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ORKEL MC1000 User Manual

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User Manual
MC1000 Compactor
MC1000.UM.2A.EN
Original version. Published 2021.
According to Directive 2006/42/EC, Annex | 1.7.4.1
Orkel AS
Valid from serial number: 21229004
Johan Gjønnes' veg 25
Orkel part number: 16827
7320 Fannrem, Norway
orkel.no/qr/mc

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  • Page 1: Lubrication System, Beka Max Ep

    User Manual MC1000 Compactor MC1000.UM.2A.EN Original version. Published 2021. According to Directive 2006/42/EC, Annex | 1.7.4.1 Orkel AS Valid from serial number: 21229004 Johan Gjønnes' veg 25 Orkel part number: 16827 7320 Fannrem, Norway orkel.no/qr/mc...

  • Page 2: Table Of Contents

    Table of contents 1 General 1.1 Introduction 1.1.1 Foreword 1.1.2 Disclaimer 1.1.3 Range of use 1.2 Control before delivery 1.2.1 Preparation at customer location 1.3 Identification of the machine 1.4 The operators manual 1.4.1 How to use this manual 1.5 Warranty 1.6 Declaration of conformity 2 Safety 2.1 Introduction...

  • Page 3: Hydraulics

    2.6 Break-in period 3 Settings and hydraulic adjustments 3.1 Main parts 3.1.1 Principle of operation 3.2 Hydraulics 3.2.1 Guidelines for hydraulic adjustments 3.2.2 Tank valves 3.3 Feed hopper 3.3.1 Control panels 3.3.2 Settings 3.4 Elevator and sub conveyor 3.4.1 Settings 3.5 Chamber 3.5.1 Opening speed settings 3.5.2 Chamber pressure settings...
  • Page 4 4 Operation 4.1 Safety 4.1.1 Safe work routine 4.1.2 Operator safety 4.1.3 Other people's safety 4.1.4 Assembly on site 4.1.5 Elements of hazard during operation 4.1.6 Danger zones during operation 4.1.7 Risk of overturning 4.1.8 Leaving the machine 4.2 Connection and setting up the machine 4.2.1 Rig up 4.2.2 Lever/Controls overview 4.2.3 Lever list...
  • Page 5 4.7.1 Wrapping arm emergency stop 4.7.2 Installing a new film roller in the wrapper 4.8 Parking brake 4.9 Operators platform 5 Transport 5.1 Transport safety 5.1.1 Speed limit 5.1.2 On road preparation 5.1.3 Lifting points 5.1.4 Strapping and tie down 5.1.5 Dismantling the machine 5.2 Highway use 5.2.1 Transport preparation...
  • Page 6 7.1.4 Control after repair or maintenance 7.2 Electrics 7.3 Wheels 7.4 Chains 7.4.1 Chain tensioner A 7.4.2 Chain tensioner B and C 7.5 Feed hopper 7.5.1 Tightening the feed hopper belts 7.5.2 Ball bearings 7.6 Elevator and sub conveyor 7.6.1 Conveyor belts and feeder carrier 7.6.2 Adjusting the conveyor chains 7.6.3 Chain tensioner, sub conveyor 7.6.4 Chain tensioner, elevator...
  • Page 7 7.11.3 Remove sprockets 7.12 Hydraulics 7.12.1 Hydraulics oil 7.12.2 Hoses and connections 7.12.3 Hydraulic pump, gearbox 7.12.4 Heat exchanger 7.13 Oil change and oil filter 7.13.1 Changing oil and filter 7.14 Welding and grinding 7.14.1 Precautions when welding 7.15 Service history 8 Lubrication 8.1 Lubrication system, beka max EP 1 8.1.1 Oil lubrication, mode of operation...
  • Page 8 8.7.3 Telescopic drawbar 8.8 Lubrication list - Manual greasing points 9 Preservation 9.1 Cleaning 9.1.1 Using high pressure washer 9.2 Storage 9.2.1 Long time storage 9.2.2 Oil filling in the grease lubrication storage 10 Electrics 10.1 Inputs and outputs sorted by type 10.1.1 Inductive sensors 10.1.2 Ultrasonic Digital sensors 10.1.3 Pressure sensors...
  • Page 9 11.1.2 Hydraulics 2 11.1.3 Hydraulics 3 11.1.4 Hydraulics 4 11.1.5 Hydraulics 5 11.1.6 Hydraulic diagram list 11.1.7 Hydraulic overview name and position 11.2 Valve overview 11.2.1 Valve list 11.3 Valve adjustments 11.3.1 Adjusting wrapping table and arms 11.3.2 Adjusting chamber speed 11.3.3 Adjusting conveyor belt speed 11.3.4 Adjusting plastic film or net brake 11.3.5 Main valves...

