setion 4 ‐ luriation and maintenane -...

4ï1

SECTION 4 ‐ LUBRICATION AND MAINTENANCE

LUBRICATION

GENERAL INFORMATION

Your baler is designed to require a minimum of

lubrication. However, regular lubrication is the best

insurance against delays and repairs and greatly

increases the life of the machine.

All gearboxes and reservoirs should be checked for

leakage daily.

Use only top grade lubricants stored in clean vessels. Recommended lubricants and amounts are summarized at the back of this manual.

Before greasing always wipe any dirt from the grease

zerks and then apply a good grade of grease. Use

Multi purpose grease classified under NLGI Class 2.

Excess grease should be wiped off.

All grease zerks on the machine are indicated with a

grease decal on which the time interval is mentioned.

1

WARNING To lubricate or service the baler manually: Always disengage the tractor PTO drive, stop the tractor engine, and apply the handbrake. Remove the tractor ignition key before leaving the cab to lubricate the baler. Turn the power off on control instruments in the tractor affecting the baler operation, to prevent accidental tripping of any of the stuffer or knotting mechanisms. Apply the flywheel brake and engage the knotter safety lock. Whenever laying under the baler is needed to carry out any kind of maintenance, support all axles on both sides to avoid getting stuck in case a tire deflates.

SECTION 4 - LUBRICATION AND MAINTENANCE

4ï2

LUBRICATION AND MAINTENANCE QUICK REFERENCE

This section is designed to a give quick and easy way of locating all the grease fittings and carrying out lubrication

and maintenance operations per interval.

SERVICE INTERVALS AND ITEMS

10 HOURS OR 400 BALES OR DAILY

Centralized greasing system (if your machine is not

equipped with the automatic greasing system, grease all five

grease banks)

x 4-5

Automatic greasing system (if fitted) x x 4-15

Ball ring hitch (if fitted) x 4-17

Stuffer clutch pawl x 4-17

Stuffer clutch housing x 4-18

Knotter clutch pawl x 4-18

Knotter clutch housing x 4-18

Automatic oiler system x x 4-23

Crop cutting knife sharpening x x 4-42

Baler x 4-85

Previous + 50 HOURS OR 2000 BALES OR WEEKLY

PTO mid ship bearing x 4-20

Knotter drive PTO (upper and lower) x 4-20

Rear wheel spindles

(on units with tandem Autosteer axle only)

x 4-21

Main drive gearbox x x 4-25

Stuffer drive gearbox x x 4-27

Knotter drive gearbox x x 4-28

Bale density hydraulic circuit x x 4-29

Chain tension x x 4-31

Main PTO drive slip clutch x x 4-34


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Needle safety linkage (Turnbuckle bearing) x 4-19

Shearbolts (knotter, flywheel, stuffer) after 2500 BALES x 4-40

SERVICE INTERVALS AND ITEMS

Previous + 100 HOURS OR 4000 BALES OR MONTHLY

Knotter drive shear hub x 4-20

Linkages, threaded rods and pivots x 4-25

Flywheel brake x 4-21

Main drive gearbox shaft couplers x 4-21

Pick‐ up overrun clutch x 4-22

Parking brake (if fitted) x 4-22

Jack x 4-22

Previous + 250 HOURS OR 10000 BALES OR YEARLY

Integrated automatic oiler (filter) x x 4-24

Stuffer drive gearbox x x 4-27

Knotter drive gearbox x x 4-28

Bale density hydraulic circuit (filter and oil) x x 4-29

Flywheel brake x 4-21

Burnishing packer slip clutch x 4-39

Stuffer brake x x 4-46

Crop holding fingers x x 4-49

Plunger knives to stationary knife clearance x x 4-52

Plunger top and side rollers x x 4-51

Hay dogs x x 4-53

Twine tension x x 4-55


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Knotter adjustments x x 4-64

Knotter trip mechanism x x 4-62

Needle adjustments x x 4-64

Maximum needle penetration x x 4-63

Tucker arm alignment x x 4-69

Needle brake x x 4-69

Needle protection linkage x x 4-71

Twine fingers x x 4-72

Brake drum linings & adjustments x x 4-83

Rotor drive cut-out clutch x 4-40

Fuses and relays x 4-74

Light bulb replacement x 4-78

Hydraulic hose check and replace as required, and by legislation in some countries

x 4-80


4ï5

CENTRALIZED GREASING SYSTEM

All machines are equipped ex-factory with a

centralized greasing system. This greasing system

provides for the greasing of many grease points,

depending on the machine configuration from four

locations on the baler.

The grease points are connected to five or more

dividers depending on the machine configuration.

Number of grease points per model are as shown in

the following table.

1

4 Knotter

Standard

4 knotter

Packer cutter

4 knotter

Rotor cutter

6 knotter

Standard

6 knotter

Rotor cutter

Counter crank needle safety 2 2 2 2 2

Packer connecting rods 6

Packer forks 2 3 3

Shuttle pivot 2 2 2 2 2

Shuttle roller 2 2 2 2 2

Shuttle crank top 2 2 2 2 2

Feeder trip mechanism 1 1 1 1 1

Packer crankshaft bearing 2

Rotor bearings 1 1

Packer rotor shaft bearing 1 1 2 1 2

Packer rotor shaft tensioner 1 1 2 1 2

Pivot top retaining fingers 1 1 1 1 1

Needle yoke connecting rods 4 4 4 4 4

Side drive output shaft 1 1 1 1 1

Plunger rollers 4 4 4 4 4

Plunger con rod bearings 4 4 4 4 4

Knotters 24 24 24 36 36

Knotter shaft central bearing 1 1

Knotter trip mechanism 2 2 2 2 2

Bale length metering wheel 1 1 1 1 1

IMPORTANT: Always use good quality, clean grease at all times. Up to quality NLGI 2 grease may be used. Do not mix lithium and calcium greases as they react with each


4ï6

other and clog up the system. Grease from the factory is Lithium based.

Grease the dividers every 8 hours of operation to

prevent plugging of grease points and bearings.

Grease each divider slowly and steadily until grease

is observed at one of the grease points connected to

the divider. This indicates that every grease point

connected to this divider has received enough

grease.

Each divider has an indicator pin on the side. When

greasing, you can see the indicator pin moving in and

out of the divider. When the indicator pin has moved

in/out or out/in one time, all grease points connected

to the divider have received a metered amount of

grease.

Several grease points from all over the machine are

centralized to dividers and/or grease banks:

All machines are equipped with:

1. Plunger divider

2. Right-hand divider

3. Left-hand divider

4. Left-hand knotter divider

5. Right-hand knotter divider

LB323S, LB333S, LB323P, LB333P, LB423S and

LB433S only

6. Grease bank

LB333P only

7. Feeder divider

The left‐ hand and right‐ hand knotter dividers have

a grease zerk fitted directly on the divider. The other

dividers have a remote grease zerk which makes the

dividers easily accessible.


4ï7

1. Plunger divider

The plunger divider (1) is installed on the plunger

inside the baler.

Grease the plunger divider daily from grease supply

fitting 1a which is easily accessible behind the right-

hand safety guard.

NOTE: As none of the grease points lubricated by the plunger divider is visible from the spot where they are greased from, give two times the number of pump strokes required on the right‐hand divider. Give three times the number of pump strokes required on the right‐hand divider in dry and dusty crop conditions.

Grease will be supplied to:

- Plunger connecting rod bearings on both sides

(2)

- Crankshaft connecting rod bearings on both

sides (2)

2

3

4

5


4ï8

2. Right‐hand divider

The right‐ hand divider (2) is installed on the right‐hand side of the baler behind the right-hand safety

guard.

Grease the right-hand divider (2) daily, from grease

supply fitting 2a which is easily accessible behind the

right-hand safety guard.

Grease will be supplied to

7 grease points: Standard units

8 grease points: Packer Cutter units

10 grease points: Rotor Cutter units

- Shuttle feeder pivot point

- Shuttle feeder roller

- Shuttle feeder top crank

- Holding fingers control pivot

- Needle yoke conrod upper (both sides)

6

7

8

9


4ï9

10

- Needle yoke conrod lower (both sides)

- Feeder drive chain tensioner

LB323S, LB333S, LB423S and LB433S

LB323P, LB333P

11

12

13


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LB333R, LB423R and LB433R

- Feeder drive shaft bearing

(LB333P, LB333R, LB423R and LB433R)

- Rotor bearings

(LB333R, LB423R and LB433R)

3. Left‐hand divider

The left‐ hand divider (3) is installed on the left‐ hand

side of the baler behind the left-hand safety guard.

Grease left-hand divider (3), from grease supply

fitting 3a which is easily accessible behind the left-

hand safety guard.

14

15

16

17


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Grease will be supplied to 9 grease points:

- Needle reclaim drive crank (2)

- Shuttle feeder pivot point

- Shuttle feeder roller

- Shuttle feeder top crank

- Stuffer trip mechanism

- Knotter drive output shaft

18

19

20

21


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4. Left‐hand knotter divider

The left‐ hand knotter divider (4) is installed on top of

the baler behind the knotter guard.

Grease left-hand divider (4), from grease supply

fitting 4a which is easily accessible from the service

platform, after opening the knotter safety guard.

Grease will be supplied to following grease points:

- 2 knotters (2 x 6)

- 2 knotters (2 x 6)

- Knotter trip mechanism (2)

22

23

24

25


4ï13

- Bale length metering wheel (1)

5. Right‐hand knotter divider

The right‐ hand knotter divider (5) is installed on top

of the baler behind the knotter guard.

Grease the right-hand divider (5), from grease supply

fitting (5a) which is easily accessible from the service

platform, after opening the knotter safety guard.

Grease will be supplied to

14 grease points (LB323, LB333) 22 grease points

(LB423, LB433):

- Knotters (2 x 6) or (3 x 6) (fig. 23 and 24)

- Knotter shaft central bearing

(LB423 and LB433 units only)

NOTE: Refer to page 4-5, for the full quantity of grease points.

6. Grease bank (LB323S, LB323P, LB333S, LB333P, LB423S and

LB433S)

Grease bank (6) is installed on the right‐ hand side of

the baler behind the right‐ hand safety guard.

