MP-2000
MP-2000
- Identification: The machine's serial number is crucial for technical assistance and should not be altered.
- Introduction: Orkel Compaction Ltd emphasizes quality and reliability, urging users to read the manual thoroughly for safe operation and maintenance.
- Range of Use: Designed for compressing soft organic materials into bales; other materials require confirmation from Orkel Compaction AS.
- Control Before Delivery: The machine is tested before leaving the plant, with setup and training provided at the customer's site.
- Warranty: Covers production and material errors for 12 months or 50,000 bales, excluding normal wear and tear and non-original parts.
- Introduction: The manual outlines safe operation routines, emphasizing caution.
- Symbols: Safety symbols indicate potential hazards, which operators must understand and adhere to.
- Operator Responsibility: Operators must read and understand safety instructions to ensure safety.
- Danger and Warning: Symbols indicate varying levels of hazard, from immediate danger to operational notes.
- Labels: Warning signs on the machine must remain visible and intact.
- Menu Navigation: Instructions on choosing menu language and navigating menus.
- Error Messages: Guidance on interpreting and responding to error messages.
- Mode of Operation: Overview of main sections and operational procedures.
- Driving on Road: Instructions for preparing the machine for transport and setting it up post-transport.
- Connecting the Machine: Details on connecting to a tractor, including PTO speed and hydraulic connections.
- Automatic Operation: Guidelines for using the machine's automatic functions.
- Operator Maintenance: Regular checks and adjustments for components like the electric system, wheels, and hydraulic system.
- Lubrication: Details on the lubrication system, including recommended grease and oil types.
- Cleaning and Storage: Instructions for using a high-pressure washer and storing the machine.
- Service History: Keeping a record of service and maintenance activities.
- Details on the electrical system, PTO, lubrication, hydraulic system, wheels, tyres, and dimensions.
- Information on available equipment and components that can be used with the machine.
- Details for the head office and service points in Norway and abroad.
- Operators must be over 16 years old and not under the influence of alcohol or drugs.
- Unauthorized persons, especially children, should be kept away from the machine.
- Use personal protective gear such as goggles, masks, and hearing protection due to dust and noise.
- Operators should familiarize themselves with the machine's functions, capacity, and limitations.
- Use all protective equipment and ensure good lighting.
- Regular cleaning and proper disposal of hazardous waste are essential.
- During assembly, check for transport damages and ensure the machine is on a stable surface.
- Maintenance should be performed by skilled mechanics with the machine stopped.
- Hydraulic safety valves must be closed before entering the chamber.
- Ensure all tools are stowed and covers are in place after maintenance.
- The machine should only be used for its intended purpose.
- Operators must be vigilant, especially when handling new plastic foil and during operation.
- Regular testing of emergency-stop switches and sensors is necessary.
- Before leaving the machine, turn off the power source and remove the key.
- During dismantling, secure large parts to prevent injury.
- The machine should be towed by the drawbar only, with a maximum speed of 40 km/h.
- Use approved lifting gear and securing straps during transport.
- Operators must read and understand all operating instructions and safety precautions.
- Maintain a safe distance from moving parts and ensure the machine is parked on level ground.
- The control box provides information on machine status and allows for manual operation if necessary.
- Advanced settings should only be adjusted by trained personnel.
The document provides detailed instructions on navigating the menu settings of a machine, allowing operators to adjust up to 30 parameters. It emphasizes the importance of recording old settings before making changes and provides guidance on switching between parameters and screens. Recommended settings are available in chapter 3.1.4.
Counters
The machine can store information for up to 50 different customers or jobs. Users can view, modify, and reset counters, with instructions on changing text or adding new customers/jobs.
User Settings
Includes adjusting display brightness, contrast, and background. It also covers sensor testing procedures and adjusting the date and time.
Parameter Settings
Chapter 3.1.4 outlines recommended settings for various machine parameters, such as chamber speed, pressure, and net/film wrapping settings. These settings are crucial for optimizing machine performance.
Operating the Machine
Chapter 4 details the machine's mode of operation, emphasizing automatic operation supervised by a control box. It describes the process from material loading to bale wrapping and highlights the importance of setting parameters based on the material being processed.
Break-In Period
New machines require a break-in period of 25 hours, during which operators should monitor functions and adjust settings as needed. The document stresses the importance of regular maintenance and adjustments to prevent mechanical breakdowns.
Driving on Road
The machine is designed for a maximum speed of 80 km/h on roads. Operators must ensure all parts are secure before transport and adhere to road conditions and speed limits.
Connecting the Machine
Instructions are provided for connecting the machine to a tractor, including PTO speed, electrical, and hydraulic connections. Proper setup is crucial for safe and efficient operation.
Net Film and Plastic Film Wrapper
Guidance is given on plastic film/net binding, adjusting the net-brake, and loading new film rollers. These steps are essential for maintaining the machine's wrapping capabilities.
Hydraulic Settings
Chapter 4.9 covers hydraulic valve operations and adjustments, including chamber speed and pressure settings. Proper hydraulic settings ensure optimal machine performance.