  • Page 10: General

    The MC1000 compactor is capable of producing bales of various sizes, ranging from Ø500 mm to Ø850 mm. The compactor must only be used for this purpose. NOTE: Other materials can also be compressed, but have to be confirmed by Orkel AS in each case. This due to 1 GENERAL...

  • Page 11: Control Before Delivery

    This machine is tested, controlled and has passed final inspection, before leaving the factory. 1.2.1 Preparation at customer location Orkel AS will set-up the machine for the customer if requested/agreed. An introduction course, both in hand- ling and operating the compactor will be held at site if requested/agreed. During commissioning and start- up period, we’re offering our technical assistance and answering all questions regarding the compactor...

  • Page 12: Warranty

    12. SPECIFICATIONS An overview over the general machine capacities and performances. 1.5 WARRANTY Orkel AS recommends that you study the document «Warranty conditions» for detailed information regard- ing warranty terms and conditions. This document can be found enclosed in the binder delivered with the compactor.

  • Page 13: Declaration Of Conformity

    1.6 DECLARATION OF CONFORMITY 1 GENERAL...

  • Page 14: Safety

    2 Safety 2.1 Introduction 2.2 Symbols 2.2.1 Warning, danger and caution 2.3 Emergency stop 2.4 To the operator 2.4.1 Exercise of security 2.4.2 Personal protection 2.4.3 Personal safety 2.4.4 Safe operation 2.4.5 Important issues 2.4.6 Danger zones 2.5 Precautions 2.5.1 Know your machine 2.5.2 Equipment control 2.5.3 Cleaning 2.5.4 Environmental protection...
  • Page 15 Always stop the tractor engine or external Do not start operating the machine power unit before; lubricating, adjusting, until you have read and understood maintaining or repairing the machine. Also, the safety precautions. remove the ignition key to prevent acci- dental start.

  • Page 16: Emergency Stop

    Do not wear loose clothes, scarfs etc. Warning signs, indicating danger or warning attached to the machine, must not be removed or painted over. Unreadable signs shall be replaced by new ones. These can be ordered from Orkel 2.3 EMERGENCY STOP The machine is equipped with 5 manual emergency stop buttons.

  • Page 17: To The Operator

    Figure 2.2 : Mushroom head type emergency stop button. Twist the head to reset. 2.4 TO THE OPERATOR 2.4.1 Exercise of security As operator, it is your responsibility that you read and understand the safety instructions given in this operator’s safety manual. These instructions must be followed without exception.

  • Page 18: Important Issues

    2.4.5 Important issues Be aware of children and other unauthorized persons in close proximity to the machine. Never allow unqual- ified persons to operate this machine. 2.4.6 Danger zones Only operators and maintenance personnel are allowed “inside” the danger zone! All others must be turned away, due to their own safety! The entire left side of the compactor is a blind spot for the operator.

  • Page 19: Cleaning

    2.5.3 Cleaning A good cleaning of the machine increases durability and safety. Therefore, keep all surfaces clean, remove dirt, oil-spills and other remains. 2.5.4 Environmental protection Hazardous waste, such as rubber, oil and other materials that could harm the environment, must be dis- posed at approved disposal centres.

  • Page 20: Settings And Hydraulic Adjustments

    3 Settings and hydraulic adjustments 3.1 Main parts 3.1.1 Principle of operation 3.2 Hydraulics 3.2.1 Guidelines for hydraulic adjustments 3.2.2 Tank valves 3.3 Feed hopper 3.3.1 Control panels 3.3.2 Settings 3.4 Elevator and sub conveyor 3.4.1 Settings 3.5 Chamber 3.5.1 Opening speed settings 3.5.2 Chamber pressure settings 3.6 Plastic tying unit 3.6.1 Principle of operation...

  • Page 21: Main Parts

    3.1 MAIN PARTS Figure 3.1 : The compactor main parts 3.1.1 Principle of operation The material is loaded into the feed hopper using a wheel loader, or directly by a conveyor belt. The material is then transported by the elevator into the chamber. The amount and speed is controlled by an ultrasonic sensor as well as settings in the display unit.

  • Page 22: Tank Valves

    3.2.2 Tank valves MC1000 got four tank valves: T1, T2, T3 and T4. 3.3 FEED HOPPER NOTE: All references to valves found in this sub chapter can be found in the hydraulic schematic and valve over- view in chapter 11 "Hydraulics"...

  • Page 23: Elevator And Sub Conveyor

    3.4 ELEVATOR AND SUB CONVEYOR 3.4.1 Settings The speed of the elevator belt and the sub conveyor may be changed from the display unit, on the machine settings page. 3.5 CHAMBER The bale chamber can handle high loads, but the set chamber pressure and the resulting bale density must be considered and possibly limited according to type of material.

