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Operator`s manual

1. i Valve number 50 Main distributor valve 51 Wrapper arm fast speed 52 Wrapper table tilting speed 53 Wrapper film knife right side speed 54 Wrapper film knife left side speed 55 Chamber tailgate opening speed 56 Feeder table speed 57 Belt under fast speed 58 Belt under slow speed 59 Elevator slow speed 60 Elevator fast speed 61 Net brake 62 Net feeder speed 63 Net brake deactivation 64 Main valve 65 Main valve 66 Main valve 67 Feeder table transport safety valve 68 Feeder table transport safety valve 69 Wrapper arm slow speed 70 Main valve 51 Localization In steel cabinet In steel cabinet Outside steel cabinet front Outside steel cabinet front Outside steel cabinet front In steel cabinet Manifold block outside cabinet rear Manifold block outside cabinet rear Manifold block outside cabinet rear Manifold block outside cabinet rear Manifold block outside cabinet rear Top on HiT unit Top on HiT unit Top on HiT unit Under frame right side Under frame right side Under frame right side Cylinder right side Cylinder left side In steel cabinet on valve block Under frame near wheel right side AN IMPORTANT General rule all hydraulic adjustments Always start adjustment by closing the valve Open gradually until wanted speed is achieved The oil must also have correct operational temperature BASIC By turning the valve clockwise the flow i
2. 2 10 1 Make good and safe routines This machine must under no circumstances be used for any other purpose than the intended one If the operator have to leave the site the tractor or any other power supply must be turned off Remove key to avoid unattended start Do not use loose or baggy clothing due to many rotating parts in the machine 2 10 2 Operator safety OPERATOR MUST be extra observant during mounting new plastic foil under the knife be extra focused on all danger zones during operation be cautious entering the machine to avoid falling check all danger zones before start up to avoid danger situations pay attention to potential danger caused by the machines automatic systems Carry out a test on emergency stop switches and sensors on a regular base to ensure they are in good working order Set the machine in manual before any work is done in the HiT unit net binding due to danger of getting fingers or hand cut pay attention to fire hazard from overheating in bearings or pressing of very dry materials Know the localization of the fire extinguisher Keep close Pay attention to danger of unauthorised personnel entering the machine s stairway danger of falling into hopper feeder The stairway is for authorized personnel only 18 2 10 3 Other peoples safety AN A WARNING The machine has multiple automatic functions who start without warning No unauthorized personnel must be c
3. Grease lubrication Use only grease of NLGI 2 class with extra protection EP additives Recommended type Shell GADUS 3 V220C 2 Statoil Greaseway 92 or similar Amount Approximately number of strokes grease gun until grease become visible Hours of oper Grease nipple number Lubrication point Amount Remark ation 1 2 3 4 Feeder table 4 50 Driving roller 5 6 Feeder table 4 50 Support roller 7 8 Base plate 2 250 9 10 11 12 Feeder table cylinder 2 50 13 14 Elevator 6 50 Support roller 15 16 Elevator 6 50 Driving roller 17 18 19 20 21 22 Belt tensioner chamber 2 50 Rear belt 23 24 25 26 27 28 29 30 Belt tensioner chamber 2 50 Front belt 31 32 33 34 Chamber cylinder 2 50 35 36 Belt under 6 50 Bearing point 37 38 Driving roller belt under 6 50 Bearing point Driving roller wrapper 39 40 41 42 4 50 Bearing point table Front roller wrapper ta 43 44 2 50 Behind belt edge ble 45 46 47 48 49 50 51 52 5 Knife arm 3 50 TWO pes Unger 3 54 56 57 bracket 58 59 60 61 Cylinder wrapper table 2 50 62 63 Emergency stop wrapper 2 250 Safeguard bow Check before 64 65 Drag 6 x transport Check before 66 Drag loop 2 X transport Check before 67 Hand brake 2 X transport Check before 68 69 70 71 72 73 Brake shaft support s 2 x transport IMPORTANT Always complete a total lubrication service of the machine after being cleaned with a high pressure washer 76 5 2 5 Operating Temperature ISO VG system In
4. Possible selections b Chamber speed Tailgate opening speed Chamber greaser Manual greasing in progress as long as the button is pressed down Chamber open close Tailgate hamber sPeed Chamber Chamber 166 ON Greaser Close Screen Menu Baler 1 26 Press baler 2 to enter menu Baler 2 Possible selections Net knife open close Net feed on Belt under Fast slow speed Press baler 3 to enter menu Baler 3 Possible selections Feed table on off Elevator fast slow speed Run table on off Wrapper table Net revolutions Set the number of layers of wide film net added to the bale in chamber Press menu to enter menu Wrapper 1 Possible selections Film revolutions Set the number of layers of plastic film added to the bale on wrapper table Table up down Wrapper table Chamber open close Tailgate Press wrapper 2 to enter menu Wrapper 2 Possible selections Home Wrapper arm back to start position Slow Fast Wrapper arm speed Auto Automatic wrapping cycle of bale when it s loaded on table Film cutter open close ermvolt HB hamber level 2 a 22 22uU Menu Baler 2 BSTART 1 Termvolt AB 8 6 2 Chamber level 25 Slbar gt Chamber sPeed z Chamber On the va Table Position On the way On n the vad the brae arm Het knife Feed table ON Run Het Elevator table revolutions Fast Slow ON
5. 44mm outside diameter Defect bearing 2 42 2 mm inside diameter Measure the diameter several places to get the correct impres sion of the bearing ovality Large type 50 New bearing 50 mm inside diameter 55 mm outside diameter Defect bearing 2 52 7 mm inside diameter Measure the diameter several places to get the correct impres sion of the bearing ovality The material thickness in bearings should under no circum stances be lt 0 2 mm If so the bearing is defect and must be replaced immediately This to avoid serious damage harmed to the rollers axle s and subsequent mechanical break down NOTE Good practice is to change the bearings before reach ing the maximum degree of wear and tear Picture 1 Slide bearing Example in picture 1 New bearing left and worn out defect bearing 62 5 1 6 Hydraulic system Hydraulic oil The oil level is monitored by the control box A alarm stating oil level low is displayed in the control box Check oil level frequently by looking into the level glass on the oil reservoir tank Top up if necessary Check the oil condition minimum once a year Change oil minimum every third year See specifications in chapter 5 2 6 Oil filter 3 pcs must be changed minimum once every year Hydraulic hoses and connections Check the hydraulic system for any leakages and no hoses is rubbing against sharp edges on the machine NOTE The hydraulic hoses has limited time of operation We re
6. Danger Keep clear of moving parts in chamber People near the machine must be aware and keep their distance when the bale is released from the pressure chamber or unloaded from the wrapper table Always use the hydraulic safety valves on the tailgate lifting cylinders to secure the tailgate in open position The net or widefilm is cut with a sharp knife Be careful during loading a new roll or if any adjustment is done to the knife system All parking of the machine must be on level ground and secured with wheel chocks Between the tractor and the machine is a rotating PTO shaft No person is to stand between tractor and machine while the engine is running Do not wear loose clothing scarfs etc Safety distance a minimum of 5 meters No persons allowed closer than 5 m when the machine is operating Danger Film holder cutter has a sharp knife and there is a risk of cutting crushing injury Always keep closed when the machine is not operating Safe distance Do not enter below hopper Noise zone Use ear protection Danger zone Access only for operator or mechanic Make sure the transmission is running with the correct speed and direction Wrong speed and or di rection can damage machinery and may cause great danger to persons nearby The machine is de signed for 850 rpm Strapping point Lifting point Jacking point Hydraulics safety device tailgate lifting cylinders 23 CHAPTER 3 CONTROL BOX 3 1 CONTROL
7. Elevator Driving roller support upper 1 pcs on each side Grease nipple No 15 and 16 Belt tensioner rear 3 pcs on each side Grease nipple No 17 18 19 20 21 and 22 Belt tensioner rear 71 Chamber front and rollers 4 pcs on each side Grease nipple No 23 24 25 26 27 28 29 and 30 Chamber tailgate lifting cylinders 2 pcs on each side Grease nipple No 31 32 33 and 34 Belt under rear support 1 pcs on each side Grease nipple No 35 and 36 Belt under rear support 72 Belt under driving roller support 1 pcs on each side Grease nipple No 37 and 38 Driving roller wrapper table 2 pcs on each side Grease nipple No 39 40 41 and 42 Front support roller wrapper table 1 pcs on each side Grease nipple No 43 and 44 Front support roller wrapper table 73 Knife arms wrapper 6 pcs on each side Grease nipple No 45 46 47 48 49 50 51 52 53 54 55 56 and 57 Cylinder wrapper table 2 pcs on each side Grease nipple No 58 59 60 and 61 Emergency stop arm wrapper 1 pcs on each side Grease nipple No 62 and 63 Emergency stop arm wrapper 74 Drag bar and loop 1 pcs on each side of the drag bar and 1 pcs on the loop Grease nipple No 64 65 and 66 Hand brake 1 pcs Grease nipple No 67 Hand brake Brake shaft support 3 pcs on each side Grease nipple No 68 69 70 71 72 and 73 Brake shaft support 75 5 2 4 1 Lubrication scheme
8. Menu Baler 3 ESTART 1 Termvolt AB 6 60 4 61 Chamber level 25 Slbard gt Chamber speed Chamber On the Table Position On the the the brakrer 1 urakber 2 On On brak arms Het knife Menu Film revolutions 13 Table Ue Down Chamber Open Close Menu Wrapper 1 ermvolt 68 60 4 6 hamber level 255 Slbar gt hamber sPeed hanber the able Position the the the 1 WraPrer 2 Or On n n Hen Film cutter Menu Wrapper 2 27 close ilm cutter Het control Film control Met type Measure weight Table down delay rotation delay rotation time e transkort Menu Settings picture 3 Advanced settings NOTE These settings must be performed by trained personnel only To get access to more parameters in menu settings Enter menu Settings as shown in picture 1 on previ ous side Press upper and lower buttons on left side simulta aps sensor type neously New parameters will now appear in dis dm zBamH play lou See picture 1 and 2 to the right to see advanced parameters to be changed Remote controll Chamber zPeed regulation F term Menu Advanced settings picture 2 NOTE These settings is only to be set by qualified personnel Do not change settings if you are not sure 28 Press Menu to enter menu settings and counters
9. Orkel OPERATOR S MANUAL MP 2000 Original operator s manual translated version Published 2013 According to Directive 2006 42 EC Annex I 1 7 4 1 Manufacturer ORKEL COMPACTION AS Johan Gj nnes veg 25 7320 FANNREM Valid from serial number 20220001 Orkel part number 16741 INDEX CHAPTER 1 GENERAL INFORMATION 1 1 1 2 1 3 1 4 IDENTIFICATION of the MACHINE 1 1 1 Serial number localization 1 1 2 Declaration of Conformity INTRODUCTION 1 2 1 Foreword 1 2 2 Range of Use limitations CONTROL BEFORE DELIVERY 1 3 1 Preparation at customer s location WARRANTY 1 4 1 Certificate of warranty 1 4 2 Warranty limitations 1 4 3 Normal wear and tear 1 4 4 Warranty procedure 1 4 5 Repairing during guarantee period 1 4 6 Delivery form 1 4 7 Warranty report CHAPTER 2 SAFETY 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 INTRODUCTION SAFETY SYMBOLS TO THE OPERATOR WARNING AND DANGER LABEL SYMBOLS SAFETY ROUTINES 2 6 1 Safety Machine in working progress 2 6 2 Important issues OPERATOR PROTECTION 2 7 1 Take care own safety SAFETY PRECATIONS 2 8 1 Know your machine 2 8 2 Personal safety 2 8 8 Equipment control 2 8 4 Cleaning 2 8 5 Environmental protection 2 8 6 Set up on site 2 9 2 10 2 11 2 12 2 13 MAINTENANCE SAFETY 2 9 1 Before maintenance 2 9 2 Control after maintenance WORKING SAFELY 2 10 1 Safe work routine 2 10 2 Operator safety 2
