Max allowed pressure 30 bars.

CAUTION
If the high pressure valve setting values do not correspond to the above mentioned
ones, apply to Colmar Technik S.p.A. after-sales service.

SB5000/700 Pag. 73
5.17 BLOCKING SHEET AND SHEAR SLIDES (ONLY SB5000/700)

Check the blocking sheet and shear slides wearing, in according to the maintenance chart, 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 blocking sheet are completely up, at half stroke
and at the end of stroke.
DANGER
To check the shear and blocking sheet 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 blocking sheet 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.
1. Unscrew the screws D in order to help the
wedge slide movement
2. Check the screws F tightening (130 Kgm
tightening torque)
3. Screw up the screws E in order to let the
wedge slide move forward to obtain the
prescribed clearance (interposing the 0,3/0,4
mm shim) The clearance must be measured
when shear and blocking sheet are at half
stroke.
4. Screw up the screws D with a 130 Kgm
tightening torque in this sequence 1,2,3 etc

5. Check the screws E tightening

6. 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
Technik S.p.A.

Pag. 74 SB5000/700
NOTE: The slides adjustment must be done on both
sides of the shear (left and right).
Blocking sheet
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 Technik
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 blocking sheet and shear slides
clearance can damage the operation hydraulic cylinders.

SB5000/700 Pag. 75
 5.18 SHEAR BLADES (ONLY SB5000/700)

The shear blades wearing must be checked in

according to the maintenance chart.
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 in according to
the maintenance chart.

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. Blocking sheet 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.

Pag. 76 SB5000/700
5.19 WELDING ON MACHINE

IMPORTANT
Proper welding procedures are necessary in order to avoid damage to the engine’s
engine control module, sensors, PLC and associated components. When possible,
remove the component from the units and then weld the component. If removal of the
component is not possible, the following procedure must be followed when you weld
with a machine that is equipped with an Electronic Engine and PLC. The following
procedure is considered to be the safest procedure to weld a component. This
procedure should provide a minimum risk of damage to electronic components.
IMPORTANT
Do not ground the welder to electrical components such as the engine control module,
PLC or sensors. Improper grounding can cause damage to the drive train bearings,
hydraulic components, electrical components, and other components. Clamp the
ground cable from the welder to the component that will be welded. Place the clamp
as close as possible to the weld. This will help reduce the possibility of damage.

1. Stop the engine. Turn the switched power to

the OFF position.
2. Disconnect the negative battery cable from the
battery. Open a battery disconnect switch.
3. Disconnect the connectors from the engine
control module and from the control board.
Move the harness to a position that will not
allow the harness to accidentally move back
and make contact with any of the engine
control module pins.
4. Connect the welding ground cable directly to
the part that will be welded. Place the ground
cable as close as possible to the weld in order
to reduce the possibility of welding current
damage to bearings, hydraulic components,
electrical components, and ground straps.
5. Protect the wiring harness from welding debris
and spatter.
6. Use standard welding practices to weld the
materials.

Note: If electrical/electronic components are used

as a ground for the welder, or electrical/electronic
components are located between the welder
ground and the weld, current flow from the welder
could severely damage the component.

SB5000/700 Pag. 77
6 EMERGENCY

6.1 EMERGENCY STOP

CAUTION
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 26, on the control board 15 and on the right side
of the radio remote control (STOP RELAY) and on the shear.

6.2 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 handle 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 fifth wheel.

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 boom, arm and
telescopic arm and the grapple manoeuvring can
be performed also without the push buttons placed
under the head of the handle.

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 Technik S.p.A. accepts no liability for any damage and/or accident arising from
the imprudent or wrong manoeuvring.

Pag. 78 SB5000/700
7 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, tires and any other machine parts requiring
separate disposal shall always be disposed of in accordance with applicable regulations by authorised
contractors.