  • Page 24: Brake And Feed Speed

    The brake automatically disengages when opening the rollers. If this for some reason doesn't happen, this may be done from the display unit () or the remote control (section 3.6.4 "Remote control") on the platform. Figure 3.3 : Plastic tying unit 3.6.2 Brake and feed speed The speed should be set so that the net/film is fed at a slightly higher speed than the bale’s peripheral speed.

  • Page 25: Settings

    Figure 3.4 : Brake and feed speed controls B1 Valve for feed speed B2 Valve for brake force C Gauge D Emergency stop switch E Electrical valve for brake release/engagement 3.6.3 Settings Feed speed: Adjusting the feed speed is done by turning the B1 valve. Clockwise decreases the speed. Coun- terclockwise increases the speed.

  • Page 26: Wrapping Table

    system starts Release brake: Press and hold red button and shortly tap blue button. Engage brake: Press and hold red button and shortly tap yellow button. The brake will automatically release and engage when the opening and closing sequences are engaged. NOTE: When the net/film system is started from the remote control, the machine will continue in auto mode when the sequence is completed.

  • Page 27: Film Cutter Settings

    3.7.3 Film cutter settings The opening and closing speed of the film cutters must be set correctly. If their speed is too high, the wrap- ping film might be damaged instead of neatly cut when the wrapping arms stop. The film cutters speed, left (valve P4) and right (valve P5), may be reduced by turning the valve clockwise.

  • Page 28: Wrapping Table Ultrasonic Sensor

    Bales dropped from the wrapping table may roll more than 10 m. 3.7.5 Wrapping table ultrasonic sensor The wrapping table ultrasonic sensor detects the bale when transported from the chamber, so that the table accepts the bale by moving to the middle position. 3.7.6 Microsonic sensor (S1) This type shows the read distance on an LCD.
  • Page 29 Telescopic drawbar Figure 3.8 : The safety lock pull cord is located in close proximity to the hydraulic levers. 3 SETTINGS AND HYDRAULIC ADJUSTMENTS...

  • Page 30: Operation

    4 Operation 4.1 Safety 4.1.1 Safe work routine 4.1.2 Operator safety 4.1.3 Other people's safety 4.1.4 Assembly on site 4.1.5 Elements of hazard during operation 4.1.6 Danger zones during operation 4.1.7 Risk of overturning 4.1.8 Leaving the machine 4.2 Connection and setting up the machine 4.2.1 Rig up 4.2.2 Lever/Controls overview 4.2.3 Lever list...

  • Page 31: Safety

    4.1 SAFETY IMPORTANT: If any dangerous situations occur, shut down the PTO right away. 4.1.1 Safe work routine This machine must under no circumstances be used for any other purpose than the intended one. Operate in daylight conditions only. Install additional worksite lighting if necessary. If the operator have to leave the site, the tractor or any other power supply must be turned off and key removed to avoid unattended start.

  • Page 32: Danger Zones During Operation

    squeezing/crushing of fingers or hands between wrapping arms and frame. impact from rotating wrapping arms. sensor on wrapping table might fail, causing a too early bale drop. a burst in a hydraulic line/hose with high pressure- and heated oil can cause severe injury to eyes and skin.

  • Page 33: Lever/Controls Overview

    Perform a function test of all the emergency stop switches before starting baling. 4.2.2 Lever/Controls overview Figure 4.1 : Lever/Controls overview MC1000 section 3.3.1 "Control panels" for descriptions of the levers/controls regarding the feed hopper. 4.2.3 Lever list Lever no:...

  • Page 34: Leveling The Machine

    Lever no: Valve function Right support leg, rear Up / down Feed hopper Up / down Left support leg, front Up / down Right support leg, front Up / down Drawbar In / out 4.2.4 Leveling the machine 1. Ensure that the feed hopper is raised clear of the ground when leveling the machine. The feed hopper may be lowered onto the ground only when the machine is properly leveled.

  • Page 35: Oil Temperature

    Feed hopper lifting cylinders, feed hopper halves (IN/OUT), jack stands, film roller storage, and draw- bar. Feed hopper lifting cylinders, jack stands, film roller storage, and drawbar. All functions are operated through manual levers on the machine. See section 4.2.2 "Lever/Controls over- view"...

  • Page 36: Checkpoints While Baling

    The first 50 hours of operation are considered to be the break-in period. NOTE: Before the compactor is shipped from the factory, Orkel has performed a thorough quality control and made a test run. The test run is done without any material. The need of some adjustments during first start up is to be expected, depending on the material being baled.

  • Page 37: Automatic Operation

    Filters IMPORTANT: Orkel recommends that the operator regularly performs visual controls of the compactor as well as active listening for abnormal noises. Perform adjustments as soon as there is a need. A problem that is not imme- diately rectified may cause further problems, and in worst case lead to mechanical breakdown.