10. up down 48 4 9 HYDRAULIC SETTINGS AN WARNING The machine s hydraulic system is under constant pressure Check hoses and fittings for any damage Re place damaged parts immediately When adjusting the machine s hydraulic valves it is forbidden to reside in moving range of the wrapper arms Be careful when adjusting the valves because the speed of func tions can change rapidly Familiarize with all functions of the machine Basic settings of the machine is been made during test run at the factory Before making any changes and surveys on the machine the hydraulic oil must have reached its normal operating temperature If the oil is too cold The pressure switches might be activated and give faster response than desired See Chapter 6 specifications which types of oil that are recommended In description of how to adjust the valves in chapter 4 9 2 the valves is refer to as numbers See the over view in chapter 4 9 1 4 9 1 HYDRAULIC VALVES OPERATION AND OVERVIEW Numbering of hydraulic valves and operational handles gt yr alve 50 6 OA ie 7 Valve 54 Valve 53 2 I E v Valve 52 49 4 9 1 HYDRAULIC VALVES OPERATION AND OVERVIEW Valve 57 Valve 58 Valve 59 hd Valve 60 Valve 61 2 Fr c B ul Valve 62 mm a Valve 63 la NG ag 50 4 9 1 HYDRAULIC VALVES OPERATION AND OVERVIEW Valve 64 na
11. 6 8 350 Nm 385 Nm 47 Nm Number of bales produced hour 20 60 6 9 DIMENSIONS AND WEIGHT Total weight Height Length Width Chamber size Bale volume Feeder table volume Power requirement 7800 kg 3760 mm transport 4200 mm drift 8000 mm transport 10000 mm drift 2500 120x115 cm 1 25m 7m3 120hp 90 kW 93 CHAPTER 7 ADDITIONAL OPTIONS 7 1 OPTIONS 7 1 1 Feeder table LB Low built 7 1 2 Grease gun 7 1 3 Air cleaning system 7 1 4 Plain belt 7 1 5 Protective axle covers elevator feeder table 7 1 6 Safe guard wrapper zone 7 1 7 Power pack 7 1 8 Internal hydraulics combination with power pack 7 1 9 Safety valve drag bar 7 1 10 Additional cooling system 7 1 11 7 2 ADDITIONAL 7 2 1 Service manual 7 2 2 Spare parts package 94 CHAPTER 8 CONTACT INFORMATION 8 1 ORKELAS HEADQUARTERS Orkel AS Johan Gj nnes veg 25 N 7320 FANNREM Telephone switch board Telefax E m il Home page 8 1 1 Sale Telephone Telefax E m il Home page 47 7248 8000 Monday Friday 08 00 16 00 47 7248 8011 orkel orkel no www orkel no 47 7248 8054 Monday Friday 08 00 16 00 47 7248 8011 formarked orkel no jarl orkel no www orkel no 8 1 2 Technical Service Telephone switch board Technical support Telefax E mail Home page 47 7248 8000 Monday Friday 08 00 16 00 47 7248 803
12. 7 SERVICE HISTORY Put down all maintenance history in scheme below to keep an overview of major repairs and service Year Date Service or major repairs Performed by 13 41 Example Orkel Compaction Ltd Stamp company and signature mechanic 89 5 8 DAILY MAINTENANCE CHECKLIST Check points before start Check all four main valves is open Check oil level in container chain lubrication system and level of grease in reservoir for the automatic grease lubrication system Check the pressure relief valve for any visual grease If grease appear on the valve it indicate a clogging in the system Repair the fault before start Check the tension on chains and conveyor belts Look for any leakages in the hydraulic system Check the levelling of the compactor Check the oil temperature according to start up procedure Chapter 4 4 5 Check points during operation Observe all machine movements and functions Check the chamber belts tracking Adjust if necessary Check the automatic greaser pump is running Frequently Keep an eye on chains if there s oil present Dry chains Check the system Check the condition of chamber rollers for any build up materials Be atten tive to the rollers and belts Avoid overfilling of elevator and subsequent too much build up of material No 1 hall space under the elevator 90 CHAPTER 6 SPESIFICATIONS 6 1 6
13. BOX 3 1 1 Choose menu language 3 1 2 Main menu Start screen 3 1 3 Program menus Basic functions 3 1 4 Values and Settings in menu Settings 3 1 5 Error messages 24 3 1 CONTROL BOX This chapter gives you a simple introduction to the control box This to make you get started quickly Software described in this chapter is MP 2000 5 0G Information area 25 Sibar Chamber sPeed Menu Function Het revolutions 4 6 5 68 1S Film revolutions area Cancel Back Information area Display information about status in different menus Also time date and counters Menu Function area Display machine information on each function in chosen menu Buttons By pressing button near under desired function the function is activated Menu button Used for switching between main menus Cancel Back button Use to cancel a on going process leave a menu or go back to start menu Re start of program If the programme stop by any reason e g overload you might complete the interrupted cycle manually to unload the bale To get started in AUTO again the control box must be restarted By pressing the tree buttons marked with a ring picture above at the same time the box is reset No data is lost Manual operation To run functions manually the sensors must be deactivated Deactivation of sensors Press menu button once Then press menu button and cancel back button simultaneously Tex
14. Counters List of customers or jobs Press Settings to enter menu settings Main menu Settings counters Menu Settings Settings carried out by operator In menu settings you can set change up to 30 pa rameters See screen pictures 1 2 og 3 Chamber max skeed By pressing button under the arrow in the display you can switch between parameters and screens pages Chamber max Pressure Elevator stor delay By pressing button under or of the chosen param erd Potty in eter the value is changed Yes On or Increase parameter press No Off or Decrease parameter press Menu Settings picture 1 NOTE Write down old settings as a back up before you start changing values in menu settings See recommended settings in chapter 3 1 4 Feed roll closed delay gela Chamber oben delau Bale on table de Film revolutions First film release Second film release a C ele Menu Settings picture 2 29 Settings Counters Press cancel back button to return to menu settings counters Settings Counters Press button to the right for counters in display to enter menu counters Main menu settings and counters Counters z 8 This menu can store information for up to 50 differ ent customers or jobs When entering the menu the first 7 counters is shown in display View stored information Switch between counters by pressing buttons under Li B Bh Amin er Ba Bh Bmin arrows in dis
15. Ltd if a problem has occurred Details To look closer at a failure press button under Details shown in display amber not closed Example Failure code 180 B Baler state HG 1 This indicate there is a error in sensor S18 See own raPPer state chapter 3 1 6 for failure codes Ch 18 14 2 BBLI 3 1 4 Values and settings in menu Settings Recommended Description of parameter settings Setting Values Chamber max speed Speed of the chamber when filling up with material 80 100 Chamber feed speed Chamber speed during net feeding and cutting 40 50 E 0 Chamber net speed Net wrapping speed 80 10096 Speed of the chamber when bale is ejected out of the Chamber bale out speed chamber 40 5096 Chamber full level Level of chamber filling when elevator slows down 60 8096 Setting of a maximum pressure inside the chamber at a Chambermax pressure point when elevator stops and net film starts 180 220 bar Elevator stop delay Delay of elevator stop after chamber is full Feed delay Delay of net feed Time necessary during net feeding to get it anchored Net feed time hooked between chamber and bale surfaces regards MP s with only net wrapping system Time necessary during net film feeding to get it an Film feed time chored hooked between chamber and bale surfaces regards machine with alternative film or net wrapping Net revolutions Number of net film wraps on
16. Pull the ring until the safety pin is released Hold the ring while maneuvering the drag bar oper ating hydraulic handle nr 3 After approx 10cm of movement on the drag bar release the ring Then keep on moving the drag bar all the way in pump gear box input shaft Open the safety valves on feeder table lifting cylinders Lower the feeder table to ideal working height Operate lever nr 6 to lower the table See chapter 4 8 Mount the side plates and covers on the feeder table IMPORTANT The four main hydraulic valves must be in open position See chapter 4 8 Connect the PTO axle according to supplier guidance The PTO guard must be in order and secured on both sides with chains Read operators manual that was supplied with the axle Connect the power supply cable to the tractors battery Se chapter 4 4 3 Activate the tractors PTO and hydraulics Run trac tor on idle to allow RPM on the PTO axle approx imately on 300 RPM Keep running until tempera ture on the hydraulic oil has reached operational temperature Confer procedure i chapter 4 4 5 The rise the PTO speed to 850 RPM Set the wrapper table in horizontal position using the control box Lay down the bale unloader fork Transport safety pin release ring IMPORTANT Check that the direction of rotation and PTO speed is correct Before any movement of the drag bar the transport safety pin must be released Carry out a thorough visual
17. See picture 2 The belt tracking should be correct and not touching the chamber side walls If the belt is tracking towards B in picture 1 the distance C in picture 2 must be increased If the belt is tracking against A in picture 1 the distance C in picture 2 must be reduced Attaching bolts Untighten the attaching bolts just a bit to allow a move ment of the bracket Loosen the counter nut and adjust the distance C by turning on the adjusting nut Tighten the counter nut and the attaching bolts of the bracket when Adjusting nut the belt has a correct tracking 58 5 1 5 2 Adjusting the rear chamber belt The adjustment s of the rear chamber belt is done preferably from the right side of the machine Dismount the cover and safety net picture 1 to get access to the adjusting bracket s and bolts seen in picture 4 The rear chamber belt might be adjusted on two loca tions Either changing the bearing point of the tension roller in picture 3 or the bearing point of the chamber roller shown in picture 1 on next side Or a combina tion of these two adjustments Safety net g Rear tension roller Picture 2 Adjusting the belt tracking is done by changing the distance C on the rollers bearing point D in picture 3 By increasing the distance C the belt tracking will en ter towards B in picture 2 When decreasing the dis tance C the belt tracking will enter towards A If the tracking of the belt is still
18. WRAPSTART WRAP2 WRAP3 WRAP4 BALING1 BALEFULL1 NETFEED1 FEEDDELAY1 NETFEED2 NETFEED3 PLASTICO PLASTIC1 PLASTIC2 PLASTIC3 PLASTICA PLASTICS OPENDELAY1 LOAD4 WRAPRAMP WRAP1 WRAPSTART WRAP2 WRAP3 WRAPA WRAP5 WRAP6 WRAP7 LOAD3 NETFEED1 NETFEED2 NETFEED3 BSTARTO1 BSTARTO05 BSTART10 BSTART 15 BALING1 BALEFULL 1 NETFEED3 PLASTIC3 when baling when baling all all all all all Also malfunction in control box or circuit all board error in the electric cabinet CHAPTER 4 OPERATING THE MACHINE 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 MODE OF OPERATION 4 1 1 Main sections BREAK IN 4 2 1 Break in precaution 4 2 2 PTO DRIVING ON ROAD 4 3 1 Preparation before transport 4 3 2 Rigging up after transport 4 3 3 Levelling the compactor CONNECTING THE MACINE 4 4 1 Tractor 4 4 2 speed 4 4 3 Electrical connection 4 4 4 Hydraulic connection 4 4 5 Oiltemperature 4 4 6 Function control before starting up NET FILM BINDING PLASTIC FILM WRAPPER 4 5 1 Plastic film net binding in chamber 4 5 2 Adjusting the net brake 4 5 3 Plastic film wrapper table 4 5 4 Wrapper adjusting the knives 4 5 5 Loading installing a new plastic film roller AUTOMATIC OPERATION WORKING PLASTIC FILM STORAGE MAGAZINE OPERATIONAL HANDLES HYDRAULIC VALVES HYDRAULIC SETTINGS 4 9 1 Hydraulic valves operation and overview 4 9 2 Wrappe