Depending on the machine configuration, grease

bank (6) contains 2, 3 or 4 grease zerks.

26

27

28

29


4ï14

Grease will be supplied to the packer forks:

LB323S, LB333S: 2 packer forks

LB323P, LB333P, LB423S and LB433S: 3 packer

forks

NOTE: On a LB333P, the fourth grease zerk on grease bank (6) supplies grease to the feeder divider (refer to next paragraph headed: 7.‐Feeder divider)

7. Feeder divider (LB323P, LB333P)

The feeder divider (7) is installed on the right‐ hand

side of the baler behind the right‐ hand safety guard.

Grease the feeder divider (7), from grease zerk which

is located on the right‐ hand side on grease bank (6).

Grease will be supplied to the packer finger con rods

x6 grease points:

- Packer crank‐ shaft bearings on both sides (2) Greasing all the dividers and the grease bank (if installed) will lubricate all grease points covered by the centralised greasing system.

IMPORTANT: A blocked line or grease point can be felt while greasing as this will stall the entire divider and prevents all other grease points attached to this divider from being greased. Call for dealer assistance to fix a blocked line or grease point.

An open line can NOT be felt while greasing. Inspect all lines on a regular basis to ensure grease is reaching its destination.

30

31

32

33


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36

AUTOMATIC GREASING SYSTEM (if

installed)

An automatic system can be added to the existing

centralized greasing system.

1. Grease reservoir

2. Electrical grease pump (controlled by the Baler performance monitor)

3. Main divider

The electrical grease pump (2) delivers frequently

grease to main divider (3) which will distribute the

grease to the other dividers and/or grease bank of the

centralised greasing system. All grease points

covered by the centralised greasing system will be

supplied with grease during each greasing cycle.

The electrical grease pump is controlled by the baler

performance monitor to provide all grease points

frequently with a metered amount of grease: every 30

minutes at normal setting, every 45 minutes at low

setting and every 20 minutes at high setting.

With the automatic greasing system installed, it 35 remains possible to grease the different dividers and the

grease bank manually. The grease zerks to grease the dividers are still present to allow them to be used for

troubleshooting or if a fault occurs with the automatic greasing system.

NOTE: With the automatic greasing system installed it is recommended to grease the different dividers and the grease bank manually on a regular basis to get a feeling about the condition of the grease circuits.

Grease specification

Keep the 4 litres (1 US gal) grease reservoir filled with

multi purpose grease classified under NLGI Class 2.

Grease reservoir filling

WARNING Before working on the grease reservoir and to avoid

injury ensure that the relay K12 is removed. This is to

prevent the grease pump from running accidently

should the monitor and or key start be activated.

NOTE: To avoid contamination the reservoir (1) can only be filled by using the grease quick fill hand pump (2).

34


4ï16

To fill the reservoir using the quick fill:

1. Attach the cartridge at port and proceed as

follows:

2. Unscrew cap (3) at the grease pump and cap (4)

at the cartridge load tool.

3. Screw head (5) of the tool at the grease pump.

4. Withdraw the rod and rubber plunger of the tool

and load a cartridge with both end caps removed

in the tool (6).

5. Screw the tool with the cartridge to the grease

pump and push the grease from the cartridge into

the reservoir.

6. Remove the complete tool with the empty

cartridge and close the filler port with cap (3) (fig.

37).

CONVENTIONAL GREASE POINTS

NOTE: Grease intervals will vary as shown on the hour decals.

Grease specification

Always use grease Multi purpose grease classified

under NLGI Class 2.


4ï17

All points should be lubricated and then excess

grease must be wiped off. 1. Ball ring hitch (rotate ball

hitch to grease)

2. Ball hitch (optional): apply grease through the

fitting and wipe off all excess grease.

3. Stuffer clutch pawl

The grease fitting is accessible after opening the left‐hand safety guard.

4. Stuffer clutch housing

39

40

41


4ï18

The grease fitting is accessible after opening the left‐hand safety guard.

5. Knotter clutch pawl

The grease fitting is accessible after opening the

knotter safety guard.

6. Knotter clutch housing


knotter safety guard.

7. Knife insert pivot on both sides (2 x 1)

Rotor-Cutter units only

8. Lubricate the safety needle turn buckle bearing

(one pump shot every 50 hrs)

42

43

44

45


4ï19

46

PTO DRIVE LINE GREASING

The baler is equipped with a 3 joint driveline. To

grease the driveline look for the grease points which

are easily identified and accessible without removal

of any covers.

IMPORTANT: Refer to the PTO manufacturer's handbook attached to the PTO shaft.

The quantity of grease to be applied varies upon the

function but in general the pumps required from the

grease gun should be sufficient enough for the grease

to extrude from the joints.

NOTE: Reccomended volume of grease at each point is as shown on the PTO decal.


4ï20

On the 3 joint driveline a midship bearing is fitted to

support the drive weight, and should be greased

whenever the drive line is greased.

1. PTO midship bearing

2. Knotter drive PTO, lower side (2)

The lower grease fittings are accessible after opening

the left‐ hand safety guard.

3. Knotter drive PTO, upper side

LB323, LB333 and LB433 models (1)

The grease fitting is accessible after removing the

knotter fan assembly.

LB423 models (2)

The upper grease fitting is accessible after

removing the knotter fan assembly.

48

49

50

51


4ï21

4. Rear wheel spindles on units with tandem

Autosteer axle on both sides (2 x 3)

FLYWHEEL

1. Flywheel with tapered bearings


flywheel safety guard.

IMPORTANT: Because of the forces involved it is important to apply here at least x6 pumps of grease at every service interval.

IMPORTANT: After a shear bolt breakage ensure to regrease the bearings.

2. Stuffer gearbox drive shaft couplers x2

The grease fittings are accessible after opening the

flywheel safety guard - left‐ hand side.

3. Main drive gearbox shaft couplers

The grease fittings are accessible after opening the

flywheel safety guard - right‐ hand side.

52

53

54

55


4ï22

4. Jack x2

56

5. Pick-up overrun clutch

NOTE: Do not overgrease, maximum two grease gun strokes.


4ï23

6. Parking brake (if fitted)

7. Tandem axle centre pivot on both sides (if fitted)

57

58

59


4ï24

8. Brakes (where fitted)

IMPORTANT: There are several brake

configurations on these machines. Ensure you become

familiar with the grease points on your machine and

service as required. Hydraulic brakes (Rotor cutter)

Pneumatic brakes all models

Brake on axles

AUTOMATIC OILING SYSTEM

All machines are as standard equipped with an

automatic oiler system. At the operator set interval,

set from the monitor, a metered amount of oil is

supplied to the following chains:

Right-hand side:

1. Packer/rotor + pick-up drive chain

5. Dispenser

2. Pick-up main drive chain + right-hand centering auger

3. Pick-up reel drive chain + left-hand centering auger

6. Dispenser

7. Dispenser

Left-hand side:

4. Left-hand centering auger drive chain

8. Dispenser

The chains receive the pumped oil from the reservoir

through PVC tubing to small manifolds, from where

the oil is dispensed through brushes to the chains.

NOTE: The brushes are held in P clips which can be loosened to adjust the brush height to chains as they wear down.

60

61

62

63


4ï25

64

65

66

WARNING Before working on the oiler ensure that the relay K13

is removed. This is to prevent the oiler pump from

running accidently if the monitor and or key start is

activated.

Automatic oiling reservoir components

1. Supply line

2. Filler opening

3. Oil reservoir

4. Electric oil pump (mounted at the rear of the reservoir and controlled by the monitor)

5. Pump to pulse valve

Oil filter and pulse valve

IMPORTANT: Always clean the reservoir and pump assembly and the surrounding area before removing any parts.

Remove the large filler cap and oil screen (1) to view

the valve and filter

The oil filter must be changed annually.

IMPORTANT: The filter (2) must be horizontal when in operation or damage to the pump will result.

Drain the oil from the lower drain plug (1) turn the filter

(2) vertically 90° (service position) remove and

discard.

Fit the new filter turn horizontally 90° (operating

position) refill the reservoir to maximum and vent the

system, Figure 68.

The relief over pressure valve (3) requires no

maintenance but should a fault occur consult your


4ï26

dealer for advice. 67 Venting the oil pump

Should the oil level fall below minimum or when the oil

is drained to change the filter it will be necessary vent the oil pump to restart it.

ATTENTION: This is important do not allow the pump to run dry for more than 4 seconds at a time or it may become damaged.

Remove the left hand connection (1) and using the

monitor oil pump test (Section 2-77), run the motor in

short runs until oil is running from the hose.

68

Reconnect the hose and top up reservoir to its

maximum level. Oil specification

Keep the 5 litres (1.32 US gal) oil reservoir filled with

oil. Add oil to the reservoir through filler opening.

Use oil Ambra ISO VG 46 biodegradable or an oil

meeting the following specifications:

DIN 51524 part 2, ISO VG 46 or API CE - MIL‐ L‐2104 E.

IMPORTANT: The Ambra ISO VG 46 is a

biodegradable oil. For environmental reasons, we

recommend to use this type of oil (where available).

LINKAGES, THREADED RODS AND PIVOTS

It is recommended to oil all linkages, threaded rods

and pivot points (including guard pivot points) which

may become stiff from corrosion or dirt and after

using a pressure washer.

69


4ï27

MAIN DRIVE GEARBOX

Oil level

Keep the gearbox filled at all times. The oil level is

correct when it just reaches the middle of check level

indicator (1) (make sure the baler is on a level

surface).

Level indicator (1) is accessible after opening the

flywheel safety guard. When necessary, add oil

through filler port.

IMPORTANT: Always clean the filler port and the 70 surrounding area before removing the filler plug to top up or replace the oil.

Oil change

Annually or every 10000 bales.

Drain the oil through plug (3).

NOTE: Avoid spillage when draining off used oil.

Refit drain plug (3) and refill gearbox through plug (2)

to level plug (1).

Gearbox capacity

20 litres (5,3 US gal)

Oil specification

Use Ambra GEAR 135H EP with:

Viscosity grade: SAE 85W-140 or an oil meeting the

following specifications: API-GL5, MIL-L-2105 D.