  • Page 38: Film Roller Storage

    When set chamber pressure is reached (elevator slow threshold) the elevator slows down in order to reduce the material flow into the chamber until the bale is finished. Then, the net/film knife opens and the feed rollers start feeding the net/film into the chamber. A predefined number of layers of net/film is laid on the bale, and the knife cuts the net/film.
  • Page 39 Empty film strecher Threading of the film shall be done as illustrated in the principle drawing Figure 4.5 : Film in the film stretcher seen from above. User resources for installing new film rollers may be found at www.orkel.com/qr 4 OPERATION...

  • Page 40: Parking Brake

    4.8 PARKING BRAKE The parking brake is located near the right side wheel (Figure 4.6). Rotate clockwise to engage, and counter clockwise to disengage. IMPORTANT: Apply the included pad lock when the park brake is activated, as to prevent unauthorized use of the compactor or disengagement of the parking brake.

  • Page 41: Transport

    5 Transport 5.1 Transport safety 5.1.1 Speed limit 5.1.2 On road preparation 5.1.3 Lifting points 5.1.4 Strapping and tie down 5.1.5 Dismantling the machine 5.2 Highway use 5.2.1 Transport preparation 5.1 TRANSPORT SAFETY Be aware of the danger of tipping when driving off road. 5.1.1 Speed limit 5.1.2 On road preparation This machine is designed for being towed by the drawbar only.

  • Page 42: Strapping And Tie Down

    NOTE: Use only certified lifting gear with sufficient lifting capacity. Figure 5.1 : Lifting- and strapping points front Lifting- (red) and strapping (blue) points rear Figure 5.2 : 5.1.4 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 this purpose.

  • Page 43: Dismantling The Machine

    5.1.5 Dismantling the machine General safety precautions must be taken when stripping down the machine. Center of gravity might change during dismantling. Secure large parts to reduce the risk of injury. Be aware of overturning. Hazardous waste like: Oil, plastic and so on, must be stored in an environmentally safe way, or delivered at a certified waste-disposal plant.

  • Page 44: Control System

    6 Control system 6.1 User interface 6.1.1 Choose menu language 6.1.2 Main menu - start screen 6.1.3 Program menus - basic functions 6.1.4 Settings 6.1.5 User settings 6.1.6 Advanced settings 6.1.7 Sensor test 6.1.8 Error messages memory 6.1.9 Values and settings in menu 6.1.10 Error messages on display 6.1 USER INTERFACE This section provides a brief introduction to the user interface, so that you quickly can get started using the...

  • Page 45: Choose Menu Language

    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.

  • Page 46: Settings

    Press baler 2 to enter menu Baler 2 Possible selections: Net knife, open - close Net feed, on Belt under, Fast - slow speed Screen menu, Baler 2 Figure 6.5 : Press baler 3 to enter menu Baler 3 Possible selections: Feed table, on - off Elevator, fast - slow speed Run table, on - off.
  • Page 47 In menu settings you can set/change up to 30 para- meters (See screen pictures 1,2 og 3) By pressing button under the arrow in the display you can switch between parameters and screens pages. By pressing button under + or - of the chosen para- meter, the value is changed.
  • Page 48 View stored information Switch between counters by pressing buttons under arrows in display. Press select button to choose a counter to look into. The chosen line should now be marked with a * behind the counter number in display. Then press details button to view stored information registered on the customer.

  • Page 49: User Settings

    Time Enter menu screen; user settings. Select Clock on the right side of screen to enter menu; Adjust date & time 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 - Figure 6.17 :...

  • Page 50: Sensor Test

    To browse faults in memory, press button under arrows up or down in display NOTE: Use this menu as a reference if you are about to contact your local dealer or Orkel Compaction Ltd, if a problem has occurred. Figure 6.22 :...

  • Page 51: Values And Settings In Menu

    To look closer at a failure, press button under Details shown in display. Example: Failure code:180 This indicate there is a error in sensor S18. See sec- tion 6.1.10 "Error messages on display" Menu advanced settings 1 Figure 6.23 : 6.1.9 Values and settings in menu Recommended set- Text:...

  • Page 52: Error Messages On Display

    Recommended set- Text: Description of parameter setting tings/values Net type Type of the net/film wrapping unit - for net only (net) or net/film PLASTIC model (plastic). Measure weight Not in use. Table down delay Delay of the table from dropping position until it starts to go up 1 - 2 s again.
  • Page 53 Message Sensor State Net did not break BSTART01, BSTART05, BSTART10, BSTART15, BALING1, BALEFULL1 Net tying failure NETFEED3, PLASTIC3 Film cutter did not close PLASTIC5 Emergency STOP (all) Emergency STOP (all) Chamber pressure sensor (when baling) broken Chamber overpressure (when baling) Under-voltage at control Control (all)

  • Page 54: Maintenance And Mechanical Adjustments

    7 Maintenance and mechanical adjustments 7.1 Safety 7.1.1 Before maintenance 7.1.2 Safety precautions during maintenance and mechanical adjustments 7.1.3 Elements of hazard during maintenance 7.1.4 Control after repair or maintenance 7.2 Electrics 7.3 Wheels 7.4 Chains 7.4.1 Chain tensioner A 7.4.2 Chain tensioner B and C 7.5 Feed hopper 7.5.1 Tightening the feed hopper belts...

