ORKEL MC1000 User manual

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
Johan Gjønnes' veg 25
7320 Fannrem, Norway
Valid from serial number: 21229004
Orkel part number: 16827
orkel.no/qr/mc

Table of contents
1 General 10
1.1 Introduction 10
1.1.1 Foreword 10
1.1.2 Disclaimer 10
1.1.3 Range of use 10
1.2 Control before delivery 11
1.2.1 Preparation at customer location 11
1.3 Identification of the machine 11
1.4 The operators manual 11
1.4.1 How to use this manual 11
1.5 Warranty 12
1.6 Declaration of conformity 13
2 Safety 14
2.1 Introduction 14
2.2 Symbols 14
2.2.1 Warning, danger and caution 14
2.3 Emergency stop 16
2.4 To the operator 17
2.4.1 Exercise of security 17
2.4.2 Personal protection 17
2.4.3 Personal safety 17
2.4.4 Safe operation 17
2.4.5 Important issues 18
2.4.6 Danger zones 18
2.5 Precautions 18
2.5.1 Know your machine 18
2.5.2 Equipment control 18
2.5.3 Cleaning 19
2.5.4 Environmental protection 19

2.6 Break-in period 19
3 Settings and hydraulic adjustments 20
3.1 Main parts 21
3.1.1 Principle of operation 21
3.2 Hydraulics 21
3.2.1 Guidelines for hydraulic adjustments 21
3.2.2 Tank valves 22
3.3 Feed hopper 22
3.3.1 Control panels 22
3.3.2 Settings 22
3.4 Elevator and sub conveyor 23
3.4.1 Settings 23
3.5 Chamber 23
3.5.1 Opening speed settings 23
3.5.2 Chamber pressure settings 23
3.6 Plastic tying unit 23
3.6.1 Principle of operation 23
3.6.2 Brake and feed speed 24
3.6.3 Settings 25
3.6.4 Remote control 25
3.7 Wrapping table 26
3.7.1 Principle of operation 26
3.7.2 Wrapping settings 26
3.7.3 Film cutter settings 27
3.7.4 Wrapping table tilt speed 27
3.7.5 Wrapping table ultrasonic sensor 28
3.7.6 Microsonic sensor (S1) 28
3.8 Drawbar 28
3.8.1 Telescopic drawbar 28

4 Operation 30
4.1 Safety 31
4.1.1 Safe work routine 31
4.1.2 Operator safety 31
4.1.3 Other people's safety 31
4.1.4 Assembly on site 31
4.1.5 Elements of hazard during operation 31
4.1.6 Danger zones during operation 32
4.1.7 Risk of overturning 32
4.1.8 Leaving the machine 32
4.2 Connection and setting up the machine 32
4.2.1 Rig up 32
4.2.2 Lever/Controls overview 33
4.2.3 Lever list 33
4.2.4 Leveling the machine 34
4.2.5 Placing the tractor with telescopic drawbar 34
4.2.6 Power take off 34
4.2.7 PTO Speed 34
4.2.8 Electrical power source 34
4.2.9 Hydraulic connections 34
4.2.10 Oil temperature 35
4.2.11 Stairs 35
4.3 Daily checklist 35
4.3.1 Daily checklist prior to startup 35
4.3.2 Checkpoints while baling 36
4.4 Break-in period 36
4.4.1 Precautions during the break-in period 36
4.4.2 After the first 50 hours of operation 36
4.5 Automatic operation 37
4.6 Film roller storage 38
4.7 Wrapping arms 38

4.7.1 Wrapping arm emergency stop 38
4.7.2 Installing a new film roller in the wrapper 38
4.8 Parking brake 40
4.9 Operators platform 40
5 Transport 41
5.1 Transport safety 41
5.1.1 Speed limit 41
5.1.2 On road preparation 41
5.1.3 Lifting points 41
5.1.4 Strapping and tie down 42
5.1.5 Dismantling the machine 43
5.2 Highway use 43
5.2.1 Transport preparation 43
6 Control system 44
6.1 User interface 44
6.1.1 Choose menu language 45
6.1.2 Main menu - start screen 45
6.1.3 Program menus - basic functions 45
6.1.4 Settings 46
6.1.5 User settings 49
6.1.6 Advanced settings 49
6.1.7 Sensor test 50
6.1.8 Error messages memory 50
6.1.9 Values and settings in menu 51
6.1.10 Error messages on display 52
7 Maintenance and mechanical adjustments 54
7.1 Safety 55
7.1.1 Before maintenance 55
7.1.2 Safety precautions during maintenance and mechanical
adjustments 55
7.1.3 Elements of hazard during maintenance 55