71

STUFFER DRIVE GEARBOX Oil level


4ï28


correct when it just reaches the middle of check level

indicator (1), make sure the baler is on a level surface.

Level indicator (1) is accessible after opening the left-

hand side safety guard.

When necessary, add oil through filler port (2).

IMPORTANT: Always clean the filler port and the surrounding area before removing the filler plug to top

up or replace the oil. 72

Oil change




Gearbox capacity

3.75 litres (1 US gal)

Oil specification

Use Ambra Hypoide NH520A with:


following specifications: API-GL5, MIL-L-2105 D

KNOTTER DRIVE GEARBOX Oil level


correct when it just reaches the middle of level

indicator (1) (make sure the baler is on a level

surface).

Level indicator (1) is accessible from the service

ladder, after opening the knotter safety guard.

When necessary, add oil through filler port (2).

IMPORTANT: Always clean the filler port and the

surrounding area before removing the filler plug to top 73 up or replace the oil. Oil change




2


4ï29

Gearbox capacity

2.75 litres (0,7 US gal)

Oil specification

Use Ambra Hypoide NH520A with:


following specifications: API-GL5, MIL-L-2105 D.

BALE DENSITY HYDRAULIC CIRCUIT

General

The system uses its own hydraulic circuit which is

independent from the tractor hydraulicsystem. A

separate oil reservoir and oil filter are installed in the

baler hitch.

Oil reservoir (1) is accessible after opening the

flywheel safety guard.

Oil filter (2) is accessible underneath the baler hitch.

74

Oil level

Keep the reservoir filled at all times. The oil level is

correct when it just reaches the middle of the level

indicator (1).

IMPORTANT: Always clean the filler opening and the surrounding area before removing the filler plug to top up or replace the oil.

Oil change or top up


A special bleeding procedure should be adhered to. Ask your dealer to do this job.

Oil capacity

Entire system: approx 4 litres (1 US gal).

Oil specification

Use Ambra HYDRAULIC FLUID BIO or a biodegradable oil meeting the following specification: DIN 51524 Part 2 HV46 or ISO VG46

Viscosity grade: 46

Oil drain

75

2


4ï30

Should it be necessary to drain oil off at any time, i.e.

oil level has been exceeded, a drain plug at the base

of the reservoir can be opened and oil drained out.

76

Oil filter change

The filter must be changed:

• At every oil change (annually or every 10000

bales) or

• If the indicator on top of the filter head enters the

red section.

IMPORTANT: Failure to do so will by-pass the oil without passing the filter and could cause problems.

77 To change the oil filter, proceed as follows:

1. Remove spin‐ on filter (1).

2. Fill up the new filter with oil and apply a film of oil

to the sealing.

3. Screw on the filter by hand. Tighten firmly but do

not use tools.

4. Top‐ up the oil, start the machine and check the

oil filter for leaks.

78

Air filter change


4ï31

Mounted on the top of the reservoir is a filter screen.

The filter must be cleaned or changed:

• At every oil change (annually or every 10000

bales)

To change the filter (2) unscrew the cap (1) from the

filler tube (3) and discard the filter.

NOTE: To fill or top up the system, with the filter cap (1) and filter (2) removed top the oil up through the filler tube (3)

Fit a new filter and reassemble in reverse order.

CHAINS

Periodically check the sprocket alignment and chain

tension, referring to the figures below.

PACKER/ROTOR DRIVE CHAIN

LB323S, LB333S, LB423S, LB433S

The packer drive chain (1) tension is correct when

packer drive chain (1) can be deflected 20 mm (25/32

in) at (2) when applying a force of 150 N

(34 lbf).

Proceed as follows:

1. Loosen nuts at (4).

2. Adjust with bolt (3).

3. Retighten nuts at (4).

81

79

80


4ï32

LB323P, LB333P

The packer cutter drive chain (1) tension is correct

when the rubber damper (2) is compressed 2 mm

(5/64 in).

Adjust with nut (3).

Adjust chain guides (4) with bolts (5) to maximum 2

mm (5/64 in) from chain (1).

82

LB323R, LB333R, LB423R, LB433R

The rotor cutter drive chain (1) tension is correct when

rubber damper (2) is compressed 2 mm

(5/64 in).

Adjust with nut (3).

83

PICK-UP MAIN DRIVE CHAIN AND PICK-UP REEL

DRIVE CHAIN

LB323S, LB333S, LB333P, LB423S, LB433S

The pick-up drive chain (1) tension is correct when

pick-up drive chain (1) can be deflected 20 mm (3/4

in) at (2) when applying a force of 100 N (22 lbf).

Adjust with idler sprocket (3).

The reel drive chain (4) tension is correct when reel

drive chain (4) can be deflected 20 mm (3/4 in) at (5)

when applying a force of 100 N (22 lbf). Adjust with idler sprocket (6).

NOTE: Shield is removed for clarity.

84


4ï33


The pick-up drive chain (1) tension is correct when

pick-up drive chain (1) can be deflected 20 mm (3/4

in) at (2) when applying a force of 100 N (22 lbf).


The reel drive chain (4) tension is correct when reel

drive chain (4) can be deflected 20 mm (3/4 in) at (5)

when applying a force of 100 N (22 lbf). Adjust with

idler sprocket (6).


85

PICK-UP AUGER DRIVE CHAIN

LB323S, LB323P, LB333S, LB333P, LB423S, LB433S

The auger drive chain (1) tension is correct when

auger drive chain (1) can be deflected 20 mm (3/4 in)

at (2) when applying a force of 80 N (18 lbf).



86

LB323R - LB333R - LB423R - LB433R

The auger drive chain (1) tension is correct when

auger drive chain (1) can be deflected 20 mm (3/4 in)

at (2) when applying a force of 80 N (18 lbf).



4ï34

87


4ï35

MAIN DRIVE

PTO DRIVE SLIP CLUTCH

All models

The slip clutch requires very little maintenance, all

that is required is the spring length setting is set and

maintained on a regular basis

To check and reset the spring insert the tang of the

special tool (identified with the torque value to match

your machine) between the two spring contact points.

Then tighten or loosen the spring retaining nut to

achieve a spring length to match the tang length.

Adjust opposite springs in a clockwise direction to

ensure all are checked and adjusted equally.

Burnishing the slip clutch

Before starting a new baling season, slip this clutch

for a few seconds.

1. Release the pressure of the friction plate by

loosening all the spring nuts slightly.

2. Block the flywheel by using the flywheel brake.

3. Engage the tractor PTO at a slow speed for a few

seconds. Stop the tractor and release the

flywheel brake.

4. Retighten all spring nuts to achieve the spring

lengths as in the table above.

Model Tool setting Spring length

LB323-S

LB323-P

LB333-S

LB333-P

Nm

(885 lbf.ft)

47.5 mm

1.87 in

LB323-R

LB333-R

LB423-S

LB433-S

Nm

(1032 lbf.ft)

45.4 mm

1.78 in

LB423-R

LB433-R

Nm

(1180 lbf.ft)

44.4 mm

1.74 in

88

89


4ï36

FLYWHEEL BRAKE

When the brake is activated, flywheel (1) should stop

within 12 seconds with the tractor PTO disengaged

and the machine at full speed.

If adjustment is needed, proceed as follows:

1. Loosen counter nut (2).

2. Adjust the brake by turning bolt (3). Tightening

bolts (3) will increase the braking effect and vice

versa.

90

3. Tighten nut (2).

NOTE: It is important that the flywheel is always adjusted to keep the baler from running when the flywheel brake is applied. Readjust immediately if it does not stall the baler.

PRODUCT FEEDING PICK-UP SLIP CLUTCH

The pick-up assembly is protected against overload

by a non‐ adjustable slip clutch (1).

The pick-up slip clutch (1) is set:

• At 1000 Nm (737 lbf.ft) for standard and packer

cutter units.

• At 1450 Nm (1070 lbf.ft) for rotor cutter units.

Before starting a new baling season, slip the clutch

for a few seconds to polish the friction discs.

Loosen Allen screws (1) slightly.

Turn the pick-up by hand in reverse direction to check

if the clutch is free.

ATTENTION: Wear gloves to do this job.

Turn in Allen screws (1) until there is a little tension on

the friction discs and slip the clutch for a few turns.

92

Tighten Allen screws (1).

Turn the pick-up by hand in operating direction to

check if the clutch can freewheel.

SHEARBOLTS WARNING Before attempting any repairs on the baler ensure the

Burnishing the slip clutch 91


4ï37

- Park brake is ON-

PTO is turned off

- The tractor engine

is turned off and

Key removed

IMPORTANT: Check why a shearbolt has failed and eliminate the cause before undertaking any repair. Always replace the shearbolts with the correct type, a different type of bolt may not shear as intended and greater damage could result. It is recommended that all three shearbolts are replaced with new after every 2500 bales.

Flywheel

Mounted behind the PTO clutch (not shown) is the

flywheel shear bolt, which protects the gearbox and

plunger. Rotate the flywheel in the opposite direction

to normal to clear any obstructions.

The shearbolt is fitted through a bush mounted in the

flywheel that can be replaced if damaged, and is

designed to protect the flywheel when the bolt shears.

IMPORTANT: If changing the bush as well ensure the bush when refitted in the flywheel is flush with the

front face of the flywheel but does not interfere with the

front hub.

93

Knotter drive

The knotter drive shearbolt protects the knotters.

needle yoke and related parts. The bolt can be

accessed from the left hand side of the baler and very

easily changed, however:

ATTENTION: It is important the knotter drive and related parts (needle to plunger timing) are reset correctly before a new bolt is fitted or serious damage could result.


4ï38

Refer to knotter drive shearbolt replacement,

Section 4-67. 94 Stuffer

The stuffer shear bolt mounted at the end of the arm

on the left hand side of the baler protects the stuffer

parts and generally breaks because the stuffer was

either overloaded with crop or a foreign object has

entered and blocked the stuffer arms.

IMPORTANT: Where fitted ensure the stuffer trip lock is engaged when working in the stuffer area and disengaged before baling.

The bolt can easily be accessed and repaired as and

when necessary.

IMPORTANT: Before restarting reduce the stuffer 95 trip tension one or two notches rearward on the quadrant as crop conditions may be causing the bolt to break.