SB5000/700 Pag. 79
8 TROUBLESHOOTING

Problem Cause Solution

No voltage on the  Battery disconnecting activate  Deactivate battery disconnecting
control board  Fuses fault  Replace fuses
 Check all the emergency push
 Emergency push button activate
buttons
 The out liner of pusher cylinder  Check that pusher cylinder collar
not in correct position press the security microswitch
Engine doesn’t start
 Battery disconnecting activate  Deactivate battery disconnecting
 Batteries discharged  Check batteries
 Fuses fault  Replace fuses
Noisy pump  Hydraulic oil viscosity is too high  Use recommended hydraulic oil
 Hydraulic oil level in the tank is too  Top up with hydraulic oil of the same
low type
 Suction hose clogged or crushed  Check duct for integrity
 A flange on the suction hose lets  Check seals and replace gasket
air in
Extreme hydraulic oil  Too low hydraulic oil level in the  Top up with hydraulic oil of the
heating. tank. same type.
 Dirty or clogged exchanger.  Clean exchanger fins and/or check
for internal obstructions.
 Solenoid valve fan protection  Replace fuse.
fuse fault.
 Little cooling water in the radiator  Add cooling water in the radiator.
 Solenoid valve fan fault.  Check solenoid valve fan fault
Slow operation of some  The pressure relief valve on the  Contact Colmar Technik S.p.A.
hydraulic functions distributor related to the circuit
section showing the problem is not
calibrated
 Worn pump  Replace pump
Irregular operation of  Oil slip between the two cylinder  Replace the cylinder gaskets
the oil hydraulic chambers with consequent non-
cylinder lifting of the load.
 Loosen piston/rod connection  Check rod/piston connection
 Pressure relief valve on the  Contact Colmar Technik S.p.A.
distributor jammed or worn
Irregular operation of  Jammed cursor  Replace block valve element
the block valve  Slips inside the distributor  Replace distributor element
 Elements with worn gaskets show  Replace gaskets
signs of oil leaks
 Cursor return spring 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  Check tension
valve

Pag. 80 SB5000/700
 Problem Cause Solution
 The pressure relief valve on the  Disassemble and clean the pressure
distributor jammed or worn. relief valve or replace.
 Pressure relief valve on the  Calibrate the valve.
distributor too low calibrated.
 Antishock valve jammed or dirty.  Replace the valve.
Irregular turret rotation
 Flow control valve not calibrated.  Calibrate the valve.
 Motor pinion-crown gear too much  Replace the motor.
slack.
 Worn fifth wheel.  Replace
 Worn reduction gear.  Replace
 Too much material loaded inside  Load the baler box as stated by this
the baler box. manual.
The doors open when
 Secondary valves on the machine  Contact Colmar Technik S.p.A.
the compacting
feeding distributor not calibrated.
cylinder is operated
 Piston locking valves not  Contact Colmar Technik S.p.A.
calibrated or worn.
 Oil seal on pumps/motors out of  Check hydraulic circuit and replace
Hydraulic oil inside the
seat owing to high pressure in the worn pump/motor.
components
casing.
 Low pilot pressure  Check hydraulic circuit
Servo controls are not  Faulty servo control  Replace
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  Check the microswitches operation.
Remote control is not remote control are non operative
working
 The machine is too far.  Approach the machine
 Fuses fault  Replace fuses
 Hydraulic oil feed valves between  Turn the valves on
compacting and shearing units are
The shearing unit turned off
does not work  Electric outlet between  Check connections between outlets.
compacting and cutting units not
connected.

SB5000/700 Pag. 81
9 HYDRAULIC SYSTEM

9.1 COMPONENT LIST

1 Diesel engine CONVERSION TABLE

2 Coupling gear (bars – PSI)
3 Variable displacement piston pump
4 Gear pump
5 Cooling gear pump
6 Crane movements piston pump
7 Cooling motor and 30 bar gear pumps
8 Relief valve
9 Cooling hydraulic motor
10 Heat exchanger
11 Filter
12 Check valve
13 Baler hydraulic block
14 Pressure sensor
15 Door 1 cylinders
16 Door 2 cylinders
17 Compacting cylinder
18 Shear hydraulic block
19 Blocking sheet cylinder
20 Shear cylinders
21 Auxiliary distributor
22 Mobile bulkhead cylinder
23 Front stabilizers cylinders
24 Lock valves
25 Rear stabilizers cylinders
26 Cabin cylinder
27 Lock valve
28 Quick couplings
29 Choker valve
30 Crane distributor
31 Boom cylinder
32 Arm cylinder
33 Turret rotation hydraulic motor
34 Telescopic arm cylinder
35 Lock valve
36 Choker valve
37 Lock valve
38 Dead man solenoid valve
39 Left handle
40 Right handle
41 Hydraulic joint
42 Priority valves
43 Air conditioning hydraulic motor
44 Valve
45 Magnet hydraulic motor
46 Grapple rotation motor
47 Lock valve

Pag. 82 SB5000/700
9.2 HYDRAULIC CIRCUIT

SB5000-700 MATR.8828
SCHEMA IDRAULICO

111000010

Pag. 83 SB5000/700
 INTENTIONALLY LEFT BLANK

Pag. 84 SB5000/700
10 ELECTRIC SYSTEM

10.1 WIRE COLOUR CODES

WIRE COLOURS
B WHITE V GREEN
G YELLOW R RED
S PINK H GREY
N BLACK M BROWN
L DARK BLUE Z PURPLE
A LIGHT BLUE C ORANGE
Two-color wires are identified with the following symbols:
G/V yellow and green transverse stripes; G-V yellow and green longitudinal stripes
In the electrical system the number by the color shows the wire section in mm2. If no number is by the
color, the wire section is 1 mm2.

Pag. 85 SB5000/700