19. bale in the chamber Continue to press the feed rollers together in mid posi tion Knife delay Delay on net film knife before cutting Delay of opening the chamber after net film wrapping completed Feed roll closed delay Chamber open delay 3 1 4 Values and settings in menu Settings Bale on table delay Film revolutions First film release Second film release Third film release Film cutter open time Film cutter close time Net control Film control Net type Recommended Setting Values To allow the bale to go all the way to the table Revolutions of film laid on the bale on wrapper table er 14 6 layers Description of parameter settings First opening of the film cutter Second opening of the film cutter Third opening of the film cutter Operating time from closed to open The time from starting to close the film cutter to finish Setting of the computer for machines with net only wrapping unit Stops the machine if net is broken or the roll is empty Setting of the computer for machines with net film wrapping unit Stops the machine if film net is broken or the roll is empty Type of the net film wrapping unit for net only net or net film model plastic PLASTIC Table down delay Bale rotation delay Extra wrap before rotation starts for stabilizing Bale rotation time Makes the bale rotate on the table while dropping Rotate feed rollers Feed rollers rotate while
20. beam di rectly on to ball bearings and electrical connections 5 3 2 Storage Before long time storage of the machine a thorough cleaning and lubrication service must be carried out This to avoid corrosion and remains from pressing material harden inside the pressing chamber Always keep the control box in dry warm place Paint damage or any abrasion should be touched up to avoid corrosion on frame and chamber 78 5 4 ELECTRICAL SYSTEM 5 4 1 Fuses A master fuse 40 A is located on the supply cable from the tractor power pack A fuse for lights 15 A is located in a rubber fuse holder inside the electrical cabinet RE wanna vere Fuse box front electrical cabinet Fuse holder number 1 Terminal A og B printed circuit board 10A 2 Sensors 10A 3 Lubrication system 5A 4 Free 5A Spare 5 Hydraulic control V1 V16 15A 6 Hydraulic control V17 V32 15A 7 Fan oil cooler 25A 8 Free 9 10 og 11 10A 15A og 20A Spare 79 5 4 2 Electrical scheme 80 s overview 5 4 3 Sensor jaybysoysamoy LES og 009 5 muyonod 775 6 05 915 auo 47 05 jam JenNsefON OZ 1104005100 PJogayyOg ES uadp saynapak 615 ddojspo 75 ISP N z WS OA 6A HA VA SZAYZAGIA BA x bid EZASZALZA SA NNN ONNNN gt NN puel 90 pau pioqayyod 65 4444 NN WW usDay
21. button to return to menu Settings and counters Fault memory Sensor test Menu Press menu button to get new main menu Press user settings button to enter menu User settings Main menu User settings Control unit Information line showing which pro Information gram and edition MP 2000 v5 0 G Control unit v5 6 Terminal B 15 Terminal B Wald Copyright c 2812 ProDevice Oy Changing brightness in display Terminal B Voltage 8 60 By pressing buttons below Brightness in display Terminal B Voltage 8 60 you can adjust to requested intensity with or Brightness Contrast Pale Pos Back By pressing buttons below Contrast in display you Menu User settings 1 can adjust to requested intensity with or Changing contrast in display Changing background Choose between bright letters on dark background or dark letters on bright background By pressing buttons under polarity you can change background with POS or NEG Calibration To calibrate scale for bale on table if installed Choose Scale button Not in use 31 Sensor Test Enter main menu User settings Press button to enter menu Sensor test A list of all sensors and their current status is shown in display Sensor Test procedure JIC CTI be EN 8 ON P bd I rd ut I TRAP Ed 5 5 5 5 5 5 5 5 Sensor test Hold piece of m
22. control checking for any transport damages before starting up Repair all damaged covers etc inmediately before operating the machine AN DANGER Also carry out a functional test of all emergency stop switches They must be in working order 41 4 3 2 Rigging up after transport 4 3 3 Levelling the compactor 1 Operate the four hydraulic jack stands until the machine is horizontally levelled See chapter 4 8 2 Use the water pass 4 ea attached on the frame to check the levelling of compactor Water pass NOTE The levelling of the compactor might change during operation if not placed on steady ground Check the water pass frequently and adjust if needed 42 4 4 CONNECTING THE MACHINE 4 4 1 Tractor The tractor must be placed on the left side of the machine See section 4 3 2 4 4 2 PTO Speed The machine require a PTO speed of p 850 RPM Ensure the tractors RPM correspond to this NOTE The performance ability of the machine are depending on constant RPM speed 4 4 3 Electrical connection The machine is designed to be connected to a 12Volt DC system with negative earth The electronic is over under voltage protected The voltage must be stabile between 10 6V and 16V Make sure the tractors elec trical system is in good order Connect the power cable directly to the battery on tractor The cable is secured by a 40A fuse on cable The signal cable from control box must be connected to corresponding socke
23. entering one of the sides the similar operation must be carried out on the left side bearings but the opposite way If reducing the distance C the belt tracking will enter towards B Adjusting brackets rear chamber belt Bearing point D tension roller 59 5 1 5 2 Adjusting the rear chamber belt Adjusting the chamber roller C Picture 1 Adjusting the belt tracking is performed by changing the distance D on the roller C Preferably on the right side bracket By increasing the distance D the belt will enter to wards A picture 2 in the chamber If decreasing the distance the belt will enter towards B picture 2 in chamber Bilde 2 If the tracking of the belt is still entering of the sides the similar operation must be carried out on the left side but in reverse order If increasing the distance D picture 1 the belt track ing will enter towards B in picture 2 60 Adjusting bracket top roller 5 1 5 3 Adjusting the belt tensioning The tension of the belts is under the influence by the force from the twin springs on the both sides See picture 1 Basic setting Turn the nut B picture 2 until there s a clearance A of 2 mm between the coils See picture 1 NOTE When pressing very light and dry materials such as hay and wooden chip the bale might have some problems start rotating If such problem oc curs the clearance must be reduced A 0 1mm B
24. fitting High pressure in system Low ambient temperature System pressure too high Main distributor clogged System clogged Valve relief spring defect 69 Remedy Replace fuse Replace electric cable Replace pump motor NOTE Correct motor mounting Bleed the pump Refill the reservoir Replace the pump element Refer to pump not working above See if grease is present on pres sure relief valve Replace hoses Retighten fittings or replace Replace hose Retighten fittings or replace Conduct a complete system check Rum greaser manually 1 or 2 times to lubricate the system Then start up once more Check the system Replace the distributor Repair clogged bearing housing Replace valve 5 2 4 Manual lubrication points The machine has multiple lubrication points The lubrication interval for each point is listed in line table Lubrication chart chapter 5 2 4 1 See specifications for recommended lubricants Feeder table Drive rollers support 2 pcs on each side Grease nipple No 1 2 3 and 4 Stickers on machine showing the lubrica tion points Feeder table Rear roller support 1 pcs on each side Grease nipple No 5 and 6 Base plate feeder table 1 pcs on each side Grease nipple No 7 and 8 Cylinder feeder table 2 pcs on each side Grease nipple No 9 10 11 and 12 Cylinder feeder table 70 Elevator Lower roller support 1 pcs on each side Grease nipple No 13 and 14
25. of a controlled cut The speed of knife arms is adjusted by turning valve nr 53 right arm and valve nr 54 left arm The speed is reduced by turning clockwise NOTE Both sides need to be adjusted equally the arms should have a smooth motion and not slammer Basic setting Close the valve then open 1 2 turn Wrapper table tilt speed By adjusting the wrapper tilt speed we can change the bale drop speed By turning valve nr 52 clock wise the drop speed will increase To avoid the risk of uncontrolled unloading of bale the drop speed shouldn t be set to fast Basic setting Close valve then open 3 4 turn 52 4 9 3 Chamber speed adjustment Chamber tailgate opening speed By adjusting valve nr 55 the speed could be changed The speed is to be set as fast as possible without slamming the tailgate Basic setting Valve 55 Close the valve then 1 2 turn counter clockwise 4 9 4 Conveyor belts speed adjustments Feeder table chain belt By adjusting valve nr 56 the belt speed on the feeder table is set Note By turning the valve clock wise the speed is increasing Opposite of the rest Basic setting Valve 56 Close by turning it counter clockwise Then turn 1 8 1 4 clock wise Belt under chain belt Belt under speed is set by adjusting the valve nr 57 fast and nr 58 slow Basic setting Valve 57 Close the valve then 2 turns counter clockwise Valve 58 Open the valve then 1 turn clockwise Elevator
26. pressure there s no need for special precau tions to be made regarding long time or winter storage Perform a complete lubrication service on the ma chine before storage If you re using a grease type according to lubrication standards but not having the anti corrosion effect the system must be filled up with anti corrosive oil Regular motor oil would be sufficient Oil filling in the grease lubrication system preservation This operation is easily done with a empty grease gun filled up with motor oil Remove the piston and the coil spring in the gun Insert a empty grease cartridge and fill the grease gun while holding it vertically Attach the gun at the inlet on the main distributor and empty the gun into the system 1 2 litre 5 2 3 Trouble shooting Grease lubrication system Problem Pump does not work Pump is working but does not sup ply grease No grease collar at all points of lubrication No grease collar on several bear ings No grease collar on one bearing Reduced pump speed Grease on pressure relief valve Cause Fuse defect Cable from control unit to pump broken Problem with pump motor Air pocket in pump Level in reservoir is too low Pump element not building up pressure no air pocket Pump does not work Clogging somewhere in the system A primary hose between main dis tributor and sub distributor is bro ken Leakage in fittings The hose serving the bearing is defect Leakage in the
27. tensioner B og C The length of the spring should be between 130 140mm Adjust Increase the chain tension by tighten the nut on the bolt Picture to the right Chain tensioner B Chain tensioner C 5 1 4 Wrapper Check out all the emergency switches is in perfect working order Check the knife s condition and its align ment with the rollers 57 5 1 5 Press Chamber A DANGER All repair and maintenance work inside the chamber are attend ed with great danger Remember to secure the tailgate lifting cylinders by closing the securing valves on both sides The machine must be stopped and PTO disconnected Securing valve tailgate lifting cylinders Chamber rollers bearings belts The pressing chamber must be checked frequently Before performing a control the chamber must be properly cleaned preferable using a high pressure wash er Check the tracking of the chamber belt s and adjust if needed Look for wear on chamber s sidewall and check the conditioning of the rollers and rubber belts The grade of wear and tear is varying depending on which material being pressed Replace damaged rollers and belts if excessive worn If there s great wear on the chamber sidewalls if might be considered to weld on wear plate s contact Orkel Compaction Ltd if relevant 5 1 5 1 Adjusting the front chamber belt All adjustment of the belt s tracking is done on the right side of the chamber the upper front roller
28. 10 3 Taking care of other s safety 2 10 4 Danger in working progress 2 10 5 Danger during maintenance 2 10 6 Risk of overturning SAFETY AFER USE 2 11 1 Leaving the machine 2 11 2 Dismantling of the machine TRANSPORT 2 12 1 Transport road conditions 2 12 2 Lifting 2 12 3 Strapping WARNING LABELS 2 13 1 Labels 2 13 2 Explanation of labels CHAPTER 3 CONTROL BOX 3 1 CONTROL BOX 3 1 1 Choose menu language 3 1 2 Main menu Start screen 3 1 3 Program menus Basic functions 3 1 4 Values and Settings in menu Settings 3 1 5 Error messages CHAPTER 4 OPERATING THE MACHINE 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 MODE OF OPERATION 4 1 1 Main sections BREAKING IN 4 2 1 Break in precaution 4 2 2 PTO DRIVING ON ROAD 4 3 1 Stripping down preparation before transport 4 3 2 Rigging up after transport 4 3 3 Levelling the compactor CONNECTING THE MACINE 4 4 1 Tractor 4 4 2 speed 4 4 3 Electrical connection 4 4 4 Hydraulic connection 4 4 5 Oiltemperature 4 4 6 Function control before starting up NET FILM BINDING PLASTIC FILM WRAPPER 4 5 1 Plastic film net binding in chamber 4 5 2 Adjusting the net brake 4 5 3 Plastic film wrapper table 4 5 4 Wrapper adjusting the knives 4 5 5 Loading installing a new plastic film roller AUTOMATIC OPERATION WORKING PLASTIC FILM STORAGE MAGAZINE OPERATIONAL HANDLES HYDRAULIC VALVES HYDRAULIC SETTINGS 4 9 1 Hy