4ï39

PICK‐UP TINE REPLACEMENT

Bent and twisted pick-up tines must be replaced

immediately. If not, they may fold inside the pick-up

guards and cause severe damage.

Standard and Packer-Cutter units only

(steel sprung tines)

To replace the pick-up tines, proceed as follows:

1. Remove pick-up guard (1) covering the damaged

tine.

2. Remove the damaged tine.

96

3. Install the new tine on the pick-up tine bar with

the tine lining up like the other tines. Take care

loop (1) matches in notch (2) of cast block (3).

NOTE: Remember how to install the tines if they are all removed.

4. Reinstall guards (1).

97 Rotor-Cutter units (rubber mounted tines)

To replace the pick-up tines, proceed as follows:

1. Remove pick-up guard (1) (Fig. 96) covering the

damaged tine.

2. Remove the damaged tine.

3. Install the new tine on the pick-up tine bar with

the tine lining up like the other tines.

NOTE: The tines in the middle of the pick-up are

different from those at both sides. 98

4. Reinstall guards (1).


4ï40

AUGER STRIPPER PLATES

On rotor cutter units, the auger stripper plates on both

sides of the pick-up are adjustable.

Adjust stripper plates (1) with bolts (2) to 1-2 mm to

auger (3) to prevent the crop from wrapping.

99

PACKER SLIP CLUTCH

The packer fingers are protected from overload by a

slip clutch.

The slip clutch needs neither adjustment nor

maintenance.

LB323S - LB333S - LB423S - LB433S

A four disc slip clutch (1), set at 2100 Nm (1550 lbf.ft),

is installed.

100

LB323P - LB333P

A six disc slip clutch (1), set at 4000 Nm (2950 lbf.ft),

is installed.

ATTENTION: It is recommended NOT to change the preset torque of this clutch as this may cause serious damage to the packer crank.

101

Burnishing the slip clutch

Before starting a new baling season, slip the clutch a

few turns to polish the friction discs.

Proceed as follows:

1. Loosen nuts (1) slightly until springs (2) are

released. Do not remove the nuts.

102


4ï41

2. Block the packer with a wooden block as shown.

3. Turn the flywheel by hand until the clutch slips.

4. Tighten nuts (1) (Fig. 102) to 40 Nm (29,5 lbf.ft)

torque.

103

ROTOR CUT‐OUT CLUTCH

The crop cutting rotor is protected from overload by a

cut-out clutch set at 6500 Nm (4800 lbf.ft) and cannot

be adjusted.

Grease the slip clutch every 250 hrs (two pump shots)

using the specified grease or at least a grease which

is lithium based.

NOTE: Keep the rotor drive chain tight at all times to obtain maximum performance, reliability and durability from the cut‐out clutch.

104

ATTENTION: Never attempt to modify the clutch adjustments as this will irrevocably distort the function of the cut-out clutch. Never attempt to reset the cut-out clutch with the tractor PTO engaged, as this will soon cause damage and consequently a loss of torque.

KNIFE DRAWER ADJUSTMENTS

(Rotor cutter units only)

Centering the crop cutting knives in the rotor blades

To centre the crop cutting knives, the locking plate of

the knife drawer can be adjusted.

Proceed as follows:

1. With the knife drawer closed and locked, loosen

two carriage bolts (2).

2. Centre the crop cutting knives in the rotor blades

with nut/jam nut (3) on eyebolt (4).

3. Tighten carriage bolts (2) and the nuts on the

eyebolt.


4ï42

105

54689


4ï43

Adjustment of the knife frame latching hooks

To adjust latching hooks (2) on both sides of the knife

frame, proceed as follows:

1. Retract knife frame cylinders (1) completely.

2. Loosen two carriage bolts (4).

3. Adjust latching plate (3) to latching hook (2) to a

clearance of X = 1 mm (0.04 in) with nut/jam nut (6) on eyebolt (5).

4. Tighten two carriage bolts (4) and nut/jam nut (6).

106

CUTTER KNIFE SHARPENING

Only sharp knives will guarantee optimum cutting

performance and feed capacity of the baler. Wear and

tear of the baler, as well as tractor horsepower (and

fuel) consumption raise sharply once the knives get

blunt or damaged by foreign objects.

Field test results indicate the knives can best be

resharpened after approximately 500 bales in clean

crop conditions. In contaminated crop conditions

resharpening may be necessary after 200 bales.

It is strongly recommended to have a spare set of

sharp knives available at all times, so the baling can

continue at any time whilst the used set is in the

workshop for sharpening.

Contact your dealer for offering you the service of

sharpening the knives: he may have special

equipment for a perfect job, thereby increasing the

overall lifetime of your knives.

Should you undertake to sharpen the knives yourself

by means of a portable grinding machine, observe the

following hints:


4ï44

• Wear gloves and safety glasses.

• Securely clamp the knife on the edge of a solid

bench.

• Grind on the smooth side of the knife only, never

on the notched side.

• Slide the machine with constant speed and equal

pressure over the full length of the cutting edge.

• Do not use grinding stone discs and certainly not

cutting discs. They do not have the correct

granulation as they self-pollute with filings and 107 produce heat.

• The best equipment is a layered, coarse grain

emery cloth disc.

• Always hold the grinder machine so that the disc

rotates away from the cutting edge of the knife. •

It is better to use a big portable grinder than a

handy-man's tool: a large size disc has less

glowing effect and will track more stable on the

knife.

STANDARD KNIVES ONLY

IMPORTANT: The following applies to standard knives only. Do not grind this front face of hard faced knives, only grind

on the back face as shown in Figure 107. • Maintain the

original bevel angle. Making the bevel flatter will not

maintain the sharp edge any longer, on the contrary;

and in stony conditions, it increases the risk of chips

breaking out of the knife.

• Do not grind each time until really all indents are

smooth. Spot damages can best be treated

individually, in this case with a handy-man small

disc tool (but also with laminated emery cloth

disc) or a round file, and from the notched side of

the knife.

• If the edge has fine burrs after sharpening, it can

be cleaned by means of a wet stone or fine file.

When reinstalling the knives, make sure they

regularly change position in the machine, i.e. middle

ones on the outside and vice versa, to equal out their

wear pattern.

55356

108

55355

109


4ï45

PRESSING Stuffer trip mechanism

The stuffer trip mechanism requires minimal

adjustment, but note the following;

Sensor plates

The left hand sensor plate (1) is fitted with a stop and linkage assembly which vary in position and determines the sensor plate response.

This will vary between the baler models, for example:

Standard, Packer cutter or Rotor cutter.

110

If the lever assembly or stop are removed for any

reason they must be refitted into the correct position,

to maintain the X dimension for the baler model.

For standard machines the top lever bolt must be

fitted to the 1st hole and forward hole of the plate (1).

The bush must be fitted into the top hole at (2).


X = 65 mm (2 9/16 in)

For packer cutter machines the top lever bolt must be

fitted to the 1st hole and rearward hole on the plate

(1).

The bush must be fitted into the middle hole at (2).

LB323P, LB333P

X = 45 mm (1 49/64 in)

111

112


4ï46

For rotor cutter machines the top lever bolt must be

fitted to the 2nd hole and lowest rearward hole on the

plate (1).

The bush must be fitted into the lowest hole at (2).

NOTE: On later machines there is only one bolt hole (2) on the rotor models.


X = 65 mm

(2.53 in)

Stuffer adjustment in the home position

Assuming the sensor plate lever and bush are fitted correctly adjust the stuffer trip setting by moving the trip plate to achieve dimension Y on the stop.


Y = 25 mm (0.97 in)

LB323P, LB333P

Y = 25 mm (0.97 in)


Y = 30 mm (1.17 in)

With the lever and bush in the correct position to

maintain dimension X, the stuffer trip set correctly to

maintain Y, you will expect to see at dimension Z be

10-14 mm (0.40-0.55 in).

If Z is not correct adjust the rod (8) which should be

All models

310 mm (12.2 in)

115

113

114


4ï47

STUFFER BRAKE

Stuffer brake (1) slips a certain period during each

cycle of operation. Adjust slip torque with nuts (2).

An overtightened brake will cause overheating of the

brake plates.

116

If the brake is too loose, excessive load will occur at

stuffer clutch dog (3), the stuffer fingers will not be

retained in the home position and will partially enter

the charge chamber, causing the crop to be caught.

117

The brake spring length is initially set at 35 mm (1 3/8

in). Check and adjust the brake as follows:

1. With the baler operating at normal speed, check

if the stuffer moves steadily and without abnormal

shocks.

2. Ensure that the stuffer returns and remains in the

home position. Observe the stuffer clutch after

making these adjustments and check if it is

possible to clear clutch dog arm (3) away from

roller (4) by hand.

Final adjustment:

After one hour working:

• the clutch must not overheat. If it does, reduce

the spring setting by loosening adjusting nuts (2)

(Fig. 116) half a turn.

• If the stuffer fork does not remain steady in the

home position, increase the spring setting by

tightening adjusting nuts (2) (Fig. 116) half a turn.

NOTE: Take care the three springs are adjusted equally.


4ï48

STUFFER FINGERS TO PLUNGER

TIMING

This timing coordinates the operation of the stuffer

drive with the operation of the plunger. To produce

well-shaped bales, it is essential to set the stuffer

fingers in relation to the plunger. The drive

mechanism shown in Figure 118 is factory set. There

should be no need to retime the baler.

Timing marks on the baler make it very easy to check

the timing. Proceed as follows:

1. Turn the flywheel until notch (1) is in line with

plate (2).

NOTE: Do not turn the flywheel in the reverse direction to obtain that plunger position.

2. At this position of the plunger, timing mark (2) on

the gearbox and the notch (1) on the clutch

should align.

118

119

120


4ï49

If this check indicates that the stuffer is not timed

correctly, a more precise timing procedure should be

adhered to:

1. Remove cover (1).

2. Trip the stuffer mechanism and turn the flywheel

in operating direction by hand until the tips of

stuffer fingers (1) are at a distance X = 80 mm (3

5/32 in) from the chamber knife bevel (2).

NOTE: Distance X must be obtained without turning the flywheel in reverse direction.