  • Page 55: Safety

    Before any maintenance or adjustments are performed on the machine, we recommend you to make a con- ference call to your local dealer or Orkel AS. All repair work shall be carried out by a skilled mechanic. 7.1.2 Safety precautions during maintenance and mechanical adjustments NOTE: Due to your own safety, Orkel AS recommends that all repair- and maintenance work on the machine is done in daylight conditions or equivalent.

  • Page 56: Control After Repair Or Maintenance

    Look for abnormal wear and tear on sprockets and chains. Replace worn out parts if needed. Contact your local supplier or Orkel AS directly if you have any doubts about parts that must be replaced. 7.4.1 Chain tensioner A Basic setting: Adjust the chamber drive chain tensioner bolt until the chain play is approximately 3 mm.

  • Page 57: Chain Tensioner B And C

    Figure 7.1 : Chain tensioner A Implications during adjustment: When adjusting either the left side (drive chain tension) or the right side (belt tracking) of this roller, these adjustments influence each other. Hence, you have to adjust both sides multiple times, until you achieve the ultimate chain tension and belt tracking combination.

  • Page 58: Feed Hopper

    Chain tensioner B and C Figure 7.2 : 7.5 FEED HOPPER 7.5.1 Tightening the feed hopper belts This belt are of chain type with welded carriers. Check the belt tensioning and look for uneven wear. Feed hopper conveyor Figure 7.3 : Procedure: Loosen the four bolts holding the bracket.

  • Page 59: Ball Bearings

    Figure 7.4 : Chain tensioner, feed hopper 7.5.2 Ball bearings The rollers in the feed hopper should be without deformations and cracks. Check the bearing clearances without belt tension. Replace worn bearings. 7.6 ELEVATOR AND SUB CONVEYOR 7.6.1 Conveyor belts and feeder carrier Sub conveyor and elevator.

  • Page 60: Chain Tensioner, Sub Conveyor

    Figure 7.6 : Sub conveyor Procedure Loosen the four bolts holding the bracket. Untighten the counter nut and tighten the bolt on the chain tensioner until correct chain-tension is achieved. Adjust both sides equally. Tighten the counter nut and the attaching bolts on bracket. 7.6.3 Chain tensioner, sub conveyor Figure 7.7 : Chain tensioner sub conveyor...

  • Page 61: Chain Tensioner, Elevator

    Replace damaged rollers and belts if excessively worn. If there is excessive wear on the chamber sidewalls, Hardox wear plates can be retrofitted on the chamber walls. Contact Orkel AS if relevant. NOTE: The play in the slide bearings is at the smallest when the compactor is brand new. This may result in increased temperature in the bearings.

  • Page 62: Adjusting The Front Chamber Belt

    NOTE: In extreme cases of heating, a special filler nipple may be used (force lubricate) after removing the hose from the bearing. Please contact Orkel if this is necessary. 7.7.2 Adjusting the front chamber belt All adjustment of the belt tracking is done on the right side of the chamber (upper front roller). See Figure 7.10.
  • Page 63 Figure 7.11 : Rear chamber adjustments Rear tension roller Adjusting the belt tracking is done by changing the distance C on the rollers bearing point D (Figure 7.13) Figure 7.12 : Tension roller By increasing the distance C, the belt tracking will go towards B (Figure 7.12).
  • Page 64 Bearing point (D), tension roller Figure 7.13 : Figure 7.14 : Adjusting brackets, rear chamber belt Upper adjustment roller C Prior to this adjustment it´s very important to ensure that the machine is levelled. Adjusting the belt tracking is performed by changing the distance D on the roller C (Figure 7.15).

  • Page 65: Adjusting The Chamber Belt Tensioner

    Figure 7.16 : Tension roller Figure 7.15 : Bracket, upper adjust- ment roller By increasing the distance D, the belt will go towards A (Figure 7.16) in the chamber. If decreasing the dis- tance the belt will go towards B (Figure 7.16) in the chamber.

  • Page 66: Replacing Chamber Belt

    7.7.5 Replacing chamber belt Clean the chamber. Use a high pressure washer. Remember to secure the chamber door lifting cylinders before entering the chamber Remove the damaged belt using a knife and cut the belt crosswise. Be observant of the rotation direction. Hook the new belt to the old one and use the chamber motor to pull the belt into place.