29. 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 ELECTRICAL SYSTEM PTO LUBRICATION SYSTEM HYDRAULIC SYSTEM WHEELS AND TYRES TYRE INFLATION TIGHTENING TORQUE CAPASITY DIMENSIONS AND WEIGHTS 91 6 1 ELECTRICAL SYSTEM Voltage Source connection Fuse Sensors 6 2 PTO Type Moment of force 6 3 Grease system Operational voltage Maximum current draw Current draw at max pressure Current draw signal lamp Fuse RPM Pump capacity each revolution Pump capacity each minute Maximum pressure Operating temperature Enclosure rating Grease type Volume reservoir Oil lubrication Oil type Oil consumption Volume container 6 4 HYDRAULIC SYSTEM Maximum working pressure 6 5 WHEELS AND TYRES Tyre Rim 6 6 TYREINFLATION Wheel 12 DC Minimum 10 6 Volt Maximum 16 0 Volt Connect directly to battery on tractor 40A on cable Type Diameter 18mm Ultra sound and pressure Cat 6 2300Nm BEKA MAX LUBRICATION SYSTEM 10 30V 6 0 A 1 0 A 04A 50A 15 RPM Pump 1 fixed amount 0 17 cm Pump 2 adjustable 0 04 0 12cm 4 3 cm minute 280 bar 35 C til 75 C IP 65 EP 2 NLGI 2 4 0 I Motor oil SAE 10W 30 15W 40 6ml each tailgate opening 0 3 l hour when pressing 50 bales hour 421 240 bar 385 65 R 22 5 7 5 x 22 5 5 5 bar 550 kPa 80 Ib in psi 92 6 7 TIGHTENING TORQUE Wheel nuts Bolts drag and loop Slide bearing housing
30. 9 Monday Friday 08 00 16 00 47 7248 8062 Monday Friday 08 00 16 00 47 7248 8011 teknisk orkel no leif orkel no anders orkel no www orkel no 95 CHAPTER 9 NOTES 96
31. CONTAINING HYDRAULIC OIL THE FRAME HAS A FUNCTION AS OIL RESERVOIR AND COOLER All welding and drilling and other work being done to the frame must be carried out with great caution Please consult your local dealer or Orkel Compaction Ltd 65 5 1 10 Wide film Net binding The Hit unit containing wide film or net is located on top of the chamber HiT High Tension Control 1 Clean and lubricate the slides for feeder rollers 2 Check chain tension and its condition Adjust the tension by loosen the bolt and turn the nylon eccen tric to add more tension to the chain Then retighten the bolt Check all movable parts bearings the HiT unit 4 Check the condition of hydraulic hoses and couplings Exam the unit for any leakages 5 Control the free wheel s function feeder rollers Feeder rollers Feeder motor 66 5 2 LUBRICATION 5 2 1 Lubrication system Beka Max EP 1 The compactor is equipped with a fully automatic lubrication system It lubricates the sleeve bearings grease and the chains oil Oil lubrication mode of operation A single piston pump driven by the hydraulic pressure supply oil to the chains through brushes which is mounted on strategic locations Each time the chamber tailgate opens the piston is activated and supply fix amount of oil to chains Grease lubrication mode of operation An electrical motor continuous drive runs an eccentric The eccentric drive two sin
32. GHT CHAPTER 7 AUXILLARY COMPONENTS AND EQUIPMENT 7 1 AVAILABLE EQUIPMENT 7 1 1 7 1 2 CHAPTER 8 CONTACT INFORMATION 8 1 HEAD OFFICE 8 1 1 Sale 8 1 2 Technical Service 8 2 ORKEL POINT OF SERVICE 8 2 1 Norway 8 2 2 Abroad CHAPTER 9 NOTES CHAPTER 1 GENERAL INFORMATION 1 1 IDENTIFICATION OF THE MACHINE 1 1 1 Serial number localization 1 1 2 Declaration of Conformity 1 2 INTRODUCTION 1 2 1 Foreword 1 2 2 Range of use limitations 1 3 CONTROL BEFORE DELIVERY 1 3 1 Preparation at customer s location 1 4 WARRANTY 1 4 1 Certificate of warranty 1 4 2 Warranty limitations 1 4 3 Normal wear and tear 1 4 4 Warranty procedure 1 4 5 Repairing during guarantee period 1 4 6 Delivery form 1 4 7 Warranty report 1 1 SERIALNUMBER 1 1 1 Localization A badge with the serialnumber is located on the right side of the machine near the wrapper zone In addi tion the number is also engraved in the frame See picture below The serialnumber must always be provided by contacting the dealer whether for share purchase or other technical assistance The serialnumber is a safe way to identify the machine it is strictly forbidden to change or remove the serial number Oriel MC 1000 Serialnumber localization Multicompactor MP 2000 EC DECLARATION OF CONFORMITY Manufacturer ORKEL COMPACTION AS Address Johan Gj nnes Veg 25 N 7320 Fannrem Norway Phone 47 72 48 80 00 Product descriptio
33. S safe use 2 8 1 Knowledge of your machine and equipment It is recommended that the operator when starting up is standing up on the platform at the top of the ma chine By doing this you are having a good overview of danger zones Know your machine Learn all the functions and actuating mechanisms You must also know the capacity and limitations of the machine This is to avoid unnecessary downtime and in the worst case mechanical brake down 2 8 2 Use of protective and safety equipment Use all available protective and safety equipment Provide good lighting in the area where the machine is positioned All covers must remain intact and attached during operation If pressing of flammable materials a fire extinguisher must be in close proximity 2 8 3 Equipment control checking before start up Before starting up make sure that the machine and its equipment is in place and in order 2 8 4 Cleaning A good cleaning of the machine increases its durability and your safety Therefore keep all surfaces clean remove oil spills and other dirt 2 8 5 Environmental protection Hazardous waste such as rubber oil and other materials that could harm the environment must be dis posed at approved disposal centres 2 8 6 Assembly on site The operator must be aware of hazards during alignment and assembly of the machine Make a visual check of the complete machine to detect any transport damages Ensure that the machine is standing on
34. a firm levelled surface WARNING 25 Take care when assembling mounting the compactor Squeeze and injuries from falling occur when maneuvering the wrapper table and during installation of the covers 17 2 9 MAINTENANCE SAFETY 2 9 1 Before maintenance Before any maintenance or adjustments are being made to the machine we recommend you to make con ference call to your local dealer or Orkel Compaction AS All repairing work or maintenance should be carried out by skilled mechanics SAFETY PRECAUTIONS REGARDING REPAIR WORK OR MAINTENANCE The machine must be stopped before any repair work or maintenance is carried out The hydraulic safety valves on the tailgate s lifting cylinders both sides must be closed before any person could enter the chamber Se chapter 5 1 Caution during cleaning of belts and rollers must be taken to avoid crushing or squeezing of body parts Be aware of the large side covers during repair work in windy conditions Secure the covers in open position to avoid personal injury Use proper work wear and shoes to avoid injuries from falling 2 9 2 Control after repair work or maintenance Check that all tools is stowed away and all covers is mounted correctly and in place NOTE Orkel Compaction recommend that all repair and maintenance work on the machine is done in day light conditions Repair work on the machine in dark conditions is on owner s risk 2 10 SAFETY DURING OPERATION
35. aded The bale is then transferred to the wrapper table by a transport chain When entering the wrapper table the tailgate is closing and a new bale is in progress 4 5 2 Adjusting the net brake Valve 61 f 61 Plastic film brake gt lt m 62 Plastic film speed 63 Net film brake disengage 44 4 5 3 Plastic film wrapper table The wrapper unit is equipped with safety guards interrupting the wrapping cycle if the switches on top is activated If the safety switch is activated a message ap pear in the control box s display To continue the error message in control box must be acknowl edged and checked out Remove the object causing the stop Move the safety guard back in position The machine must be restarted by a command in control box to con tinue the interrupted process 4 5 4 Wrapper adjusting the knives Speed regulation Use valve 53 right og 54 left to set the speed A height adjustment is normally not necessary 8 J Valve 53 3 Valve 54 s3 as LX possible when being cut Valve 52 Height setting The film must enter the knife at mid section if Knife arm rollers Knife arm in upright position Both rollers should easily be rolled Roller locked Knife arm cutting position The outer roller on each arm should not be able to roll move This to hold the film while being cut Check that the knife is aligned between the two
36. ailgate is closing at the same time and a new bale is in progress The wrapping cycle start automatically when a bale is registered on the table Any loss from the baling pro cess is transported back to the elevator by a conveyor belt belt under and fed back into the process Pa rameters like chamber pressure amount of widefilm net and number of layers of plastic film being added on the wrapper table and more can all be set in the control box 4 1 1 Compactor main sections Compactor main sections left side view Main sections 1 Hopper 2 Elevator feeder 3 Press chamber 4 Wrapper table 5 HiT Hi tension Unit 38 4 2 BREAK IN 4 2 1 Break in precaution new compactor must go through break in period and should not be run at maximum capacity at the first 25 hours The operator must be observant monitoring that all functions are working correctly and be ing aware of unpleasant sounds from the machine Fine tuning the whole process must be carried out until the compactor has reached it s optimum capacity based on the material being baled NOTE Slide bearing clearance is tight when the machine is new This may result in increased temperature in bearings The slide bearings must be checked frequently during brake in period If the temperature rise in some of the bearings activate the manual greaser from the control box to increase the amount of grease supplied to bearings Check Each bearing t
37. an and a effective utilization of the machine With regards Orkel Compaction Ltd 1 2 2 Range of use limitations The compactor is designed for compressing soft organic materials to bales Then wrap them in plastic film for storage or transport The compactor must only be used for this purpose Other materials can also be compressed but have to be confirmed by Orkel Compaction AS in each case This due to warranty legislations 1 3 CONTROL BEFORE DELIVERY This machine is tested controlled and passed the final inspection before leaving the plant Please check that this operator s manual correspond with your machine 1 3 1 Making the compactor ready customer site One of our employees will set up the machine for the customer A course in handling and operating the com pactor will be held at site if necessary During start up period we will be helpful with technical assistance and answering questions regarding the compactor Please see Delivery warranty formula in section 1 4 10 1 4 WARRANTY 1 4 1 Warranty liabilities Orkel Compaction guarantee this machine against failure in production and material error for a period of 12 months or 50 000 bales produced from date of delivery 1 4 2 Warranty limitations 1 Warranty is limited to the actual value of the machine According to performed maintenance range of use and condition 2 Warranty is limited to the value of damaged components only 3 Warranty is limit