7.1.4 Control after repair or maintenance 56
7.2 Electrics 56
7.3 Wheels 56
7.4 Chains 56
7.4.1 Chain tensioner A 56
7.4.2 Chain tensioner B and C 57
7.5 Feed hopper 58
7.5.1 Tightening the feed hopper belts 58
7.5.2 Ball bearings 59
7.6 Elevator and sub conveyor 59
7.6.1 Conveyor belts and feeder carrier 59
7.6.2 Adjusting the conveyor chains 59
7.6.3 Chain tensioner, sub conveyor 60
7.6.4 Chain tensioner, elevator 61
7.6.5 Ball bearings elevator 61
7.7 Baling chamber 61
7.7.1 Inspection 61
7.7.2 Adjusting the front chamber belt 62
7.7.3 Adjusting the rear chamber belt 62
7.7.4 Adjusting the chamber belt tensioner 65
7.7.5 Replacing chamber belt 66
7.8 Plastic tying unit 66
7.8.1 Control and maintenance 67
7.9 Wrapping table 67
7.9.1 Inspection 67
7.10 Frame, drawbar, attachments 68
7.10.1 Frame 68
7.10.2 Main components, fastening points 68
7.11 Chamber roller bushings 69
7.11.1 Wear inspection 69
7.11.2 Permissible wear 70

7.11.3 Remove sprockets 71
7.12 Hydraulics 71
7.12.1 Hydraulics oil 71
7.12.2 Hoses and connections 71
7.12.3 Hydraulic pump, gearbox 71
7.12.4 Heat exchanger 72
7.13 Oil change and oil filter 72
7.13.1 Changing oil and filter 73
7.14 Welding and grinding 74
7.14.1 Precautions when welding 74
7.15 Service history 74
8 Lubrication 76
8.1 Lubrication system, beka max EP 1 76
8.1.1 Oil lubrication, mode of operation 76
8.1.2 Grease lubrication, mode of operation 76
8.1.3 Beka max grease lubrication system 78
8.2 Refilling lubricants 78
8.2.1 Refilling the oil reservoir 78
8.2.2 Adjusting the amount of grease 79
8.2.3 Bleeding the grease system 79
8.3 Electric pump and main distributor 80
8.4 Troubleshooting for Beka max 80
8.5 Oil temperature 81
8.6 Approved lubricants 81
8.6.1 Hydraulics 81
8.6.2 Chain lubrication 81
8.6.3 Greasing 81
8.6.4 Gearbox and gears for hydraulic motors 81
8.7 Manual lubrication charts 82
8.7.1 The compactor 82
8.7.2 Feed hopper 83

8.7.3 Telescopic drawbar 84
8.8 Lubrication list - Manual greasing points 85
9 Preservation 86
9.1 Cleaning 86
9.1.1 Using high pressure washer 86
9.2 Storage 86
9.2.1 Long time storage 86
9.2.2 Oil filling in the grease lubrication storage 86
10 Electrics 87
10.1 Inputs and outputs sorted by type 87
10.1.1 Inductive sensors 87
10.1.2 Ultrasonic Digital sensors 88
10.1.3 Pressure sensors 88
10.1.4 Level and high temp/switch 88
10.1.5 Emergency stop switches 88
10.1.6 Simulate bale on table switch 88
10.1.7 Safety switch 88
10.1.8 Grease pump 88
10.1.9 Valves 88
10.2 Sensor overview 90
10.3 Sensor list and function 91
10.4 Fuses 91
10.5 Schematics 92
10.5.1 Main board 93
10.5.2 Main board BD1 Left 94
10.5.3 Main board BD1 Right 95
10.5.4 Complete electrical schematics 96
11 Hydraulics 97
11.1 Hydraulic diagram 97
11.1.1 Complete diagram 98