  • Page 67: Control And Maintenance

    Figure 7.19 : Plastic tying unit, location 7.8.1 Control and maintenance 1. Clean and lubricate the slides for feed rollers. 2. Check the chain tension and the chain condition.(SeeFigure 7.20) Adjust the tension by loosening the bolt and turn the nylon eccentric to add more tension to the chain. Then retighten the bolt. 3.

  • Page 68: Frame, Drawbar, Attachments

    Figure 7.22 : Wrapping table, emergency stop handles Knife bed Figure 7.23 : 7.10 FRAME, DRAWBAR, ATTACHMENTS 7.10.1 Frame IMPORTANT: Check the welding for cracks or deformations once a month. 7.10.2 Main components, fastening points Check all major bolt connections and re-tighten if necessary. Drawbar—frame Drawbar—eye Chamber—frame...

  • Page 69: Chamber Roller Bushings

    Feed hopper—frame Elevator—frame Pay extra attention to the bolts fixing the draw bar and eye. (574 Nm) Figure 7.24 : Fixing bolts for drawbar eye 7.11 CHAMBER ROLLER BUSHINGS IMPORTANT: The bushings must be controlled every 5000 bales produced, or when 1000 hours of operation are reached.

  • Page 70: Permissible Wear

    This is the most typical condition. These bushings are worn the most when the chamber is «full», and the bale pressure forces the rollers outwards. Thus the most wear on the bushings will be on the outer side. 2. Drive chain This condition occurs on the bushings that are affected by the drive chain direction.

  • Page 71: Remove Sprockets

    NOTE: Good practice is to change the bearings before reaching the maximum degree of wear. 7.11.3 Remove sprockets The sprockets are fastened to the axle with an eccentric connection. Follow this procedure to loosen the sprockets. 1. Make an indication mark across both the sprocket and axle (red line) that indicates movement between the axle and the sprocket.

  • Page 72: Heat Exchanger

    Figure 7.29 : Dipstick with max and min level indicators Gear box and hydraulic pump Figure 7.30 : The oil level must be between max and min on the level indicator. Top up if necessary. The gear oil must be changed minimum once a year, or when needed. See approved lubricants in section 8.6.4 "Gearbox and gears for hydraulic motors"...

  • Page 73: Changing Oil And Filter

    Some pressure can remain in the hydraulic system/hoses/pipes, even though the machine is shut down. IMPORTANT: Always change filters when changing the hydraulic oil! 7.13.1 Changing oil and filter Hydraulic oil 1. Heat the oil up to about 30°C. 2. Slightly tilt the compactor towards the drain plug. The plug is placed on the underside of the tank. 3.

  • Page 74: Welding And Grinding

    1. Place an empty container beneath the drain hole. 2. Remove the drain plug. 3. Drain until empty. 4. Clean the plug. 5. Clean up the oil spill. 6. Reinsert the plug (replace sealing if necessary). 7. Refill with Shell Omala S2 220. 8.
  • Page 75 Date/year Service/maintenance/major repair Performed by; Name/company 7 MAINTENANCE AND MECHANICAL ADJUSTMENTS...

  • Page 76: Lubrication

    8 Lubrication 8.1 Lubrication system, beka max EP 1 8.1.1 Oil lubrication, mode of operation 8.1.2 Grease lubrication, mode of operation 8.1.3 Beka max grease lubrication system 8.2 Refilling lubricants 8.2.1 Refilling the oil reservoir 8.2.2 Adjusting the amount of grease 8.2.3 Bleeding the grease system 8.3 Electric pump and main distributor 8.4 Troubleshooting for Beka max...
  • Page 77 Figure 8.1 : Pump element, suction phase Figure 8.2 : Pump element, pressure phase The grease lubrication system is a progressive system. It operates all types of grease of NLGI kl. 2 type. See recommended lubricants in section 8.6.3 "Greasing". A progressive lubrication system, means that all the bearings are lubricated one by one.

  • Page 78: Beka Max Grease Lubrication System

    8.1.3 Beka max grease lubrication system Figure 8.3 : Beka Max grease lubrication pump system, exploded view with description on major parts. 1. Reservoir, transparent 7. Delivery piston 2. Stirrer scrape 8. Non return valve 3. Suction area, pump 9. Pressure relief valve 4.

  • Page 79: Adjusting The Amount Of Grease

    1/2 turn on the adjusting screw reduces the grease added by 0,013cm³. Please contact Orkel Compaction if you have any questions. It is also possible to regulate the grease amount for the control unit. Adjustable from 100% down to 40%.

  • Page 80: Electric Pump And Main Distributor

    8.3 ELECTRIC PUMP AND MAIN DISTRIBUTOR 8.4 TROUBLESHOOTING FOR BEKA MAX Problems Cause Remedy Fuse defective Replace fuse Pump does not work Problem with the power supply Replace electrical cable Problem with pump motor Replace pump motor NOTE: Correct motor mounting Air pocket in pump Bleed the pump Pump is working...