3. Engage the flywheel brake.

4. The plunger knife bevel (3) should be at a

distance Y = 230 - 255 mm (9 1/16 in - 10 in) from

the bale chamber knife bevel (2).

5. Disengage the flywheel brake and check if the

plunger is moving to the rear of the baler when

turning the flywheel in operating direction.

Continue to turn the flywheel until the stuffer cycle

is completed.

6. If necessary, the above described situation can

be obtained with a fairly good accuracy by

adjusting the position of half shaft coupling (1) on

splined shaft (2).

IMPORTANT: When changing this timing, note that the needles to plunger timing and the needle protection linkage adjustment will change as well. We

highly recommend this job to be carried out by your 123 dealer.

CROP HOLDING FINGERS

To check correct operation of the crop holding finger

mechanism, proceed as follows:

1. Check if the finger tips are aligned; if not, each

finger can be realigned individually by bending it.

2. Ensure that the holding finger shaft rotates freely.

121

122


4ï50

3. Pull the crop holding finger out of the charge

chamber until the rubber stops (2) are touching

the charge chamber. At this position, the tips of

the crop holding fingers should be flush with the

front edge of the slots in the cross beam through

which they protrude. If not, adjust rubber stops (2)

with washers (3).

NOTE: This distance should be obtained without compressing the rubber stops.

124

4. Trip the stuffer mechanism and turn the flywheel

in operating direction until cam (1) engages

5. The tips of the crop holding fingers (4) should

withdraw from the charge chamber by X = 0 to

MAXIMUM 10 mm (0 in to 3/8 in) when the roller

of linkage (2) is on the highest point of cam (1).

6. If necessary adjust X by loosening lock nut (5) on

clevis end (6). Remove the clevis pin. Rotate

clevis end (6) to shorten or lengthen holding

linkage (2) and withdraws the crop holding fingers (4) Fig. 125.

125


4ï51

finger arm (3) as necessary to meet the above

dimensions. Retighten lock nut (5).

7. Continue to turn the flywheel until the stuffer

returns to the home position. Crop holding fingers

(4) are now returned inside the charge chamber.

8. Ensure there is a clearance Y of approximately

10 mm (3/8 in). To adjust this clearance, loosen

nuts (8) and move rubber stop (7) on its support.

Retighten nuts (8).

STUFFER ADJUSTMENT

The stuffer movement is controlled by the profile of

the cam wheel and a gap at (X) of minimum 4.5 mm

(0.177 in) maximum 5 mm (0.197 in). This should be

maintained when lifting up the arm manually at its

home position.

When the dimension can not be maintained at (X) it

will be necessary to add shims at the buffer stop (1).

To adjust place a 5 mm (0.196 in) slip gauge between

the cam and roller at X and check the gap at the stop (1).

Any gap at (1) can be closed by loosening the nut at

(2) and sliding in slotted shims to close the gap,

retighten the nut once sufficient shims have been

inserted.

Repeat the exercise on both sides of the machine.

PLUNGER/BALE CHAMBER

Plunger rollers

The plunger is carried by four rollers. The left-hand

front roller (4) is adjustable up and down.

Observe the plunger rollers when the baler operates

at low speed to see if all four rollers rotate correctly.

in the same direction during the entire plunger stroke.

One roller should never bind by rolling against the top

of the track. If such a situation arises, adjust the

position of the front left-hand roller, as follows:

128

1. From outside the baler, loosen the bracket

hardware (3) and at (1) from the inside of the

baler rotate the eccentric plate (2) as required to

lower or raise plunger rollers, to achieve a

126

127


4ï52

clearance X between plunger carrier rollers (1)

and top rails (2) which should be 0.6 mm to 1.5

mm (0.030 in to 0.060 in).

2. Tighten eccentric locking bolt (1) and (3) Figure

128. Turn the flywheel by hand and observe the

plunger as described previously. Repeat step (1)

and (2) as required.

3. Check the plunger rollers again and tighten nut

(3) and bolt (1) to 240 Nm (177 lbf.ft).

After 15,000 bales, check the clearance X again

between plunger carrier rollers (1) and top rails (2)

again.

It may be necessary to insert shims at (3) between

rail and plunger frame to achieve dimension X in

which case consult your dealer for advice.

rollers, one on each side. During the entire plunger

stroke, there should be a clearance of 1 to 2 mm (0.04

in to 0.08 in) between the side roller and rail.

To adjust, loosen the roller support bolts and adjust

to the above setting.

Run the plunger several times and recheck the

setting.

130

Side roller replacement

Loosen the hardware (1) and remove the roller from

the plunger body.

Replace with a new bearing but in reverse order and

observe the settings at Figure 130, and torque nuts

(1) to 200 Nm (148 lbs ft).

131 Plunger knives to stationary knife clearance

The side tracking of the plunger is carried out by two 129


4ï53

The clearance between plunger knives (1) and

stationary knife (2) should be set to X = 3 mm (1/8 in).

To adjust this clearance, proceed as follows:

1. Remove plate (3) (if fitted).

2. Loosen nuts (1).

3. Add or remove shims at (2) as required.

4. Tighten nuts (1).

5. Reinstall plate (3) Figure 132 (if fitted).

ATTENTION: As rails and rollers wear, the clearance

between the knives will become smaller which may lead

to serious damage produced. Check the knife clearance

after 8,000 bales or annually and readjust when the

clearance has become 2 mm (5/64 in).

132

Plunger top, bottom and side scrapers

Always check the plunger main rollers and side rollers

adjustment before adjusting the plunger knives and

the top and side face scrapers.

• Position top face scrapers to obtain a clearance

of 8 mm (5/16 in) between the scrapers and the

bale chamber.


4ï54

133


4ï55

• Position side face scrapers to obtain a clearance

of 5 mm (3/16 in) on both sides between the

scrapers and the bale chamber.

• Bottom scrapers (3) to 2 mm (0.078 in).

HAY DOGS

It is imperative that the hay dogs along both sides and

top of the bale chamber do not extend past the inside

surface of the chamber. If this condition exists, it is

possible that the hay dog becomes misallocated and

lodges against the bale chamber, damaging either the

hay dog, or the bale chamber, or both.

If heel (5) of upper hay dogs (2) (Fig. 136) is less than

X = 15 mm (19/32 in), and heel (5) of side hay dogs

(1) (Fig. 137) less than Y = 5 mm (3/16 in) from the

inside surface (4) of the bale chamber, build up

contacting surface (3) of the hay dog mounting

bracket sufficiently by welding to obtain at least the

minimum dimension shown.

TWINE TYING MECHANISM The baler has a double knot twine tying system.

When checking and making adjustments, close

attention is vital. Familiarize yourself with the trouble

shooting charts and the following adjustments. In

order to find a fault in the knotting system, it may be

necessary to turn the flywheel by hand, whilst a

second person watches the knotting phase.

The knotter is adjusted and tested at the factory. It

should work correctly without immediate adjustment.

134

135

136

137


4ï56

If, from the outset, knot failures are experienced with

a new baler, do not readjust straight away. The failure

may be caused by the paintwork, rust or roughness.

Continue to work until the twines loosen up the

knotting parts.

Experience shows that the majority of tying difficulties

are due to poor twine tension adjustment. Before

working on the knotters, check the adjustments. After

determining the cause of a particular problem, carry

out the necessary adjustment and then check the

result on 4 or 5 bales.

The most common causes are listed below, and

should be checked before any adjustments are

carried out:

• Dirty twine tensioners (clean this area every day)

• Incorrect twine tension

• Twine tangled in twine box

• Incorrect twine routing

• Knotter parts rough or rusty (bill hook, stripper

arm, twine finger...)

• Needles out of adjustment

• Twine disc(s) out of timing, or incorrect twine disc

tension

• Twine finger(s) out of adjustment

• Incorrect adjustment of twine tensioners outside

the twine box

• Incorrect knotter adjustment

• Spring broken on lower or upper slacker arms, or

crop build-up on these arms

• Lower or upper slacker arms seized or jammed

• Twine tensioner serrated rollers worn or broken

• Twine finger(s), or twine finger shaft seized

• Hay dog(s) or spring(s) broken

• Plunger top scrapers misadjusted or broken

TWINE BREAKAGE

DANGER Serious injury may result from threading the needles

or adjusting the twine tensioners with the baler

running. The needle frame can move at any time.

Shut off the PTO and tractor engine and engage the needle safety lock prior to carrying out any repair or adjustment.

Refer to Section 3-36.

Should the twine break at any time it can easily be

corrected as follows:

Top twine

1. Clear any loose twine from the knotter area.

2. Rethread the twine as before through the rollers

and allow the loose end to drop through the

needle area and hang below the baler, or tie it to

the cross beam in line with the knotter.

Bottom twine

1. Clear any loose twine from the needle area

2. Rethread the twine as before and tie a loop in the

loose end, then hang the loop on the hook welded

to the rear of the needle frame (in line with the

tying needle) then check the result on 4 or 5

bales.

TWINE TENSION TOP Completely loosen the twine tensioners.


4ï57

Pull the twine (in the bale chamber or after the tucker

arm) towards you.

Increase twine tension until the slacker arm comes

down and just stays down (rests against the twine

finger shaft) while pulling twine from the twine boxes.

NOTE: Do not over tension

138

TWINE TENSION LOWER

Completely loosen the twine tensioners.

Pull the twine (in the bale chamber or after the

needle) towards you.

Increase twine tension until the slacker arm comes

and just stays up (rests against the slacker arm /

twine tensioner mounting plate) while pulling twine

from the twine boxes.

139

NOTE: Incorrect twine tension will cause several knotter malfunctions. Also, tension may change after initial break-in of components.

NOTE: The various twines available on the market are featuring different specifications in terms of size and stiffness. Therefore, pay special attention to the twine tensioner adjustment whenever changing the twine supplies.

When the second knot is formed, the quality of the

knots mainly depends on the twine tension exerted by

the lower roller tensioners.

Twine tensioner too tight: Formation of a frayed and

fragile knot.

Twine tensioner too loose: Formation of a loose knot

that can fail later on, knot ends are too short.

The knotter area should be kept clean at any time.