38. ation If you fail to comply with instructions given it could result in personal injury or loss of life IMPORTANT The word IMPORTANT refers to special instructions or procedures that could lead to the destruction of equipment if you fail to comply with them NOTE The word NOTE mark items of particular interest for more efficient and convenient operation or repair 2 5 SYMBOLS STICKERS AND LABELS WARNING Warning signs indicating danger or warning attached the machine must not be removed painted Unreadable signs must be replaced by new ones These can be ordered from Orkel Compaction Ltd See chapter 2 13 Description of stickers and labels 2 6 GOOD SECURITY PRACTICES 2 6 1 Safe operation WARNING No person under 16 year s of age should under no circumstances operate this machine WARNING EN Personnel under influence of alcohol or other drugs should not operate this machine 2 6 2 Important issues Be aware of children and other unauthorized persons in the vicinity of the machine Never allow unqualified persons to operate this machine 16 2 7 OPERATOR SAFETY 2 7 1 Personal protecting gear AN WARNING The Compactor might generate a lot of dust and noise depending on which material being compressed For your own health we recommend that operators use protective equipment such as goggles mask with air filter and hearing protection during operation 2 8 SAFETY PRECAUTION
39. belt The conveyor belt speed in the elevator is adjusted by turning on valve nr 59 fast and nr 60 slow Basic setting Valve 59 Close the valve by turning it clock wise then 1 turn counter clock wise Valve 60 Close the valve by turning it clock wise then 1 turn counter clock wise 4 9 5 Plastic film or net brake Tension and feeder speed Plastic film net brake There must be some pre tension added to the film before it s added on to the bale Adjust the brake by turn ing valve nr 61 By turning the knob clock wise the tension is increased Basic setting Increase the pressure while reading the manometer When the film is torn reduce the pres sure by 10 NOTE If the oil is cold the pressure might be higher than the adjustment was made The film might be torn Adjust the net brake when oil is cold if the problem occurs Plastic film or net feeder speed Adjust the feeder speed by turning valve nr 62 the speed is reduced when turning the valve clock wise Basic setting Valve 62 Close the valve by turning it clock wise then 3 4 turn counter clock wise Plastic film or net brake release By closing valve nr 63 the net brake can be disengaged This operation is performed when loading a new film og net roller in HiT unit Basic setting Valve 63 Closed 4 9 6 Main valves The machine is equipped with four main valves Valve number 64 65 66 and 70 These valves must be closed only when repair work is don
40. cated in a envelope enclosed delivery of the machine NOTE All warranty repairs must be agreed in a written form e mail or letter before any repair of the ma chine could take place 1 4 5 Repair work and service in warranty period All repair and service work must be carried out by skilled mechanics If not Owners risk there might be some limitations in the warranty given by Orkel Compaction Ltd 11 1 4 6 Delivery and Warranty form Note This form must be completed in 3 copies One for the customer one for supplier and one to be filed at Orkel Compaction AS Orkel Compaction AS Delivery form Model type Serialnumber Date of delivery customer Customer Supplier Distributor Address Address The delivery is controlled pursuant to order specifications Operator s manual has been reviewed along with customer Safety instructions has been examined along with customer Remark to delivery Signature owner Signature Supplier Distributor 1 4 7 Warranty report Orkel Compaction Warranty report Customer Supplier Address Product Description of failure Date of delivery form Date of failure Serial number Qty Part name Price EUR Sum credit EUR Hours of work performed Total amount parts Hour rate EUR Hours of travel Hour rate EUR Mileage Orkel Consultant Place and da
41. commend to change the hydraulic hoses each 6 year Hydraulic pump gearboks Check the input shaft it s splines and bearings Check the bolts holding the gearbox and retight en if necessary Check the oil level in gearbox by unscrewing the dipstick Dip stick max and min level Level should be between max and min Top up if necessary The gear oil must be changed minimum once a year or when needed See approved lubricants in chapter 5 2 6 Dip stick Magnet plug Drain plug Gearboks and hydraulic pump note When changing gear oil the magnet plug must also be cleaned Inspect the amount of met al shavings on the plug If there s a lot of shavings present it s indicating excessive wear in the gear box 63 5 1 7 Feeder table Elevator Belt Under Conveyor belts and feeder dog Feeder table belt belt under and elevator belt These belts is of chain type with welded dogs Check the belt tensioning and look for uneven wear from oblique angel on belts Adjusting the chain belts Same procedure on all the three belts Tighten the belt ten sioner until all clearance is gone Tighten equally on both sides and check that the tracking of the belt is centred If the wear in the segments is too large to tighten the belt properly one segment can be removed Procedure x4 Su NEM Loosen the four bolts holding the bracket Untighten the counter nut and tighten the bolt on the chain tensioner u
42. draulic valves operation and overview 4 9 2 Wrapper adjustments 4 9 3 Chamber speed adjustment 4 9 4 Conveyor belts speed adjustments 4 9 5 Plastic film or net brake Tension and feeder speed 4 9 6 Main valves 4 9 7 Chamber pressure settings CHAPTER 5 REPAIR AND MAINTENANCE 5 1 OPERATOR MAINTENANCE Control and adjustments 5 1 1 Electric system 5 1 2 Wheels 5 1 3 Chains 5 14 Wrapper 5 1 5 Chamber 5 1 5 1 Chamber belt front adjustment 5 1 5 2 Chamber belt rear adjustment 5 1 5 3 Chamber belt tension 5 1 5 4 Installing replacing a new chamber belt 5 1 5 5 Slide bearing rollers 5 1 6 Hydraulic system 5 1 7 Hopper Elevator Belt under 5 1 8 Belt wrapper table 5 1 9 Frame Main bolts 5 1 10 Wide film Net tying 5 2 LUBRICATION 5 2 1 Lubrication system 5 2 2 Refill 5 2 3 Troubleshooting 5 2 4 Lubrication scheme 5 2 5 Approved Recommended types of Grease and Oil 5 3 CLEANING AND STORAGE 5 3 1 High pressure washer 5 3 2 Storage 5 4 ELECTRIC WIRING DIAGRAM 5 4 1 Fuses 5 4 2 Wiring diagram 5 4 3 Sensors overview 5 5 HYDRAULIC SCHEME 5 6 WELDING AND GRINDING 5 6 1 Precautions before welding 5 7 SERVICE HISTORY 5 7 1 Scheme Service and maintenance CHAPTER 6 SPECIFICATIONS 6 1 ELECTRICAL SYSTEM 6 2 6 3 LUBRICATION SYSTEM 6 4 HYDRAULIC SYSTEM 6 5 WHEELS 6 6 TYRES 6 7 TYRE PRESSURE 6 8 TIGHTENING TORQUE 6 8 1 Wheel nut 6 8 2 Miscellaneous 6 9 DIMENSIONS AND WEI
43. e on the system or if any leakages has occurred Keep the valves always open Major harm on hydraulic motors can happen if the valves remain closed during start up 53 4 9 7 Chamber pressure settings Setting of the chamber pressure value is done in the control box During start up the elevator belt runs at fast speed When chamber full level pre set value is achieved the speed on elevator is reduced to obtain a higher density on the bale When the value of chamber pressure is reached the bale is ready for film or net binding Parameters to be set in control box is Fully pressed bale 100 240bar Start slow speed elevator belt 0 10096 by pre set pressure Example Material Wood chips Chamber pressure 200bar Chamber full level 8096 When the sensor register a chamber pressure of 160bar 8096 of 200bar the elevator belt speed is reduced to slow speed The belt speed will remain slow until chamber pressure reaches 200 bar AN IMPORTANT THE CHAMBER PRESSURE MUST NEVER EXCEED 240 BAR Chamber sensor oil pressure right side cabinet 54 CHAPTER 5 REPAIR AND MAINTENANCE 5 1 Operator Maintenance Control and adjustments 5 1 1 Electric system 5 1 2 Wheels 5 1 3 Chains 5 14 Wrapper 5 1 5 Chamber 1 Chamber belt front adjustment 2 Chamber belt rear adjustment 3 Chamber belt tension 4 Installing replacing a new chamber belt 5 Slide bearing rollers 5 1 6 Hydraulic system 5 1 7 Hopper Eleva
44. ed to elapsed time to repair Assessed and determined by Orkel Compaction AS 4 Warranty repairs must be agreed with Orkel Compaction AS before repair takes place 5 A completed warranty form must be submitted to Orkel Compaction within 14 days of delivery Orkel Compaction Ltd is under no circumstance responsible for consequential damages to 3 party arising out of any matters relating to the machine 1 4 3 Normal wear and tear Normal wear and tear on parts such as Rubber belts tyres hydraulic hoses knives chains and bearings is not included in the warranty PTO On the PTO shaft there is a warranty form delivered by the manufacturer Please see manufacturers own warranty coverage in attachment on the axle Other Use of non original parts improper use and insufficient maintenance will lead to the disappearance or re duction of the previously mentioned warranty The warranty may be withdrawn if the instructions given in this manual are not followed 1 4 4 Warranty procedure If anything happens to your machine during the warranty period Stop the machine immediately to avoid further damage Contact your local dealer or Orkel Compaction AS Please see contact information in section 9 Delivery and warranty form must be sent handed over to Orkel Compaction AS within 14 days after first start up The form must be completed in three copies One for customer one for local dealer and one for Orkel Compaction AS This form is lo
45. elt tensioner rear Left side 5 1 5 4 Changing the chamber belts Clean the chamber as described in chapter 5 1 5 Remember to secure the tailgate lifting H cylinders before entering the chamber Remove the damaged belt using a knife and cut the belt crosswise Fit the new belt into place and push the locking rod in to complete the belt Secure the locking rod by mounting the two washers on each side See picture 3 Check the tracking of the belt in chamber and adjust if necessary as described earlier in this chapter 61 5 1 5 5 Slide bearing rollers AN IMPORTANT The slide bearings must be controlled every 5000 bales produced or when 1000 hours of operation is reached Whatever comes first Note The machine is equipped with slide bearings of different length or diameter Make sure you have received the right type before dismounting start IMPORTANT The distributed load to the bearings will not be even and therefore the wear is not evenly distributed on the bearing Clean the bearing carefully to get the right impression of the rate of wear before inspection Control A quick control of the degree of wear clearance might be done with a bar and a dial gauge If no excessive wear is found there s no need to further dismantling of the bear ings The load of force onto the bearings is illustrated with arrows in picture to the right Permissible wear Small Type 40 New bearing 40 mm inside diameter
46. er hand it s not possible to describe every operational and safety matters that may arise Carefully consider all your actions if the pose a safety hazard to you or others close to the compactor Accidents may kill you or make you disabled Accidents can be avoided 2 2 SAFETY AND DANGER SYMBOLS This symbol means ATTENTION BE CAUTIOUS YOUR PERSONAL SAFETY IS EXPOSED When you see this symbol in the operator s manual be aware that violation of instruc tions given can cause you or others in the working area of the machine being injured or killed 2 3 TO HE OPERATOR Exercise of security As a operator it s your responsibility that you read and understand the safety instructions given in this operator s manual These instructions must be followed without exception It s you who are the key to the safety of this machine not only for yourself but for other people in the compactors working area Follow the safety instructions punctually and you will experience the compactor as a safe and secure place to work 15 2 4 DANGER AND WARNING Danger warning and caution Each time you see the words and symbols shown below please note the different directions they symbolize AN DANGER AN The symbol and a word DANGER state a direct or immediate dangerous situation that will cause DEATH OR SERIOUS INJURY if not avoided AN WARNING AN 4 The symbol and the word WARNING indicates potentially hazardous situ