  • Page 81: Oil Temperature

    Problems Cause Remedy A primary hose between main distributor Replace hoses No grease collar on and sub distributor is broken multiple bearings Retighten fittings or replace Leakage in fittings The hose serving the bearing is defective Replace hose No grease collar on one bearing Leakage in the fitting Retighten fittings or replace...

  • Page 82: Manual Lubrication Charts

    8.7 MANUAL LUBRICATION CHARTS 8.7.1 The compactor 8 LUBRICATION...

  • Page 83: Feed Hopper

    8.7.2 Feed hopper 8 LUBRICATION...

  • Page 84: Telescopic Drawbar

    8.7.3 Telescopic drawbar 8 LUBRICATION...

  • Page 85: Lubrication List - Manual Greasing Points

    8.8 LUBRICATION LIST - MANUAL GREASING POINTS MC1000: Description: Qty on each side: Location: Total Intervall Elevator, lower Left and right Handbrake Right Sub conveyor, elevator side Left and right Brake shaft, support Left and right Under elevator, bearings on rollers...

  • Page 86: Preservation

    9 Preservation 9.1 Cleaning 9.1.1 Using high pressure washer 9.2 Storage 9.2.1 Long time storage 9.2.2 Oil filling in the grease lubrication storage 9.1 CLEANING 9.1.1 Using high pressure washer The compactor can be cleaned with a high pressure washer. Avoid directing the beam towards any electrical connections and components.

  • Page 87: Electrics

    10 Electrics 10.1 Inputs and outputs sorted by type 10.1.1 Inductive sensors 10.1.2 Ultrasonic Digital sensors 10.1.3 Pressure sensors 10.1.4 Level and high temp/switch 10.1.5 Emergency stop switches 10.1.6 Simulate bale on table switch 10.1.7 Safety switch 10.1.8 Grease pump 10.1.9 Valves 10.2 Sensor overview 10.3 Sensor list and function...

  • Page 88: Ultrasonic Digital Sensors

    10.1.2 Ultrasonic Digital sensors Ultrasonic Digital sensors Pin 3 Description Pin 1 Pin 2 Pin 4 Pin 5 S01 Bale on table KR3-4 KR1-4 KR5-1 S21 Feedhopper KR4-21 KR2-21 KR6-21 10.1.3 Pressure sensors Pressure sensors Pin 2 Description Pin 1 Pin 3 Pin 4 Pin 5...
  • Page 89 Directional valves, globe valves, proportional valves Pin 3 Description Pin 1 Pin 2 Pin 4 Pin 5 V05 Table UP KR13-5 KR15-5 V06 Table DOWN KR13-6 KR15-6 V07 Run wrapping table KR13-7 KR15-7 V08 Net knife KR13-8 KR15-8 V09 Wrapping arm slow KR13-9 KR15-9 V10 Wrapping arm fast...

  • Page 90: Sensor Overview

    10.2 SENSOR OVERVIEW 10 ELECTRICS...

  • Page 91: Sensor List And Function

    10.3 SENSOR LIST AND FUNCTION Inputs on controllers for standard system No. Description Type Brand & type Range Comment Bale on table ultra- Digital ultra- 100...2000 Microsonic mic+130/D/TC Default 70 cm sound sound Table in middle pos- Pepperl&Fuchs NBB8- Inductive PNP 3...8 mm ition 18GM50-E2-V1...

  • Page 92: Schematics

    5. Hydraulic control V1 - V16 15A 6. Hydraulic control V17 - V32 15A 7. 15A 8. Free 9, 10 and 11. 10A, 15A og 20A (Spare) 10.5 SCHEMATICS All schematics can be found online at www.orkel.com/qr for higher resolution. 10 ELECTRICS...

  • Page 93: Main Board

    10.5.1 Main board 10 ELECTRICS...

  • Page 94: Main Board Bd1 Left

    10.5.2 Main board BD1 Left 10 ELECTRICS...

  • Page 95: Main Board Bd1 Right

    10.5.3 Main board BD1 Right 10 ELECTRICS...

  • Page 96: Complete Electrical Schematics

    10.5.4 Complete electrical schematics 10 ELECTRICS...

  • Page 97: Hydraulics

    11 Hydraulics 11.1 Hydraulic diagram 11.1.1 Complete diagram 11.1.2 Hydraulics 2 11.1.3 Hydraulics 3 11.1.4 Hydraulics 4 11.1.5 Hydraulics 5 11.1.6 Hydraulic diagram list 11.1.7 Hydraulic overview name and position 11.2 Valve overview 11.2.1 Valve list 11.3 Valve adjustments 11.3.1 Adjusting wrapping table and arms 11.3.2 Adjusting chamber speed 11.3.3 Adjusting conveyor belt speed 11.3.4 Adjusting plastic film or net brake...