4ï58

141

DESCRIPTION OF THE KNOTTER ASSEMBLY

140

1. Knotter frame

2. Bill hook

3. Twine disc

4. Stripper arm

5. Twine knife

6. Knotter cleaner

7. Twine holder

8. Twine holder spring

9. Bill hook cam

10. Bill hook cam tension spring

NOTE: The knotter assembly shown above is the current design level, with all settings through the following knotter adjustments being applicable.

However the shape and profile of some parts shown in the adjustments section may vary slightly from the above view.

KNOTTER ADJUSTMENTS

All adjustment steps described in this section should

be performed with the baler stationary and the

knotters/needles in their home position. If necessary,


4ï59

remove knotter lock pins (1) and pivot each knotter

frame up.

CAUTION When pivoting the knotter up the stripper arm swings

to the right. Any person doing this without the

necessary care, will risk some severe pinching of their

fingers.

To pivot the assembly a piece of twine or a locally

fabricated tool can be used to raise the knotter.

Remove the knotter lock pin (1) shown above and lift

the knotter just enough to free the mounting lug.

Place a piece of twine (2) or a suitable tool through

the mounting hole and pull the knotter up.

CAUTION When pivoting the knotter down the stripper arm

necessary care, will risk some severe pinching of

their fingers. 142

Knotter bill hook and cam adjustment

Bill hook cam (3) operates under spring tension to

apply pressure on bill hook tongue (4) (Fig. 145) when

the knot is being formed.

The normal tension applied to billhook cam spring (1),

is by tightening the leaf spring to zero clearance until

the billhook can not be lifted manually.

If the knot comes apart or is tied so loose that it can

be pulled apart, tighten the adjusting nut slightly (1/4

turn at a time). If the knot hangs on the bill hook,

loosen the adjusting nut slightly. 143 Practical

billhook adjustment is to loosen the billhook spring nut

until the billhook opens.

Hold the billhook tongue open with your finger.

Tighten the nut until the billhook tongue just closes.

NOTE: Do not overtighten.

144


4ï60

Rough edges and burrs on the bill hook may cause

the knot to hang on the bill hook or cause the fibres

in the twine to be cut, thus weakening the knot. All

rough edges and burrs must be removed with a file

and then thoroughly smoothed with an emery cloth.

145

Stripper arm knife replacement

Stripper arm knife (1) must be sharp for optimum

operation of the knotter assembly.

Since plastic twine requires a sharp knife, sharpening

or replacement will be necessary occasionally. To

sharpen the knife, remove it from the stripper arm (2).

Sharpen the knife with a stone because it is made of

high carbon hardened steel. When the knife becomes

worn, replace it with a new one.

146

Stripper arm adjustment

When stripper arm (1) is actuated, half-moon shaped

notch (2) in the stripper arm flange will rub against the

heel of the bill hook (3).

A force of 40 to 60 N (9 to 13 lbf) should be necessary

to move the stripper arm flange (1) over the heel of

the bill hook (3).

147

When adjusted correctly, the notch of the stripper arm

will travel beyond the end of the bill hook with a

minimum distance X = 15-17 mm (0.59-0.66in).

In case of doubt, remove the clevis pin and swing the knotter assembly up. If a slight adjustment is necessary, it is possible to bend the stripper arm with a

hammer, pry bar, or adjustable wrench without removing any parts of the knotter. When considerable adjustment is required, it is

advisable to completely remove the stripper arm from the knotter and bend it by using a wide jaw vice.


4ï61

148


4ï62

Twine disc adjustment

The twine disc setting is determined by the position of

the notch in twine disc (1) in relation to disc cleaner

(2).

To receive the two twines, delivered by the needle,

correctly, adjust the notch in twine disc (1) to a

distance X = 2 to 3 mm (5/64 in to 1/8 in). This setting

will allow the twines to pass between the disc cleaner

and the twine holder.

If the notch in the twine disc is advanced too much

(rotated clockwise), the twine disc will not pick up 149 twine from the needle.

Retarding the notch too much (rotated counter-clockwise) can cause the twine to wrap on the bill hook shaft or the bill hook tongue to miss the twines.

To change the position of the notch in the twine disc,

proceed as follows:

1. Loosen nut (3) that secures worm gear (4).

2. Tap the nut end of the worm gear shaft lightly to

loosen worm gear (4) from the tapered worm gear

shaft.

3. Turn twine disc (1) to its recommended position,

X = 2 to 3 mm (5/64 in to 1/8 in).

4. Hold twine disc (1) so it will not move out of

position and turn the worm gear so it fits against

spacer washers (5) located between the frame

and the worm gear.

5. Tighten nut (3) on the end of the worm gear shaft

and recheck the adjustment before baling.

NOTE: Spacer washers (5) between the frame and the worm gear are provided to take any end play out of the worm gear shaft. Too many spacer washers will prevent the worm gear from seating on the taper of the worm gear shaft. Maximum allowed end play of the worm gear shaft is 0.4 mm (0,016 in).


4ï63

Twine holder

The function of twine holder (1) is to hold the twine in

the twine disc. Twine holder springs (2) apply

pressure to twine holder (1).

The adjustment of the twine holder should be carried

out in the field. When making an adjustment to the

twine holder tension, do not turn adjustment nut (3)

more than 1/4 turn at a time.

150

Check the knot pigtail length (1) and twine drop length

(2) from the twine holder. Both should be minimum 15

mm (19/32 in) long when this adjustment is correct.

NOTE: The twine holder adjustment should be adapted to the twine quality.

During the bill hook rotation, a small amount of twine

is needed to make the knot. This is why the twine

holder must give the possibility for the twine to slide a

little at this moment. Furthermore, some twine has to

be fed from the rear and the bottom of the bill hook.

Twine holder set too loose: The pigtails are too long,

i.e. knots are hanging on the bill hook or the knots are bow knots.

Twine holder set too tight: The pigtails are too short

and the knots are pulling loose when pressure is

applied to them.

151

KNOTTER TRIP ELECTRIC (WHERE FITTED)

WARNING Before working on the trip motor ensure that the relay

K15 is removed. This is to prevent injury should the

knotters run accidentally if the monitor and or key

start is activated.

Bale length can be set by the operator on the monitor

with this system. It is designed to complement the

existing mechanical trip (both can run together).

152

KNOTTER TRIP MECHANISM

To obtain proper functioning of the knotter cycle, it is

essential that this trip mechanism is properly

adjusted.

Knotter trip mechanism in the home position

Check the position of the clutch dog arm (1) on the

declutch cam (2). There must be an overlap X = 25-27

mm (0.98-1.062 in). If necessary:

1. Loosen lock nut (4).


4ï64

2. Remove the clevis pin and adjust the length of

control linkage (3) with clevis (5) to obtain the

correct overlap.

• When the linkage is shortened, the overlap is

reduced.

• When the linkage is lengthened, the overlap

is increased.

3. Install the clevis pin and tighten lock nut (4).

The length of spring (6) should be Y = 213-217 mm

(8.36-8.54 in). If necessary, adjust with nut (7).

153

Resetting the knotter trip mechanism

The trip mechanism is reset when cam (1) controls

roller (2). In this position, check the clearance

between trip arm (6) and metering roller (5). This

clearance should be

X = 3 mm (1/8 in). If necessary:

1. Loosen lock nut (4).


4ï65

2. Move reset roller arm (3) on the declutch arm to

meet the correct clearance X.

3. Tighten nuts (4).

ATTENTION:

• If the clearance is less than 3 mm (1/8 in), bales of uneven length will be produced.

154

•


4ï66

NEEDLE ADJUSTMENT

To perform or to check the adjustments listed below,

start the following steps with the needles in the home

position. Then trip the knotters manually and slowly

rotate the baler flywheel in operating direction. Needle

to bale chamber adjustment

Rotate the flywheel until needles (1) entered the bale

chamber completely.

Check that the needle feet are centered in the bale

chamber lower slots.

If not correct, loosen needle fixation bolts (3) and (4).

Move needle (2) sideways on needle mounting (1)

until it is perfectly centered in the bale chamber lower

slots.

Tighten the fixing bolts: lower nuts (3), 50-60 Nm 155

(37-44 lb ft) and upper counter nuts (4), 60-70 Nm

(44-52 lb ft).

Rotate the flywheel until the needle tips are located

under the bale chamber top slots.

Check that the top section of the needle has an

overlap to the right side of

X = 1.5 to 3 mm (0.059 in to 0.118 in).

If not correct, bend the top section of the needle, by means of a pry bar, to the right to obtain the desired

position.

NOTE: After this adjustment always perform the needle to twine disc adjustment.


4ï67

156

Nee

dle

to

twin

e

disc

adju

stm

ent

Rotate the flywheel until the rollers of the needle are

above the twine disc.

The clearance between the second needle roll and

the twine disc should be

X = 1.5 to 3 mm (0.059 in to 0.118 in).

If necessary, adjust distance X with fixation nuts at

the bottom end of the needle.

157


4ï68

To reduce this clearance, loosen nuts (4) and tighten

nuts (3).

To increase the clearance between the needle roll

and the twine disc, loosen nuts (3) and tighten nuts

(4).

Tighten the fixing bolts: lower nuts (3), 50-60 Nm (37-

44 lb ft) and upper counter nuts (4), 60-70 Nm (44-52

lb ft).

NOTE: Always check this clearance with no twine in the needles.

158

After the needles are adjusted to the bale chamber

and to the twine disc cleaner, rotate the flywheel to

perform a complete knotter cycle and check that the

needles are centered in the bale chamber lower slots,

as well as in the plunger slots. Only the top part of the

needle should rub against the right-hand side of the

bale chamber upper slots and the knotter frame.

Check the clearance between the second roller and

the twine disc cleaner.

MAXIMUM NEEDLE PENETRATION

After having completed the above adjustments, the

needle penetration should be adjusted.

Rotate the flywheel by hand until needle actuating rod

(2) intersects the centre line of the knotter shaft as

shown.

At this position, the needles are at their maximum

penetration.

Measure the distance X between the upper twine disc

and the centre of the upper needle roll. This distance

should be

X = 140 - 150 mm (5 1/2 in - 5 7/8 in).