47. er gasket is ok Se chapter 5 8 2 Electrical scheme for further details Check that all electrical contacts is in good condition and correctly mounted Check the driving lights and other lightening equipment are in working order Check that all the emergency switches is OK and working properly Fuses There are three fuses in the machine s electrical system Master fuse directly on power supply cable 40 A Fuse for lights in cabinet Fuse holder in rubber 15 A Fuse box in front of cabinet Content see chapter 5 8 Fuse box Fuse for lights 15 A Electrical cabinet 56 5 1 2 Wheels Check the condition of the tyres they should have sufficient tread depth and be without tears Control the tyre inflation and wheel nut torque before transport to new location See specifications chap ter 6 5 and 6 6 5 1 3 Kjeder The chain tension must be controlled and that the chains are supplied with sufficient lubricant oil Look for abnormal wear and tear on gears and chains Replace worn parts as needed Contact your local supplier or Orkel Compaction AS directly if you have any doubts about parts must be re placed Control Chain tensioner A Basic setting Tighten the bolt until there is a 3mm clearance on chain See picture to the right Adjust Untighten the bolts holding the bracket Adjust the chain tension by turning the nut on the bolt Tighten the bolts holding the bracket when the chain tension is OK Control Chain
48. erence Orkel Compaction if this is relevant Bleeding the grease system If the level in reservoir is too low it might be needed to bleed the system after refilling Disconnect the plastic pipeline mounted under the pressure relief valve on the pump Activate the function greaser in the control box until a constant smooth flow from the outlet Reconnect the plastic pipeline in it s original position Activate the function greaser in control box once more The pump will run as long as the button in control box is pressed PwWNP Maintenance and control All the parts of the BEKA max system is maintenance free We although recommend a external cleaning of the pump and lines from time to time with a high pressure washer Don t wash directly on to electrical con tacts NOTE New machine In the first weeks of operation the system must be checked frequently Check that there s a visual grease collar on all lubrication points This indicates all the bearings is lubricated Keep also track on grease consumption Beware if any changes in daily consumption of grease this might indicate that s something s wrong Lubrication Manual greaser points The compactor has a number of greasing points that need to be lubricated manually These points has to be greased minimum every 20th hour of operation See overview in chapter 5 4 4 68 Long time storage If you re using grease of NLGI class 2 with EP additives extra
49. etal steel in front of the sensor watch at the same time the current sensor status in dis play The sensor status should now change between ON and OFF while moving the metal piece in and out of the sensor front In that case the sensor is OK If there s no change in status of the particular sensor there is a failure in sensor or a cable break down See sensor s overview and their numbers in chapter 5 4 3 Start Up Screen Press Cancel Back button twice to return to start up screen 14 82 13 85 29 ESTART 1 1 B ah amin 294 tolbar Bx Settings Chamber level Chamber seed Select counter Het revolutions 8 845 8 Film revolutions B713 START START Start up screen 32 Time Enter menu screen user settings See previous page Select Clock on the right side of screen to enter menu Adjust date amp time 14 82 15 EE 33 Move cursor along the line by pressing button under the arrow shown in display Move the cursor to the value you d like to change Increase Decrease value press or Menu adjust date amp time Confirm new time by pressing OK Fault error messages memory Press fault memory in main menu user settings to enter menu fault memory In this menu the last 30 errors is stored continuous ly To browse faults in memory press button under ar rows up or down in display NOTE Use this menu as a reference if you are about to contact your local dealer or Orkel Compaction
50. flange 90 1 2 x 30 19 Hydraulic gear 8 4 1 5 Gate flange straight 3 4 x 40 20 Throttle valve 1 4 7 Block 33 3 21 G Rotor 8 Block 33 4 22 Hydraulic gear 16 4 1 5 High pressure relief valve 1 2 J Cun 150 bar 10 Flow Div 24 G Rotor 11 Block 33 2 25 Cylinder 50 x 30 x 600 12 G Roller Br 26 Cylinder 32 x 20 x 150 13 Block 33 1 27 Cylinder 40 x 25 x 500 14 Manometer 0 100 bar R1 4 28 Check valve 3 8 T High pressure relief valve 1 2 m EE 180 bar 16 Solenoid valve 30 Check valve 60 1 0 35 bar 16A Coil 12V 32 Return filter 16B DIN Plug 12 24V 33 Pressure relief valve 50 l min 70 bar 17 G Rotor 34 Block 35 Check valve 3 8 40 l min 0 35 bar 87 5 6 WELDING CUTTING GRINDING 5 6 1 Precautions before welding Before any welding work could be done on the machine the control box and cable must be disconnected Attach the welders earth connection as near as possible to the place to be welded Always look out for ex cessive heat generation and cool down the area 5 6 2 Precautions before cutting and grinding The frame is partly a reservoir and cooler for hydraulic oil Pay attention if any repair work is made or if any improvements is done to the frame Please conference Orkel Compaction Ltd before cutting NOTE Apply touch up paint after any welding and grinding is done to the machine to avoid corrosion Always keep a fire extinguisher nearby when working with heat generating tools 88 5
51. gle working pistons which press fix amount of grease through pressure relief valve and further on to main distributor The main distributor supply then grease to sub distributors which deliver the correct amount of grease to each bearing NOTE Not the same amount of grease to all bearings Pump element suction phase Pump element pressure phase The grease lubrication system is a progressive system It operate all types of grease of NLGI kl 2 type See recommended lubricants in chapter 5 2 6 progressive lubrication system means that all the bearings is lubricated one by one This progressive system make the lubrication system easily monitored trough a high pressure relief valve nr 9 figure 1 If a lubrication line to a bearing is clogged the pressure will increase 280 bar and visible grease appears on the relief valve Please check the pressure relief valve on a regular base If visual grease is present a line or a distributor is clogged An another malfunction could be that a line is broken but then there s no visual grease on the relief valve Beka Max grease lubrication system Reservoir transparent Stirrer scrape Suction area pump Screen Eccentric cam Pressure ring Delivery piston Non return valve QD 400 c Ov BGN Pressure relief valve Motor 12V DC a Refill nipple
52. here must be a visible grease collar Do also check the pressure relief valve on the grease pump there should be no visible grease present NOTE The tension of the elevator belt must be checked the first 1 3 hours of operation Due to paint re mains in the belt segments you might have to tighten up the belt WARNING N When controlling the slide bearings and performing manual lubrication the tractors engine or additional power supply must be switched off NOTE In the case of having trouble lubricating some of the bearings remove the hose belonging to the actu al bearing Then mount special nipple to get the bearing lubricated manually After lubricating the bearing remount the hose which was dismounted earlier Contact Orkel Compaction Ltd if this is relevant The elevator and sensor which control the amount of material being fed into the chamber must also be controlled An adjustment of this parameter could be carried out manually please see chapter 3 1 4 NOTE Before the compactor left the factory a careful quality control has been taken place On the other hand this control has not bees done with the material you are proceeding need of complementary adjust ments and change in settings is therefore foreseeable Chamber pressure control The compactor is designed to stand huge stress and output but do not exagger ate bale density An exaggeration in setting of chamber pressure will reduce the life span of the chambe
53. horizontal position after being checked Sensors on wrapper table Up horizontal and down Sensor test in control box Wrapper arm low speed Press slow Set speed to 10 RPM basic setting by adjusting valve nr 69 Wrapper arm fast speed Press fast Set speed to 25 RPM basic setting by adjusting valve nr 51 Adjusting the wrapper is described in chapter 4 9 2 43 4 5 NET FILM BINDING PLASTIC FILM WRAPPER 4 5 1 Plastic film Net binding in chamber Binding the bale in chamber with plastic film or net is performed by the HiT unit High Tension on top of the machine When installing a new roller guide the film as shown in figure 1 emphasized line Feeder rolls Figure 1 Binding a bale in chamber mode of operation After filling up the chamber and a pre set chamber pressure value have been reached The feeder motor in HiT unit starts and film net is being fed into the chamber When the rope end is long enough the bale create a drag on the film net and start pulling it out At the same time the feeder motor stops and feeder arms is moving outwards A freewheel in feeder motor allow the film net to enter the chamber without any prob lem The net brake is then being activated making a pre tension applied to the film net This ensures a tight and even binding of the bale in chamber After added a pre set number of film net layers to the bale the cham ber tailgate is opened and the bale is unlo
54. icture below Dismount the side covers between feeder table and elevator Put the feeder table s side covers on to feeder table Secure the covers along with earlier dismounted covers onto the feeder table Also dismount the bannister and put stairs in transport mode Rise the feeder table into transport position using maneuvering handle nr 6 Se chapter 4 8 Secure the feeder table in transport mode by closing the valves on the feeder tables lifting cylinders Handle nr 67 og 68 on each side See chapter 4 9 Rise the four hydraulic operated jack stands completely by using the maneuvering handles nr 1 2 4 and 5 See chapter 4 8 Disconnect the battery cable hydraulic couplings and control cable Secure all the cables and hydrau lic hoses from possible transport damages Connect the tractor to the drag bar Connect the light cable and the hydraulic brake hose to tractor Perform a brake test and check all lights is working properly before driving off 40 10 11 12 4 3 2 Rigging up after transport The compactor must be placed on a flat and lev elled surface Disconnect the light cable hydraulic brake hose and the drag bar The tractor must be parked on the compactors left side in 90 angle to the compactors longitudinal axe Also aligned with the input shaft on the hy draulic gear box Connect the hydraulic hoses to a single operating outlet on tractor Level the compactor see chapter 4 3 3
55. loop round the front crossbeam Beam Dim 100 x 100mm Rear Use lifting points on the hydraulic jack stands is NOTE Use long straps or chains to avoid pinched Lifting point front damages to the machine during lifting operation EA NOTE Only use lifting gear witch is approved and with sufficient lifting capacity s 2 12 3 Strapping and tie down Secure the machine from moving if transported by lorry train or boat Only use approved securing straps or chains designed for the purpose There is four points of strapping one on each hydraulic jack Strapping point stand See picture to the right per 20 2 13 DESCRIPTION OF WARNING LABELS 2 13 1 Stick on Labels b 4 S BN xc 5 I 8 10 11 12 13 14 15 16 17 18 19 20 2 13 2 Stick on labels explanation Do not start operating the machine until you have read and understood the operating instructions and safety precautions Always stop the tractor engine before lubricating adjusting maintaining or repairing the machine Also remove the ignition key to prevent accidentally start Ensure that there are no people between tractor and machine when connecting and disconnecting It can quickly result in crushing injuries Never allow children to stay near the machine during operation Especially young children can do un predictable things