11.1.2 Hydraulics 2 99
11.1.3 Hydraulics 3 100
11.1.4 Hydraulics 4 101
11.1.5 Hydraulics 5 102
11.1.6 Hydraulic diagram list 103
11.1.7 Hydraulic overview name and position 103
11.2 Valve overview 104
11.2.1 Valve list 104
11.3 Valve adjustments 107
11.3.1 Adjusting wrapping table and arms 108
11.3.2 Adjusting chamber speed 108
11.3.3 Adjusting conveyor belt speed 108
11.3.4 Adjusting plastic film or net brake 109
11.3.5 Main valves 109
11.3.6 Chamber pressure settings 109
12 Specifications 110
12.1 Electrical system 110
12.2 Power take off 110
12.3 Lubrication system beka-max 110
12.4 Hydraulic system 111
12.5 Wheels and tyres 111
12.6 Dimensions and weight 111
12.6.1 Measurements 111
12.6.2 Power requirements 111
12.6.3 Dimensional sketch, operating mode 112
12.6.4 Dimensional sketch, transport mode 113
Glossary 114
Index 116

1 General
1.1 Introduction 10
1.1.1 Foreword 10
1.1.2 Disclaimer 10
1.1.3 Range of use 10
1.2 Control before delivery 11
1.2.1 Preparation at customer location 11
1.3 Identification of the machine 11
1.4 The operators manual 11
1.4.1 How to use this manual 11
1.5 Warranty 12
1.6 Declaration of conformity 13
1.1 INTRODUCTION
1.1.1 Foreword
The products from Orkel AS are well known for their high quality, reliability and strength. We will therefore
congratulate you, choosing one of our products.
To fulfill our own goals, regarding quality and strength, Orkel AS has implemented a continuing product-
developing process. All compactors undergo a thorough quality control before leaving the factory.
Read thoroughly, and familiarize yourself with our recommendations, regarding machine - safety, use and
maintenance. Make daily maintenance a routine. By doing this, the machine will be safe to operate, and you
will contribute to a longer machine lifespan and an effective utilization of the machine.
With regards
Orkel AS
1.1.2 Disclaimer
The original parts used in an Orkel® machine are designed and built to provide optimal fit, function, safety,
and structural integrity. For this reason, Orkel® DOES NOT in any circumstance approve of the use of after-
market, gray market, or imitation parts.
The information provided by Orkel® hereunder is provided “as is" and with all faults, and the entire risk asso-
ciated with such information is entirely with the Buyer.
Orkel® does not grant, explicitly or implicitly, to any party any patent rights, licenses, or any other IP rights,
whether with regard to such information itself or anything described by such information.
Information provided in this document is proprietary to Orkel®, and Orkel® reserves the right, at its sole dis-
cretion, to make any changes or modification to the information in this document or to any products and ser-
vices at any time without notice.
Orkel® does not assume responsibility for any damages associated with the machine or failure caused by
incorrect use of the machine. Neither do we assume responsibility for any changes to the product made
after initial delivery.
1.1.3 Range of use
The MC1000 compactor is designed for compressing soft organic materials to bales wrapped in plastic film
for storage or transport. 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 10

warranty legislations.
1.2 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
start-up.
NOTE: Please see the delivery - warranty formula included with the user manual.
1.3 IDENTIFICATION OF THE MACHINE
A sticker describing the serial number is located on the right side of the machine. In addition, the number is
also imprinted on top of the frame. See Figure 1.1.
The serial number must always be provided when contacting your dealer, either it’s for ordering parts or
technical assistance.
The serial number is the safest way to identify your machine. Do not remove or change the serial number.
Figure 1.1 : Serial number location
1.4 THE OPERATORS MANUAL
1.4.1 How to use this manual
This manual is organized after the «see—think—use»-principle. The content and explanations are arranged
in smaller sequential operations, and the main chapters are arranged according to the normal use of the
machine (Example: Setup —> Operation —> Maintenance).
Chapter overview:
1 GENERAL 11