To adjust this distance, proceed as follows:

1. Loosen nuts (4) on both sides.


4ï69

2. Turn needle actuating rods (2) to lengthen or

shorten the rods to obtain the correct distance X.

3. Tighten nuts 4 to 100 Nm (74 lbf.ft).

CAUTION When the maximum penetration of the needles is adjusted, always check and/or adjust the needles to plunger timing and the needle protection linkage as

described further in this section before running the baler at full PTO speed.

159

NEEDLES TO PLUNGER TIMING / KNOTTER DRIVE SHEARBOLT REPLACEMENT

The needle timing coordinates the operation of the

needle and knotter drive in relation to the plunger.

The drive mechanisms have been set ex-factory.

There should be no need to time the baler, except in

the event the knotter drive shearbolt failed.

IMPORTANT: It is recommended that all shearbolts are changed after 2500 bales.


4ï70

Knotter drive shearbolt replacement

In the event a knotter drive shearbolt failed, proceed

as follows:

NOTE: Timing marks on the baler drives will ease setting the baler components in the correct position before installing a new shearbolt. It is important to be accurate when matching the marks.

1. Check why the shearbolt failed and eliminate the

cause.

160

2. Turn the flywheel manually until notch (1) is in line

with plate (2).

3. Apply the flywheel brake.

161

4. Turn the knotter drive PTO shaft in the inverse

direction (counter clockwise) until timing mark (2)

on the knotter gearbox and notch (1), (middle

between the two bolts), on the clutch align

perfectly.

5. It will not be possible to install a new shearbolt

with every turn of the knotter clutch housing.

Repeat step 4 until the shearbolt can be installed

with the timing marks on the knotter drive

matching perfectly [maximum deviation between

the marks: 5 mm (3/16 in)].

6. Install the shearbolt.

162


4ï71

In case the knotter PTO drive shaft has been

removed, proceed as follows:

1. Trip the knotter/needle drive by hand.

2. Turn the flywheel manually until the needles start

to enter the bale chamber.

NOTE: Do not turn in reverse direction to obtain this position.

3. Engage the flywheel brake.

163

4. The distance between the centre of the needle tip

roller and the tip of the plunger knife should be X

= 0 to 40 mm (0 in to 1 9/16 in).

needle protection linkage as described further in this 164 section before running the baler at full PTO speed.

TUCKER ARM ALIGNMENT

Turn the flywheel manually until needle tip rollers (1)

catch the upper twines from tucker arms (2).

The tucker arm twine rollers should be offset by 3 mm (1/8 in) towards the left of the needle centre line, with

the needles being firmly applied against the right-hand side of the bale chamber upper slots.

If one individual arm is not properly adjusted in

relation to the corresponding needle, bend tucker arm

(2) to obtain the correct position.

165

Make sure that the tucker arm roller is properly

centered on the control cam.

5. If this distance is found incorrect, advance or retard the timing by repositioning the drive shaft

(1) on the gearbox output shaft splines.


4ï72

NEEDLE CARRIAGE SUPPORT

The tightening torque of four nuts (1), on both sides of

the baler must be 200 Nm (148 lbf.ft). Check this weekly.

NEEDLE BRAKE

Needle brake (1) is designed to maintain a constant

load on needle arms during the tying cycle. This load

prevents the needles from overrunning the drive and

also helps to hold the needles in the neutral position.

IMPORTANT: At the start of a season or after a time of no use, burnish the brake by slow rotation of the baler before full baling. The brake springs length (2) must be adjusted and maintained at a length of

Spring length = 26.5mm (1.04 in).

x4 springs on 3ft wide units x6 springs on 4ft wide units. If the above spring length is not sufficient, operate the baler at 540 revs min and start the knotter cycle without twine. Turn the bolts of the brake shoe sufficiently to stop the needle yoke falling down in the 2nd cycle of the knotting by its own weight, and follows the knotter clutch dog. Afterwards tighten the bolts a little more.

Brake adjustment with baler in rotation

CAUTION Before carrying out this adjustment, observe all safety precautions listed at the beginning of this manual and adjust the needle protection linkage as instructed further in this section.

To perform this check, run the baler at the rated

speed of 1000 rpm at the PTO Then trip the knotters

manually several times and check the following:

1. Test made without twines being threaded: When

the brake setting is correct, clutch arm (7) may be

lifted 0 to 5 mm (0in to 3/16 in) any time lobe (9)

passes clutch roller (8), possibly making a

clicking noise.

2. Baler in operation and after each knotting cycle:

The clicking noise possibly noticed before should

not be heard.

166

167


4ï73

Check the brake adjustment on a weekly basis.

If the brake is set too tight:

1. The lobe (9) on the knotter drive sprocket will

strike the clutch roller (8), causing damage to it.

2. Excessive load will be applied to drive the

knotters which could result in failure of the drive

system.

If the brake setting is too loose:

1. On the way back the needle will overrun the drive

and may cause damage to the clutch arm (7) and

trip linkage.

2. A loose brake will also allow the needle to enter

the bale chamber during the bale formation

causing repeated needle reclaims and possible

damage to the trip linkage.

3. The bale becomes too long because the tripping

mechanism does not work.

168

NEEDLE PROTECTION LINKAGE

The needle protection linkage operates in conjunction

with the plunger drive system to ensure that the

needles are removed from the bale chamber in case

of any malfunction.

To adjust, proceed as follows:

1. Check that the needle brake is properly adjusted.

2. Trip the knotter manually.

3. Turn the flywheel until a complete knotter cycle is

finished.

4. As soon as the needles start to raise, check

distance X between loop (3) and roller bearing

(4). When distance X is minimal, adjust the length

of linkage (2) with nuts (1) to obtain a distance X

= 1 to 2 mm (0.04 to 0.08 in).


4ï74

5. Repeat steps 2 and 3 and check again.

CAUTION Repeat this adjustment each time the needle adjustment is changed (timing, maximum penetration, needle brake).

DO NOT ADJUST the length of the protection linkage when the needle yoke is in its home position.

When the needle timing is to be adjusted, or the needle

brake setting is changed, NEVER trip the knotter at full PTO speed without PREVIOUSLY having adjusted the protection linkage as instructed above.

169

TWINE FINGERS

The twine finger positions the twine from the needle

into the path of the bill hook. It is important that the

twine fingers operate freely and are set correctly

since a large percentage of tying failures is due to

improper adjustment.

NOTE: The needles must be properly adjusted before checking the twine fingers adjustment.


4ï75

There are two adjustments to be considered when

checking each twine finger:

1. The clearance between the tip of the twine finger

and the needle.

2. The position of the twine finger at the end of its

stroke.

NOTE: The first adjustment must be made first since it affects the second adjustment.

To adjust the clearance between the twine finger tip

and the needle, proceed as follows:

1. Trip the knotter mechanism and rotate the

flywheel manually, observing the operation of the

twine finger and the needle.

2. When the tip of the twine finger begins to pass

the needle, the clearance between the twine

finger and the needle should be 1 to 3 mm (0.04

in to 0.12 in).

3. If necessary, loosen mounting bolts (1).

4.

5.

Move twine finger mounting (2) to the front or to the rear to set the correct clearance between the twine finger tip and needle (3).

Tighten mounting bolts (1).

170

Tucker arm alignment

The tucker arm alignment after all other adjustments

are made, should be offset 0 + 2 mm (0 + 0.078 in) to

the left at (X).


4ï76

171

To adjust the position of the twine finger at the end of

its stroke:

1. Turn the flywheel until the twine finger cam roller

reaches the highest point on the twine finger

control cam.

2. At this point, the inner surface of the twine finger

(1) should be perpendicular to the needle slot (2),

as shown in figure.

3. If necessary, loosen lock nut (4).

4. Remove the clevis pin.

5. Rotate clevis (5) to lengthen or to shorten rod (3)

as necessary to meet perpendicularity between

the inner surface of twine finger (1) and needle

slot (2), angle to = 90° + 5° /- 0°.

6. Install clevis pin and tighten lock nut (4).

7. Turn the flywheel to complete the knotter cycle.

172

ELECTRICAL SYSTEM

General

The following pictures and text detail service or

adjustment procedures are not to be carried out on a

routine basis.

When an electrical malfunction occurs, the procedures

listed below should help in determining and correcting the problem.

• Check that all wiring harnesses are correctly

connected.

• Check that all connector pins and sockets are

inserted correctly in the connectors.

• Check for broken or short wires.

• Check power supply and ground wires.

• Check for blown fuses.

• Refer to section Operation to fully understand the

various features and correct function. • Refer to

the Service mode in the monitor for possible error

messages (refer to section Field and site

operation, paragraph headed monitor).

Fuses and relays


4ï77

Fuse/relay box (1) is located on the right-hand side of

the machine.

Except for the road lights, all electrical devices on

your baler are power supplied from the fuse/relay box.

Loosen four screws (2) and remove the cover to gain

access to the fuses and relays.

ATTENTION: Be sure the box is free from dust or dirt before opening. Never operate the baler with the box

open. This to avoid dust accumulation and water 173 ingress in the box causing bad connections or shorted circuits.

Shown below is the fuse board decal located on the

fuse cover from serial number 4700.

174


4ï78

ATTENTION: The electrical system is designed to run all the standard equipment as recommended by the manufacturer. Do not run additional electrical equipment that requires a heavy current above normal, because overheating and damage may result. IMPORTANT: All fuses are fitted ex-factory in the fuse bank. Never replace a blown fuse with another of a different rating. When replacing a relay, make sure the new relay has the same ampere rating and the same structure (visible on the relay housing). Always use genuine parts.

NOTE: The fuse boards shown may vary slightly from 175 your machine and depends upon options fitted which determines fuses used.