56. lose to the machine during operation 2 10 4 Elements of risk during operation Pay attention to the risk of Squeezing crushing cutting of fingers or hands near the knife for widefilm net Squeezing crushing of fingers or hands between conveyor belts and sprockets Squeezing crushing of fingers or hands between belt and roller and under the wrapper table Squeezing crushing of body and feet when bale is dropped from the wrapper table Squeezing crushing of fingers or hands between wrapper arms and frame Impact from rotating wrapper arms Sensor failure at wrapper table might result in an early bale roll out Leakage of hydraulic oil under high pressure that witch can result in severe injury to eyes and skin 2 10 5 Elements of risk during maintenance Pay attention to the risk of Squeezing crushing of fingers and hands near chain and sprockets if side covers are dismounted Side co vers should only be opened when machine is stopped Squeeze crushing of finger and hands during cleaning of conveyor belts and rollers Safeguards should only be dismounted when the machine is stopped get entangled into PTO axle Endanger of PTO loosens or brake might result in body impact Do not stay in PTO area slipping and falling entering the staircase getting moderate burns oil is approximately 70 C 158 F 2 10 6 Risk of overturning JN WARNING ZN The operator must take precautions to the risk of overturning duri
57. male sleeve Figure 1 67 NOTE The slide bearings on chamber rollers is under huge stress and force during operation It s of great importance that the lubrication system is in good working order IMPORTANT Don t ever operate the compactor without a proper functioning lubrication system 5 2 2 Refilling of lubricants Make sure the level of lubricants is always between max and minimum in the reservoirs Oil and Grease Check the level on a daily regular base before start up Refilling the grease reservoir The grease lubrication system is sensitive to the influence of external contamination such as dust and dirt Keep the cap on and refill through the male sleeve nipple nr 11 figure 1 when refilling grease NOTE Keep the reservoir male sleeve nipple and pump always clean NOTE We recommend to purchase grease in larger containers Pails of 20 litres 16kg s in combination with air or electrical operated tools for refilling Standard grease gun with 0 5 litres cartridges might also be used A grease gun for cartridges with special nipple might be ordered as a option Part number 58086 Adjusting the amount of grease The grease lubrication system is set to a maximum delivery of 29cm However one of the pumps is adjustable PE120V Remove plug 2 to get access to adjusting screw 3 By turn ing the screw clockwise the amount is reduced 1 2 turn on the adjusting screw reduces the grease added by 0 013cm gt Please conf
58. n Agricultural Industrial multi compactor Model Orkel MP 2000 Type 202 With serial number 1234567 Orkel Compaction AS hereby declare that the identified product above is conform to the require ments of Directive on machinery 2006 42 EC Electromagnetic compatibility Directive 2004 108 EC and EN ISO 12100 EN ISO 4413 EN ISO 13850 EN 349 A1 EN ISO 13857 Person in EC authorized to compile technical files Name Anders Smaaoien Project engineer Orkel EU Ltd 28 29 The broadway Ealing broadway London W5 2NP UK Fannrem November 16 2012 Leif Haugum sign Technical director Bjorn Slupphaug sign Logistics Manager stamp 1 2 INTRODUCTION 1 2 1 Foreword The products from Orkel Compaction Ltd is well known for their high quality reliability and strength We will therefore congratulate you choosing of one of our machines To fulfil our own goals regarding quality and strength Orkel Compaction Ltd has implemented a continuing product developing process We are also carrying out a thorough quality control on all of our machines before leaving the factory You as a owner or operator must read this operator s manual with safety instructions before start up Read thoroughly and familiarize with the rules and demands regarding machine safety use and mainte nance Make daily maintenance as a routine By doing this the machine will be safe to operate contribute to a long life sp
59. ng rigging set up and operating the machine 19 2 11 PRE USE SAFETY 2 11 1 Before leaving the machine WARNING Before leaving the machine the operator must turn off tractor engine or any other power source must be switched off such as power pack Remove key or secure the power pack to avoid unwanted start 2 11 2 Phasing out or dismantling the machine WARNING General safety precautions must be taken when stripping down the machine Centre of gravity might change during dismantling secure large parts to avoid danger of injury Be aware of overturning Hazardous waste like oil rubber and so one must be stored in environmentally safe way or delivered at certified waste disposal plant 2 12 TRANSPORT 2 12 1 Highway transport Preparation This machine is designed to being towed by the drawbar only Ensure the tractor is equipped with a drag bar of sufficient strength Weight on drag bar 1800 Kg 3970Lb Before set up and mounting of the machine after being transported The operator must carry out visual control of the machine to reveal any transport damages Be aware of danger of overturning during transport Don t exceed recommended speed limits set by Orkel Compaction Ltd Maximum speed 40km t Picture 1 Picture 2 2 12 2 Lifting points Net weight of the machine is 7800 kg 17200Lb All lift done to the machine must be performed as shown in picture 1 and 2 Front Use nylon strap to make
60. ntil correct Chain belt tension is achieved Adjust both Tensioner bolt sides equal Tighten the counter nut and the attaching bolts on bracket Chain E Tensioner bolt ad N Chain tensioner belt under Chain tensioner elevator Roller Bearings The rollers in feeder table elevator and belt under should be without deformations and cracks Check the bearing clearances without belt tension Replace worn ball bearings and rollers 64 5 1 8 Belt wrapper table Figure 1 The length of the wrapper table s belt must be adjust ed as shown in figure 1 Correct length of wrapper table belt Adjusting the wrapper tables belt The belt tension can be changed by relocating the roller There are five alternative holes to mount the roller support Loosen the upper bolt to allow some movement on the bearing housing Dismount the lower bolt and pull the roller backwards replace the bolt in a suitable hole Both sides must be equal mounted If the belt tracking is incorrect try to change location side of the belts 5 1 9 Frame Main components fastening points Frame Check the welding for cracks or deformations j Main components fastening points Check all major bolt connections and retighten if necessary Pay extra attention to the bolts fixing the drag bar and loop 574 Nm Fixing bolts drag bar and loop AN IMPORTANT THE FRAME IS PARTLY HOLLOW AND ARE
61. opening rollers Yes no Gives extra oil to the belt under when moving to the table Fast Normal Bale transport Delay of the table from dropping position until it starts to go up again 1 2s 3 1 5 Error and Fault messages in display Version 2000 4 65 and later FET TEEN EET Bale on the table Bale didn t move to the table Table not in middle position Table didn t move to the middle Wrapper arms not in start position No wrap pulse Wrapper arm speed too high Wrapper arm obstructed Table didn t move to the down Table didn t move to the up Film broken or roll empty Film broken or roll empty Both films broken or rolls empty Bale chamber not open Bale chamber didn t open Chamber not closed Bale chamber didn t close Netknife didn t open Feed roll didn t open Netknife didn t close Feed roll didn t close Net didn t broke Net tying failure Film cutter didn t close Emergency STOP Emergency STOP Chamber pressure sensor broken Chamber overpressure Under voltage at control unit Under voltage at control unit Under voltage at terminal unit Under voltage at terminal unit Malfunction at the control cable Malfunction at the control cable S18 519 519 520 520 520 520 522 57 523 530 530 control unit control unit terminal terminal control unit control unit 36 OPEN1 OPEN2 OPEN3 LOAD1 LOAD2 LOAD3 LOAD5 WRAP1 WRAP6 WRAP7 BALEREADY1 DROP1 DROP2 DROP3 READY1
62. p 2 HE ar LID I 1 I 5 TT Lec F i mETTICH 2 HITRA War Kid iz ee ge den VT rut T s I in LE UL JUL i gt i Ss i gt Ll ERN i gt U l VCOOTOEOT 1 gt gt cona 4 91000 11 91000611 910005 IPENA TA I d EIA Li SA 1 4 9A 6A SPE MBA EI nmm NU AWAIT W WA W H H a V TA IA TA 1 1 Trott rond 6068 VEOV dl g TIOETEDA G C J BR 0205004 a S ef le 2 9 7 S 3 5 3 E 5 5 2 12 a DUERME m E 8 ra 1 a YOLOW 9 m T 5 26 n gt 5 n 96 TY T ah Ud z 00 81 0001 187400 N I 1 07 YOLOW dVUM U sc ERR Ger STISTONIOEOSV YICTOH OTIOZTOOSSZOHV YTENVHD 83 DIO IH 1090804HH 610008 IPENA 010008 I Irena e sere LLA MLA lt LR Az ALT BEO9LSTLALA 1THOTL IONA uS E U d 2 2 om a rT3 S U u8 E S W B E a c
63. play Press select button to choose a counter to look into Back The chosen line should now be marked with a be hind the counter number in display Then press details button to view stored infor mation registered on the customer Number of bales and time spent preter IJK Change text or add a new customer job not available h Bmin Choose the counter to be changed Press details button then modify button Last reset Reset Modify Delete counter ABC Skip through alphabet from the start and Counter 2 backwards and then numbers ZYX Skip through numbers and alphabet from the end and forwards Change or write letters and numbers Press ABC or ZYX button until requested letter is in cursor ales E Total weight enot available Hor k time Bh Bmin Created 14 2 Then press arrow button to move to next letter or eee reset make a space AEC ZW gt Clear OK Cancel Counter 3 Erase a letter press clear button Confirm changes press OK button 30 Reset Counter NOTE Make sure the correct counter you d like to reset is chosen Picture counter 2 i ABCDEFGHLIE Press reset counter Confirm or invalidate by press pales Pais ing Yes or No Hor k time Ah Amir Created 14 2 Used Erase counter customer or job Last reset Are You sure Press delete Then confirm or invalidate by pressing res No Yes or No Counter 4 User settings Press cancel back
64. r e materials See chapter 3 1 4 NOTE Assorted materials requires different chamber pressure IMPORTANT Orkel Compaction Ltd recommend Visual controls of the compactor must implemented in daily maintenance routines Active listening and make adjustments once the requirement is revealed This to avoid consequential damages to the machine If not doing so it might result in a mechanical break down 4 2 2 PTO axle The PTO axle that comes along with this machine is delivered with it s own operator s manual Attach and service the axle as described in the suppliers manual NOTE Make sure the PTO ratio in control box is set to 1 00 See chapter 3 1 3 1 Advanced settings 39 4 3 DRIVING ON ROAD DANGER This machine is designed for a maximum speed of 80 km t on road conditions Do not exceed maximum speed Before driving on road ensure all the compactors covers and detachable parts is safe and secure However the speed must be adapted to the actual road conditions and national speed limits 10 4 3 1 Preparation before transport Turn the un loader fork backwards against the wrapper table Rise the wrapper table control box to allow free movement of the drag bar The drag must be fully extended by maneuvering the handle nr 3 until the transport safety lock engages See chapter 4 3 2 Pull the belt tensioner backwards Picture to the right Disconnect the PTO axle from tractor and secure it in transport mode Se p
65. r adjustments 4 9 3 Chamber speed adjustments 4 9 4 Conveyor belts speed adjustments 4 9 5 Plastic film or net brake Tension and feeder speed 4 9 6 Main valves 4 9 7 Chamber pressure settings 37 4 1 THE COMPACTOR MODE OF OPERATION The machine is operating automatically supervised by the control box The operators main task is to ensure there is enough material in hopper and stove away bales produced Mode of operation The material is loaded on the hopper feeder by a wheeled loader or excavator or similar If the compactor is equipped with a low built hopper the material can be dumped directly in the hoppers tray The material is then transported by a conveyor belt into the chamber and being pressed to a bale The amount of material being fed into the chamber is controlled by speed regulation sensors and parameters set in control box All functions in the baling process can be adapted and optimized depending on which material is being pressed baled The hopper has a capacity of 7 cubic meter of loose material The hopper feeder is also de tachable and the elevator might be filled directly by a conveyor belt or a similar device When the pressing cycle is finished a net or widefilm from the HiT unit is being added to the bale in the chamber By doing this the bale keep it s shape while being unloaded from chamber and transported on to the wrapper table When the bale is loaded onto the wrapper table the chamber t