1. GENERAL This chapter contains some of the formularities associated with a new compactor. Quality
control, identification the machine, and copies of the delivery and warranty forms.
2. SAFETY This chapter consist of the general safety measures one have to consider at all times when
dealing with the machinery. More specific safety measures and warnings are listed and explained
when relevant.
3. SETTINGS AND HYDRAULIC ADJUSTMENTS An introduction to the functionality of the machine. Fur-
thermore, it explains how and where one can adjust the hydraulics to achieve the wanted func-
tionality. Topics organized and gathered for every machine module. Same order as in chapter 7
"Maintenance and mechanical adjustments".
4. OPERATION Describes the rig up process, what to consider prior to and during operation. It also spe-
cifies the running in period.
5. TRANSPORT States all the safety measures and preparations necessary for successful and safe trans-
port of the compactor.
6. CONTROL SYSTEM Gives a detailed overview of the control system and its functions.
7. MAINTENANCE AND MECHANICAL ADJUSTMENTS A detailed overview of the necessary maintenance
and procedures for mechanical adjustments. Topics organized and gathered for every machine mod-
ule. Same order as in chapter 3 "Settings and hydraulic adjustments".
8. LUBRICATION Explains oil and grease lubrication functionality, settings, troubleshooting and shows
detailed lubrication charts for manual lubrication.
9. PRESERVATION Washing, and other preparations prior to and during long time storage.
10. ELECTRICS Electric schematics.
11. HYDRAULICS Hydraulic diagrams.
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. You can also contact our after sales department.
1 GENERAL 12

1.6 DECLARATION OF CONFORMITY
1 GENERAL 13

2 Safety
2.1 Introduction 14
2.2 Symbols 14
2.2.1 Warning, danger and caution 14
2.3 Emergency stop 16
2.4 To the operator 17
2.4.1 Exercise of security 17
2.4.2 Personal protection 17
2.4.3 Personal safety 17
2.4.4 Safe operation 17
2.4.5 Important issues 18
2.4.6 Danger zones 18
2.5 Precautions 18
2.5.1 Know your machine 18
2.5.2 Equipment control 18
2.5.3 Cleaning 19
2.5.4 Environmental protection 19
2.6 Break-in period 19
2.1 INTRODUCTION
This operator’s safety manual is made to describe safe and good routines when operating the compactor.
On the other hand, it is not possible to describe every operational and safety matters that may arise. Care-
fully consider all your actions, if it is posing a safety hazard to you, or others close to the compactor! • Acci-
dents may kill you or make you disabled. • Accidents can be avoided.
2.2 SYMBOLS
This symbol means:
lATTENTION!
lBE CAUTIOUS!
lCONSERNFORYOURPERSONALSAFETY!
When you see this symbol in the operator’s manual, be aware that violation of instructions given, can cause
you or others in the working area of the machine, being injured or killed.
2.2.1 Warning, danger and caution
Each time you see the words and symbols as shown below, please note the different directions they sym-
bolize. The pictograms are used in this manual or/and on the machine.
The symbol and the word DANGER,
state a direct or immediate dan-
gerous situation that will cause
DEATH OR SERIOUS INJURY if not
avoided.
The symbol and the word WARNING, indic-
ates a potentially hazardous situation. If
you fail to comply with instructions given it
could result in personal injury or loss of life.
2 SAFETY 14

Do not start operating the machine
until you have read and understood
the safety precautions.
Always stop the tractor engine or external
power unit before; lubricating, adjusting,
maintaining or repairing the machine. Also,
remove the ignition key to prevent acci-
dental start.
Ensure that there are no people
between tractor and machine during
connecting and disconnecting.
Never allow children to stay near the
machine during operation. Young children
can do unpredictable things
Danger rotating parts. Keep clear of
moving/rotating parts in chamber.
Operator or others close to the machine
must be aware when the bale is unloaded
from the wrapper table. Bales dropped may
roll more than 10 m, or even dropped pre-
maturely.
Always use the hydraulic securing
valves on the chamber door lifting
cylinders, to ensure that the
chamber door stays in open position
during maintenance or repair.
The net or widefilm is cut with a sharp
knife. Be careful when loading a new roller,
or if any adjustment is done to the knife sys-
tem.
All parking of the machine must be on
a firm levelled ground, and secured
with wheel chocks.
Unauthorized personell are not allowed
closer than 5 meters, when the machine is
operating or when maneuvering.
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.
Keep clear! Do not enter below bunker or
frame when operating the compactor.
Noise zone. Use ear protection. Stairway. Access only for operators or
mechanics.
2 SAFETY 15