- Ensure the compactor is on a flat surface and disconnect all transport connections.
- Connect hydraulic hoses and level the compactor using hydraulic jack stands.
- Open safety valves and lower the feeder table to the working height.
- Connect the PTO axle and power supply cable to the tractor.
- Activate the tractor's PTO and hydraulics, ensuring correct RPM and temperature.
- Use hydraulic jack stands to level the machine horizontally.
- Check leveling frequently using water passes attached to the frame.
- Ensure the tractor is positioned correctly and the PTO speed is set to 850 RPM.
- Connect the electrical system to a 12V DC system, ensuring voltage stability.
- Ensure all main hydraulic valves are open for proper operation.
- Monitor oil temperature and adjust PTO speed accordingly.
- Ensure hydraulic valves are adjusted correctly to prevent damage.
- Use the HiT unit for binding bales with plastic film or net.
- Adjust net brake and wrapper settings as needed.
- Start the machine using the control box, ensuring all hydraulic systems are operational.
- Monitor chamber pressure and adjust feeding speed accordingly.
- Perform functional tests on emergency stop switches and repair any damages immediately.
- Regularly check hydraulic hoses and fittings for damage.
- Familiarize with valve operations and adjust speeds as necessary.
- Ensure oil is at operational temperature before making adjustments.
To set the slow speed, adjust valve nr. 69 to a maximum of 10 RPM. Ensure the film cutter operates correctly by observing the wrapper arm and readjusting if necessary, especially as oil warms up.
Knife Arm Setting
Adjust the rise and lowering speed of the knife arms using valve nr. 53 for the right arm and valve nr. 54 for the left arm. Both sides should be adjusted equally for smooth motion.
Wrapper Table Tilt Speed
Adjust the wrapper tilt speed using valve nr. 52 to control bale drop speed. Avoid setting the drop speed too fast to prevent uncontrolled unloading.
Chamber Speed Adjustment
Adjust the chamber tailgate opening speed with valve nr. 55. Set the speed as fast as possible without slamming the tailgate.
Conveyor Belts Speed Adjustments
Feeder table chain belt speed is adjusted with valve nr. 56. Belt under speed is set with valves nr. 57 and nr. 58. Elevator belt speed is adjusted with valves nr. 59 and nr. 60.
Plastic Film or Net Brake
Adjust the tension using valve nr. 61 and feeder speed with valve nr. 62. The brake can be disengaged by closing valve nr. 63.
Main Valves
The machine has four main valves (nr. 64, 65, 66, and 70) that should remain open unless repair work is being done.
Chamber Pressure Settings
Set chamber pressure in the control box. The pressure should not exceed 240 bar. Adjust parameters for fully pressed bales and elevator belt speed.
Repair and Maintenance
Operators should perform maintenance with caution, ensuring the machine is shut down and cleaned before work. Specific sections cover the electrical system, wheels, chains, wrapper, chamber, hydraulic system, and more.
Lubrication
Includes a lubrication system, refill instructions, troubleshooting, and recommended grease and oil types.
Cleaning and Storage
Guidelines for using a high-pressure washer and proper storage.
Electric and Hydraulic Schemes
Includes wiring diagrams, fuses, and sensor overviews.
Welding and Grinding
Precautions before welding are outlined.
Service History
Includes a service and maintenance scheme.
Operator Maintenance
Operators should perform visual checks and ensure all components are in good condition. Specific checks include electrical contacts, emergency switches, tyre conditions, and chain tension.
Chamber Maintenance
Regular checks and adjustments are necessary for the chamber's rollers, bearings, and belts. Instructions for adjusting belt tracking and tensioning are provided.
Hydraulic System
Monitor oil levels and condition regularly, with oil changes recommended every three years.
Regularly inspect the hydraulic system for leaks and ensure hoses are not rubbing against sharp edges. Hydraulic hoses should be replaced every six years due to their limited operational lifespan.
Inspect the input shaft, splines, and bearings of the hydraulic pump and gearbox. Check and retighten bolts if necessary. The oil level in the gearbox should be between the maximum and minimum marks, and the gear oil must be changed at least once a year. When changing gear oil, clean the magnet plug and inspect for metal shavings, which indicate excessive wear.
Check the tension and wear of the feeder table belt, elevator belt, and belt under. Adjust the chain belts by tightening the tensioner until all clearance is gone. If wear is excessive, remove a segment to tighten the belt properly. Inspect rollers and bearings for deformations and replace if necessary.
Adjust the wrapper table belt by relocating the roller to one of five alternative mounting holes. Ensure both sides are equally mounted and adjust belt tracking if necessary.
Inspect the frame for cracks or deformations and check all major bolt connections, especially those fixing the drag bar and loop. The frame also functions as an oil reservoir and cooler, so any modifications should be done with caution.
Maintain the HiT unit by cleaning and lubricating feeder roller slides, checking chain tension, and inspecting hydraulic hoses and couplings for leaks. Ensure the free wheel function of feeder rollers is operational.
The compactor features an automatic lubrication system for sleeve bearings and chains. The system uses a progressive lubrication method, ensuring each bearing is lubricated sequentially. Regularly check the pressure relief valve for signs of clogging or system issues.