66. rollers Adjust the knife if necessary 45 OL EWN 4 5 5 Loading installing a new plastic film roller Pre stretch bow Plastic film holder and pre stretcher Loading new plastic roller Grab the bow on the pre stretch unit and pull to the right Lift the locking lever and push the bracket upwards the lock the lever temporary Replace the empty roller with a new one Centre the roller on the holders and lover the bracket to secure it Lock the lever The plastic film must be thread as shown in figure 2 then grab the bow and lay the pre stretch unit on to the new film roller Bind the two plastic film ends together from each side and continue wrapping Figure 2 Plastic film in pre stretcher 46 4 6 AUTOMATIC OPERATION IMPORTANT Ensure the four main hydraulic valves are opened If somehow you forget to open this valves there is a great probability of severe damage is harmed to hydraulic motors See chapter 4 9 1 By pressing the start button in control box this will happen The hydraulic motor for chamber belt rotation is starting the elevator and belt under motor is starting Ma terial is being fed into the chamber controlled by sensor in elevator When the pre set value of chamber full level is reached the elevator speed is reduced to reduce the feeding amount into chamber The bale is now being pressed until pre set value chamber pressure is achieved The net knife is opening and the ne
67. s reduced and therefore the speed The opposite occurs when turning the valve counter clockwise The exception is Feeder table speed valve 56 By turning this valve clockwise the speed will increase 4 9 2 Wrapper adjustments Wrapper arm fast speed adjustment Valve 50 is controlling the total flow to the wrapper If the valve is turned clockwise the total oil volume will decrease and all the movements in wrapper unit will be slower Valve 51 is controlling the amount of oil to the wrapper arm If the valve is turned clockwise the arm speed is reduced Wrapper arm maximum allowable rotation speed is 25 RPM HOW TO ADJUST WRAPPER Close the valve nr 50 then open 3 4 turn basic setting Close valve nr 51 completely then open gradually until correct speed on the arm is achieved Maximum 25 RPM Adjust the speed on the belt with valve 50 to correspond the rotation of arm and overlap of film layers Wrapper arm slow speed adjustment After the fast speed is correctly adjusted the slow speed must be set By turning valve nr 69 adjust and set the slow speed to maximum 10 RPM NOTE The slow speed must be correctly adjusted to ensure the film cutter is working properly The speed will increase when the oil is warm Observe the wrapper arm carefully and adjust the slow speed once again if necessary Knife arm setting The rise and lowering speed of the arms must be correctly set If the speed is too high the film is torn in stead
68. t Sensors deactivated is displayed on screen Functions can now be run manually NOTE Be careful no functions is monitored when sensors are deactivated Risk of colliding machine parts Activation of sensors Press cancel back button once to activate sensors 25 First start of control box 3 1 1 Choose menu language When connecting the box for the first time picture to the right appear on screen Press immediately the button under side of the language you want For lat er start up the control box will remember the lan guage your have chosen MPZ2B8 8 8 v5 6 G Available languages EN English DE German FR French NL Dutch TR Turkey PL Polish CS Czech DE FR NL TR SK Slovak HU Hungarian Start up screen language 3 1 2 Main menu Start screen 14 82 13 85 29 ESTART 1 In this screen you get information of 1 8 Settings Chamber level rSlbar gt Ratio of charge and chamber pressure Chamber speed select Chamber speed LEE Number of turns of widefilm net Number of turns of plastic film wrapper Possible selections START START START HET WRAP Start screen Start machine Start Net Widefilm net in chamber Bale dropping Manual or Auto Wrapper table Additive On or Off Silage additive Start wrap only if a bale is on the table 3 1 3 Program menus Basic functions Press menu button to enter menu Baler 1 ermvolt A B hamber level
69. t motor is starting feeding net film into the chamber A pre set numbers of layers of film net is added to the bale and the film net is then being cut by the knife The chamber tailgate opens and the bale is being transported on to the wrapper table A wrapper sensor is activated and the wrapper table moves to horizontal position another sensor is then being activated and close the tailgate A new bale is then being processed At the same time the wrapper cycle start Wrapper arms speed is reduced the first turn until the knife arms release the film The wrapper arm speed is then increased to fast until a pre set number of layers is added to the bale The number of layers being added to the bale on wrapper table are depending on which material is being pressed if the bale is to be stored or transported Read the user manual from film roller supplier 47 4 7 PLASTIC FILM STORAGE MAGAZINE A storage magazine with a capacity of 11 rollers is mounted on both sides of the compactor 4 8 OPERATIONAL HANDLES HYDRAULIC VALVES The compactor is equipped with to set of operating handles on the right side These handles is used for level ling the machine moving the drag in or out and for lowering or rising of the feeder table transport mode Operating handles front Operating handles rear 1 Jack stand left front 4 Jack stand left rear 2 Jack stand right front 5 Jack stand right rear 3 Drag in out 6 Feeder table
70. t under the switchboard casing The control box is equipped with magnets allowing it to be placed directly on the machine Preferably it can be placed on the right side near the wrapper zone The control box should be disconnected and stored in dry conditions Always keep connectors clean and dry 4 4 4 Hydraulic connection IMPORTANT MAKE SURE ALL MAIN HYDRAULIC VALVES ARE IN OPEN POSITION Ea 4 Hydraulic power supplied from tractor system operate the four hydraulic jack stands drag bar and feeder table lifting cylinders All other hydraulic power is serviced by a integrated hydraulic pump located on the machines left side 4 4 5 Oil temperature A temperature indicator is attached to the oil reservoir Read the oil temperature if the oil temperature is too cold do this Run tractor on idle speed with 300 RPM on PTO axle approximately 10 to 25 minutes until the temperature has reached start temperature A sticker on the oil reservoir is stating which oil type the machine is equipped with Type T32 minimum start temp 15 C Warm up time 10 min one minute per minus degree Type T46 minimum start temp 3 C Warm up time 10 min one minute per minus degree Increase PTO speed to 850 RPM when the oil has reached operating temperature 4 4 6 Function controls before starting up The drag bar must be in operational position in mim Temperature indicator Wrapper table up and down function The table must be set in
71. te Km at EUR Total amount exclusive VAT Invoice new parts Signature Orkel internal processing Treatment of complaints Warranty report received date Dismissal Warranty parts returned pictures received Approved Ground for dismissal The claim is considered Credit Note 4 13 CHAPTER 2 SAFETY 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 INTRODUCTION SAFETY SYMBOLS TO THE OPERATOR WARNING AND DANGER LABEL SYMBOLS SAFETY ROUTINES 2 6 1 Safe operation 2 6 2 Important issues OPERATOR PROTECTION 2 7 1 Personal protecting gear SAFETY PRECAUTIONS 2 8 1 Know your machine 2 8 2 Personal safety 2 8 8 Equipment control 2 8 4 Cleaning 2 8 5 Environmental protection 2 8 6 Set up on site MAINTENANCE SAFETY 2 9 1 Before maintenance 2 9 2 Control after maintenance WORKING SAFELY 2 10 1 Safe work routine 2 10 2 Operator safety 2 10 3 Taking care of other s safety 2 10 4 Danger machine in working progress 2 10 5 Danger during maintenance 2 10 6 Risk of overturning SAFETY AFER USE 2 11 1 Leaving the machine 2 11 2 Dismantling the machine TRANSPORT 2 12 1 Transport on road conditions 2 12 2 Lifting 2 12 3 Strapping WARNING LABELS 2 13 1 Labels 2 13 2 Explanation of labels 14 2 1 SAFETY INTRODUCTION This operator s manual is made for describing safe and good routines operating the compactor On the oth
72. ternational Standardization Organization Viscosity Grade The ISO standard 3448 divide industrial oils in to several ISO VG classifications The standard tells which vis cosity the oil are suppose to have at 40 The lower the ISO grade is the thinner the oil gets NOTE This machine is designed to operate in temperatures between 15 C up to 50 C 5 2 6 Approved lubrications Hydraulic system Use hydraulic oil of ISO VG 32 classification when operating in temperatures between 15 C til 30 C Recommended type Shell Tellus 32 Statoil HydraWay HVXA 32 UNO X Rando HD 32 As an alternative use hydraulic oil of ISO VG 46 classification if operating in higher ambient temperatures Between 10 C til 50 Recommended type Shell Tellus 46 Statoil HydraWay HVXA 46 UNO X Rando HD 46 Lubrication system Oil lubricants Use regular motor oil SAE 10W 30 40 or SAE 15W 40 to lubricate the chains Recommended type Shell Helix HX5 Statoil ClassicWay Havoline Premium 15W 40 Grease lubricants Use grease of NLGI 2 class with extra protection EP additives Recommended type Shell GADUS 3 V220C 2 Statoil Greaseway CAH 92 UNO X Multifak EP 2 Gear box on hydraulic pump and gear on hydraulic motors Recommended type Use gear oil Shell Omala S2 220 77 5 3 CLEANING AND STORAGE 5 3 1 High pressure washer The machine can preferably be cleaned by using a high pressure washer But don t direct the jet
73. tor Belt under 5 1 8 Belt wrapper table 5 1 9 Frame Main bolts 5 1 10 Wide film Net tying 5 2 Lubrication 5 2 1 Lubrication system 5 2 2 Refill 5 2 3 Troubleshooting 5 2 4 Lubrication scheme 5 2 5 Approved Recommended types of Grease and Oil 5 3 Cleaning and storage 5 3 1 High pressure washer 5 3 2 Storage 5 4 Electric wiring diagram 5 4 1 Fuses 5 4 2 Wiring diagram 5 4 3 Sensors overview 5 5 Hydraulic scheme 5 6 Welding and grinding 5 6 1 Precautions before welding 5 7 Service history 5 7 1 Scheme Service and maintenance 55 5 1 OPERATOR MAINTENANCE Control and adjustments WARNING All control of functions must be carried out with extreme caution if the machine is running If controlling wear and tear the machine must be shut down and PTO axle disconnected IMPORTANT Control simple repair and adjustments mentioned in this book might be carried out by trained operators which have completed maintenance course All other major repairs should be per formed by qualified mechanics Note The machine must be cleaned properly before start doing any maintenance work This will make control and maintaining the machine easier and no dirt contamination the components if they re disman tled 5 1 1 Electrical system Visual control of cable linings See to that they re not damaged or running over sharp machine edges Check the electrical cabinet casing No damage is made to the cabinet housing and rubb
74. v 3 UA a gt OZ 9IOZEWDAHS 2 ez u8 E us e A YOLOW Ex S Id INVUA lt lt A 61 CONO0IDHHS SE 8L6809LIWHH LIN Sa 5 7 r Uva SEO YOLON YIHGINVHO I 3 LSt600Cc Lua WAAGNN LIAA SCONO0IOHHS 5 WA e YOLOW 3THV L 8 E ee INOLIOG z 3 u8 E U m CIN avasi u8 E U RED TAO e 91D0SINDHEHS EE YOLON LAN GD SYATION JAINN LAIN Fi 84 um ep uuu OLE Om qr 8 ata gar HIL TES LOLSTE TULHA ud 1 a ZCDTHEDYTOXT DH gt aec Hydraulic scheme MP 2000 85 790010703 4000024 i SCLELOESO4 UL 10d x f 8TLLIOESOA 701 Hydraulic scheme 2000 TIOEEDA 400024 OG 189 0 1 0605024 80111055024 1800024 ac TW Lay L YOLON 8606060318 CONOS IHHS 190010703 10024 CCHCOCQO CC CO COO TIE Tq QT 0605004 04204 81004 SCLEIOESOS CT JuOd quv V 3 3 024 0024 86 5 5 Hydraulic scheme name and position Pos no Name Pos no Name 1 Triple pump 18 Hydraulic gear 3 1 1 4 Gate
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