Make sure the transmission is run-
ning with the correct speed and
direction. Wrong speed and/or
direction can damage machinery and
may cause great danger to persons
nearby. The machine is designed for a
PTO-speed of 850 rpm.
Stay clear, rotating machinery.
Strapping point. Lifting point.
Jacking point. Hydraulics securing valves, locking the tail-
gate lifting cylinders.
Between the tractor and the machine, there is a rotating PTO-shaft.
No one is allowed to stand between the tractor and the machine
while the engine is running. 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
AS.
2.3 EMERGENCY STOP
The machine is equipped with 5 manual emergency stop buttons. Four are accessible from ground level and
one on top of the machine as indicated on Figure 2.1.
Figure 2.1 : Red circles indicates emergency stop locations. Two more buttons are located on
the opposite side, ground level.
When an emergency stop button has been triggered, the emergency stop button has to be reset so that the
machine can be started from the control panel.
2 SAFETY 16

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
lAs operator, it is your responsibility that you read and understand the safety instructions given in this
operator’s safety manual.
lThese instructions must be followed without exception. The operator is the key to safety on this
machine, not only for you, but also for others in the compactors working area.
lFollow the safety instructions, and you will experience the compactor as a safe and secure place to
work.
2.4.2 Personal protection
The Compactor might generate a lot of dust and noise, depending on which material being com-
pressed. For your own health, we recommend that operators use personal protective equipment,
such as safety goggles, dust/filter mask, and ear-protection during operation.
2.4.3 Personal safety
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.
2.4.4 Safe operation
Persons under 16 years of age should under no circumstances operate this machine.
Personnel under influence of alcohol or other drugs must not operate this machine.
2 SAFETY 17

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.
2.5 PRECAUTIONS
2.5.1 Know your machine
Know your machine. Learn all the functions and actuating mechanisms, and familiarize where the emer-
gency stop switches are located. Learn the machines capacity and limitations, to avoid unnecessary down-
time and mechanical break-down.
IMPORTANT: If any dangerous situations occur, shut down the power take off (PTO) right away.
2.5.2 Equipment control
Before starting up, make sure that the machine and its equipment is in place and in good working order! See
chapter 7 "Maintenance and mechanical adjustments".
2 SAFETY 18

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.
2.6 BREAK-IN PERIOD
Check Check points
Do not run compactor at maximum capacity the first 25 hours of operation
Be observant – monitor that functions are working correctly.
Check for abnormal sounds from the machinery
Fine tune the process to be carried out so that the compactor can reach maximum capacity,
based on material being baled.
All bearings have a visible grease collar. Figure 2.3
No visible grease on the relief valve on the grease pump.
Precautions: A new compactor must go through a break-in in period. It shouldn’t be run at maximum capa-
city at the first 25 hours of operation. The operator must be observant, monitoring that all functions are
working correctly, and being aware of abnormal sounds from the machinery. Fine tuning of the process
must be carried out, until the compactor has reached its optimum capacity, based on the material being
baled.
Figure 2.3 : Grease collar on bearings/bushings
NOTE: Slide bearing clearance is tight when the machine is new, and could lead to increased temperature in the
bearings. The slide bearings must be checked frequently during the break-in period. If the temperature is rising
in some of the bearings, activate the manual greaser from the control panel to increase the amount of grease
supplied to bearings.
2 SAFETY 19

3 Settings and hydraulic adjustments
3.1 Main parts 21
3.1.1 Principle of operation 21
3.2 Hydraulics 21
3.2.1 Guidelines for hydraulic adjustments 21
3.2.2 Tank valves 22
3.3 Feed hopper 22
3.3.1 Control panels 22
3.3.2 Settings 22
3.4 Elevator and sub conveyor 23
3.4.1 Settings 23
3.5 Chamber 23
3.5.1 Opening speed settings 23
3.5.2 Chamber pressure settings 23
3.6 Plastic tying unit 23
3.6.1 Principle of operation 23
3.6.2 Brake and feed speed 24
3.6.3 Settings 25
3.6.4 Remote control 25
3.7 Wrapping table 26
3.7.1 Principle of operation 26
3.7.2 Wrapping settings 26
3.7.3 Film cutter settings 27
3.7.4 Wrapping table tilt speed 27
3.7.5 Wrapping table ultrasonic sensor 28
3.7.6 Microsonic sensor (S1) 28
3.8 Drawbar 28
3.8.1 Telescopic drawbar 28
3 SETTINGS AND HYDRAULIC ADJUSTMENTS 20