Maintain lubricant levels between maximum and minimum in reservoirs. Refill the grease reservoir through the male sleeve nipple to avoid contamination. Adjust the grease delivery as needed and bleed the system if the reservoir level is too low. Clean the lubrication system components periodically.
Common issues include pump malfunctions, air pockets, and system clogs. Remedies involve replacing fuses, cables, or pump elements, and checking for clogs or leaks in the system.
The machine has multiple manual lubrication points that require greasing every 20 hours of operation. Use grease of NLGI 2 class with EP additives and follow the lubrication chart for specific intervals and amounts.
The machine is designed to operate between -15°C and +50°C. The ISO-VG system classifies industrial oils by viscosity at 40°C, with lower grades indicating thinner oils.
- Hydraulic System: Use ISO VG 32 oil for temperatures between -15°C and 30°C. Recommended brands include Shell Tellus 32 and Statoil HydraWay HVXA 32. For higher temperatures, use ISO VG 46 oil.
- Lubrication System: Use SAE 10W-30/40 or SAE 15W-40 motor oil for chains. Recommended brands include Shell Helix HX5. Use NLGI 2 class grease with EP additives for grease lubrication.
- Gearbox: Use Shell Omala S2 G 220 gear oil.
- Use a high-pressure washer for cleaning, avoiding direct contact with ball bearings and electrical connections.
- Before long-term storage, clean and lubricate the machine to prevent corrosion.
- Master fuse: 40A on the supply cable.
- Various fuses for sensors, lubrication system, and hydraulic control.
Details on hydraulic components and their positions are provided, including pumps, valves, and cylinders.
Disconnect the control box before welding. Use protective gear and keep a fire extinguisher nearby.
Maintain a record of all maintenance and repairs.
Includes checking valves, oil levels, chain tension, and hydraulic system for leaks.
- Electrical System: 12 DC voltage, 40A fuse.
- PTO: Cat 6, 2300Nm force.
- Lubrication System: Grease system with specific voltage and pressure requirements.
- Hydraulic System: Maximum pressure of 240 bar.
- Wheels and Tyres: Specific tyre and rim sizes with inflation details.
- Capacity: Produces 20-60 bales per hour.
- Dimensions and Weight: Total weight is 7800 kg with specific transport and drift dimensions.
Includes feeder table, grease gun, air cleaning system, and more.
Details for Orkel AS headquarters, sales, and technical service.
Catalog excerpts
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 Gjønnes veg 25 N– 7320 FANNREM Valid from serial number: 20220001 Orkel part-number: 1
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INDEX CHAPTER 1 -GENERAL INFORMATION 1.1 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 SAFETY - SYMBOLS LABEL SYMBOLS SAFETY ROUTINES 2.6.1 Safety. Machine in working progress 2.6.2 Important issues OPERATOR PROTECTION 2.7.1...
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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 - 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 Choose menu language Main menu - Start screen Program menus - Basic functions Values and Settings in menu: Settings...
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CHAPTER 4 - OPERATING THE MACHINE 4.1 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 PTO speed 4.4.3 Electrical connection 4.4.4 Hydraulic, connection 4.4.5 Oil temperature 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...
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5.1 OPERATOR MAINTENANCE, Control and adjustments 5.1.5.1 Chamber-belt front, adjustment 5.1.5.2 Chamber-belt rear, adjustment 5.1.5.4 Installing, replacing a new chamber-belt 5.1.5.5 Slide bearing, rollers 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 5.2.5 Approved/Recommended types of Grease and Oil 5.4 ELECTRIC - WIRING DIAGRAM 5.6.1 Precautions before welding 5.7.1 Scheme - Service and maintenance
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ELECTRICAL SYSTEM LUBRICATION SYSTEM HYDRAULIC SYSTEM TYRE PRESSURE TIGHTENING TORQUE 6.8.1 Wheel nut 6.8.2 Miscellaneous CHAPTER 7 – AUXILLARY COMPONENTS AND EQUIPMENT 7.1 CHAPTER 8 - CONTACT INFORMATION 8.1 HEAD OFFICE 8.1.1 Sale 8.1.2 Technical Service ORKEL POINT OF SERVICE 8.2.1 Norway 8.2.2 Abroad
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CHAPTER 1 -GENERAL INFORMATION 1.1 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 Certificate of warranty Warranty, limitations Normal wear and tear Warranty procedure Repairing during guarantee period Delivery form Warranty report
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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 addition, 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 serialnumber. Serialnumber, localization
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EC DECLARATION OF CONFORMITY Manufacturer: ORKEL COMPACTION AS Address: Johan Gj0nnes Veg 25 N-7320 Fannrem Norway Phone: + 47 72 48 80 00 Product description: Agricultural/Industrial - multi compactor Model: Orkel MP 2000 With serial number: 1234567 Orkel Compaction AS hereby declare, that the identified product above is conform to the requirements 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...
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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...
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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 limited 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...
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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 Date of delivery (customer) 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 Signature owner Signature Supplier/Distribut
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