  • Page 98: Complete Diagram

    11.1.1 Complete diagram 11 HYDRAULICS...

  • Page 99: Hydraulics

    11.1.2 Hydraulics 2 11 HYDRAULICS...
  • Page 100 11.1.3 Hydraulics 3 11 HYDRAULICS...

  • Page 101: Hydraulics

    11.1.4 Hydraulics 4 11 HYDRAULICS...

  • Page 102: Hydraulics

    11.1.5 Hydraulics 5 11 HYDRAULICS...

  • Page 103: Hydraulic Diagram List

    11.1.6 Hydraulic diagram list Outputs on controllers for standard system Type Brand & type Current drawn at 12VDC Resistance in Ohms Directional valve Duplomatic DS3-S1/10N 2,72A Directional valve Duplomatic DS3-S3/10N 2,72A Directional valve Duplomatic DS3-S3/10N 2,72A Directional valve Duplomatic DS3-S4/10N 2,72A Directional valve Duplomatic DS3-S3/10N...

  • Page 104: Valve Overview

    Pos. no Name Pos. no Name DIN Plug 12/24V Pressure relief valve 50 l/min 70 bar G. Rotor Block Check valve 3/8” 40 l/min 0,35 bar 11.2 VALVE OVERVIEW 11.2.1 Valve list Valve number Description Location Main distributor valve In cabinet Wrapper arm, fast speed In cabinet Wrapping table tilting speed...
  • Page 105 Figure 11.1 : Cabinet Figure 11.2 : Wrapping table speed 11 HYDRAULICS...
  • Page 106 Figure 11.3 : V51, wrapper speed Figure 11.4 : 11 HYDRAULICS...

  • Page 107: Valve Adjustments

    V52, V53 and V54, Wrapping table tilt and knives Figure 11.5 : Figure 11.6 : V55, Chamber opening speed 11.3 VALVE ADJUSTMENTS 11 HYDRAULICS...

  • Page 108: Adjusting Wrapping Table And Arms

    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 adjustments: By turning the valve clockwise, the flow is reduced and therefore the speed. The opposite occurs when turning the valve counter clockwise.

  • Page 109: Adjusting Plastic Film Or Net Brake

    Elevator, belt The conveyor belt speed, in the elevator is adjusted by turning on valve 59 (fast) and 60 (slow) Basic setting: Close valve 59 by turning it clock wise, then 1 turn counter clock wise. Close valve 60 by turning it clock wise, then 1 turn counter clock wise.
  • Page 110 12 Specifications 12.1 Electrical system 12.2 Power take off 12.3 Lubrication system beka-max 12.4 Hydraulic system 12.5 Wheels and tyres 12.6 Dimensions and weight 12.6.1 Measurements 12.6.2 Power requirements 12.6.3 Dimensional sketch, operating mode 12.6.4 Dimensional sketch, transport mode 12.1 ELECTRICAL SYSTEM 24 Vdc with alternator located by the pump unit and dual 12 V 55 Ah Power supply: lead acid batteries in series.
  • Page 111 12.4 HYDRAULIC SYSTEM Chamber drive: 280/340 bar (SW/relief valve) Sub-conveyer, feed hopper and film system: 180 bar Elevator and chamber door: 170 bar Wrapper 150 bar 12.5 WHEELS AND TYRES Tyre dimension: 385/65 R 22,5 Rim dimension: 11,75 x 22,5, 10-bolt Inflation pressure: 8,0 bar / 800 kPa / 116 psi (lb/in²) Wheel nuts torque: 8,0 bar / 800 kPa / 116 psi (lb/in²) Wheel nuts torque:...
  • Page 112 12.6.3 Dimensional sketch, operating mode 12 SPECIFICATIONS...
  • Page 113 12.6.4 Dimensional sketch, transport mode 12 SPECIFICATIONS...
  • Page 114 Glossary Bale chamber The material is transported into the chamber and shaped into a compact bale. After shaping the material, several layers of net/film is laid on the bale by the net/film system ensuring that the bale maintains its shape during the transport to the wrapping table. Usually referred to as "the cham- ber".
  • Page 115 Wrapping arms Wraps the bale with film while it lays on the wrapping table by rotating the arms around the bale. Safety features are mounted on the arms so that the emergency stop is triggered if something hits the safety features. Wrapping table The wrapping table is placed at the front of the compactor, and retains the bale while it is being wrapped in film by the wrapping arms.
  • Page 116 Index Break-in period 19, 36-37, 71 Daily checklist 35 Film roller Installing a new film roller 38 How to use this manual 11 Hydraulics Recommended grease 81 Recommended oil types 21 Lubrication Approved lubricants 72, 81 Greasing 36, 45, 62, 81, 85 Lubrication charts 12, 82 Maintenance 11, 54, 56 INDEX...

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