Fuses in use ECU & relays in use

F1 - Main power on rail 1 fuse (30 A) -



F5 - Moisture and bale weight (5 A) (where fitted) ECU - Power

F8 - Proportional valve 3 A K1 - Power Rail 1

F11 - Revolving flashlight (10 A) (where fitted) K1 - Power Rail 1

F12 - Grease pump (7.5 A) K1 - Power Rail 1

F13 - Oiling (5 A) K1 - Power Rail 1

F14 - Accessory 2 (7.5 A) K1 - Power Rail 1

F15 - Bale length trip motor (7.5 A) (where fitted) K1 - Power Rail 1

F21 - Knotter fans (30 A) K2 - Power Rail 2

F22 - Accessory 1. Grease pump (5 A) (where fitted) K2 - Power Rail 2

F31 - Worklights K3 - Power Rail 3

F321 - Running lights K3 - Power Rail 3

F322 - Stuffer work light (7.5 A). Bulb 55 W (where fitted) K3 - Power Rail 3

F323 - Pick up light (7.5 A) (where fitted) K3 - Power Rail 3

SYSTEM OVERRIDE

If the main power relays are still powered:

In case the required output can not longer be

controlled by using the monitor, due to malfunctioning

of the baler controller or malfunctioning of the relay

related, the output can directly be activated by

replacing the fuse using the spares.

Proceed as follows:

1. Locate the fuse that powers the electrical device

you want to activate.

2. Remove that fuse from its original position.

3. Install the fuse in the free position of fuse bank

next to its original position.

4. The selected electrical device will be energized.

If the main power relays are not powered:


4ï79

NOTE: In this case the monitor will not function.

1. Change switch SW1, from its automatic position

into its manual override position.

2. Locate the fuse that powers the electrical device

you want to activate.

3. Remove that fuse from its original position.

4. Install the fuse in the free position of fuse bank

(2) next to its original position.

5. The selected electrical device will be energized.

NOTE: In both cases of overriding remember to remove the fuses again when the baler is stopped from working to avoid unnecessary electric power consumption. When the electronic system has been repaired, remember to place the fuses back in their original position on fuse bank 1. Failure to do so will result in electrical devices not being controlled from the monitor.

POWER DISTRIBUTION

When switching on the monitor, the main power

relays that are powered will be:

Main Power Relays Main relay

K1, K2 K3

These power relays will then distribute electric power

according to the chart below.

Code Circuit identification

K1 Greasing pump (where fitted)

Accessory 2

Revolving flashlight

Oiling

Bale length trip motor

K2 Knotter fans

K3 Work lights (where fitted)

ECU

Power

Moisture and bale weight (where

fitted)

ECU - PWR


4ï80

Knotter fans

WARNING Before working on the knotter fans ensure that the

relay K21 is removed. This is to prevent the knotter

fans from running accidently if the monitor and or key

start is activated.

IMPORTANT: Should the knotter fan fuse fail, check the rotation of the fan. If blocked by any crop spill, clear the blockage and ensure free rotation of the fan blade before fitting a new fuse.

Avoiding electrical problems

IMPORTANT: With the advancement of electrical equipment it is easy to forget the voltage, current, draw and subsequent increase in heat generation. Therefore simple routine maintenance can help prevent problems occurring.

• DO NOT add high current drain equipment to the

system other than that recommended by the

manufacturer.

• DO NOT allow dust, chaff or debris to build up in

the knotter fans. Clean with a soft brush and

ensure free rotation of the fans.


or around the fuse board housing.


or around worklamps.

• DO NOT allow loose wires or cables to get trapped

or chafe together.

• DO NOT change fuses to a higher amperage than

is already fitted by the manufacturer.

• DO NOT allow water ingress to enter electrical

connections or equipment when washing or

hosing the baler.

Sensors (digital)

Three types of sensor are used on this baler and they

are:

Twine tensioner

M12 Blue optimum gap: 1-1.5 mm (0.059-0.078 in)

Knotter gearbox

M18 yellow optimum gap: 2.5 to 3 mm.

(0.098-0.118 in)

NOTE: The sensor thread is a 1mm/turn. A good adjustment tool is to turn the head of the sensor against the tooth of the gearwheel and then turn 2.5 to 3 turns back.

All other sensors except the above

M18 black optimum gap: 3-5mm (0.118-0.196in)

NOTE: The sensor setting shown as the optimum, any settings lesser or greater than these may cause the baler to malfunction. An LED is mounted in the sensor body and will illuminate when there is no metal in the detection range. This can be checked with the ignition ON, by passing a metal object in front of the sensor.

LIGHTS‐BULB REPLACEMENT

IMPORTANT: Never replace a bulb by another with a higher power rating than indicated on the original bulb. When replacing the plastic lens, take care not to overtighten the retaining screws. Front road lights

To gain access to the light bulb, extract the two

securing screws and remove the plastic lens.

Bulb specifications: 12V 10W (DIN 72601)

Side lights


4ï81



Bulb specifications: 12V 4W (T8/4 - HL - DIN 72601)

176

Rear road lights



Bulb specifications:

1: 12V 21W (P25 - 1 - DIN 72601)

2: 12V 21W (P25 - 1 - DIN 72601)

3: 12V 10W (R19/10 - DIN 72601)

177

License plate light



Bulb specifications: 12V 5W (C11 - DIN 72601)

178


4ï82

Working light

To gain access to the light bulb, extract the four securing

screws and remove the plastic lens.

To remove the bulb, detach the electric terminals of the

bulb and unlock spring (1).

Bulb specifications: 12V 55W (H3 - DIN 72601)

Revolving flashlight

To gain access to the bulb, remove plastic lens (1).

Bulb specifications: 12V 55W (H1 - DIN 72601)

HYDRAULIC SYSTEM

Hydraulic hose replacement

Hydraulic hoses are an important safety element in

modern machinery. However, hose characteristics

alter under pressure, thermal and UV light load over

the years. Therefore, most hoses now have a

production date printed on the metal clamp bushing

which allows to determine the age.

Legislation in certain countries and good practice

require that the hydraulic hoses are replaced when

they become 6 years old.

CAUTION Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Protect

179

180

181


4ï83

hands and body from high pressure fluids. Search for leaks with a piece of cardboard.

If an accident occurs, call for a doctor immediately. Any fluid injected in the skin must be surgically removed within a few hours. If not, gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source.

Density valve

The hydraulic density valve (1) on the left-hand side

can always be operated manually in case the

automatic or semi-manual system can not be used by

adjusting item (2).

For more information refer to Section 3 - FIELD AND

SITE OPERATION, paragraph headed Manual bale

density control.

182

WHEELS AND TIRES

Tire pressure

The life and performance of the tires depends largely


4ï84

upon maintaining the correct pressure. Keep the tires

inflated to the pressures given in the table.

183

Tire inflation is also shown on a decal on t he left-hand

side twine box.

184


4ï85

Wheel changing

1. Determine where to lift the baler with the jack (1)

under the axle and where to place the jackstand (2). The support points should be as close to the side of the baler wheel as possible.

2. Lift the wheel off the ground and let the weight of the

baler down onto the jackstand.

3. Remove the wheel nuts (1) and wheel.

NOTE: Reassemble in reverse order the wheel, tighten the nuts, re-jack, remove the stand, lower the baler, remove jack and re-torque the nuts.

Wheel nuts torque

The wheel nuts torque must be checked and torqued

correctly before using the baler for the first time.

Using a suitable torque wrench.

Do not use a hammer gun.

Torque the nuts to:

Minimum: 410 Nm (302 ft. lbs)

Maximum: 492 Nm (363 ft. lbs)

IMPORTANT: Thereafter, the nut torque must be checked and re-torqued daily during the first days of operation, then on a weekly basis until the torque of

the nuts has stabilized. If nuts become loose regularly 187 inspect and consider replacing the wheel nuts and bolts or even the wheel rim if damaged. Recheck the torques at the beginning of every new season.

BRAKE SYSTEM (WHERE FITTED)

Brake drum linings

The brake drum linings should be checked by your

local dealer annually.

Brake adjustment

185

186


4ï86

The aim of this adjustment is to ensure that the

wheels can turn with a minimum of resistance, whilst

maintaining maximum braking performance.

Brake adjustment should be checked frequently at

the beginning and periodically thereafter as part of a

regular maintenance schedule.

The brakes of the baler are adjusted ex-factory. After

a short bedding-in period, readjust the brakes. To

adjust the brakes proceed as follows:

1. With the brake hose connected to the tractor

braking system, depress the tractor brake pedals

to activate the braking system.

2. While keeping the pedals depressed, measure

the distance the brake cylinder(s) is (are)

extended. Then release the brake pedals.

3. If this distance is more than 60 mm (2-3/8 in),

adjust lever (1) on splined shaft (2).

188

HYDRAULIC BRAKE SYSTEM (WHERE FITTED)

The baler is equipped with one (single axle) or four

(tandem axle or tandem Autosteer axle) hydraulic

brake cylinders.

Bleeding the brake control cylinder(s)

With the brake hose connected to the tractor braking

system, depress the tractor brake pedals to activate

the braking system. While keeping the pedals

depressed, slightly release the coupler on top of the

brake cylinder(s) to bleed the circuit. Then retighten 189

the coupler and release the brake pedals.

AIR BRAKE SYSTEM (IF FITTED)

The air reservoir (1) incorporates a water bleed valve

(5) to drain any solid or liquid material that

accumulates in the air reservoir.

Bleed off regularly.

Air reservoir specification

(according to European Directive 87/404/EEC)


4ï87

• Trade mark: Wabco

Filter elements (4) need to be removed, cleaned or

replaced every year. When filter elements are

reinstalled, make sure the rubber seal is in place.

191

HYDRAULIC HOSE REPLACEMENT

Hydraulic hoses are an important safety element in

modern machinery. However, hose characteristics

alter under pressure, thermal and UV light load over

the years. Therefore, most hoses now have a

production date printed on the metal clamp bushing

which allows to determine the age.

Legislation in certain countries and good practice

requires that the hydraulic hoses are replaced when

they become 6 years old.

• Type: EN286-2

• Capacity: 40 litres (10.6 US gal)

• Maximum operating pressure:

14.5 bar

(210 lbf/in2)

• Maximum operating temperature:

100"C

(212"F)

• Minimum operating temperature: -50"C (-58"F)

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CAUTION Escaping fluid under pressure can penetrate the skin

causing serious injury. Avoid the hazard by relieving

pressure before disconnecting hydraulic or other

lines. Tighten all connections before applying

pressure. Protect hands and body from high-pressure

fluids. Search for leaks with a piece of cardboard.

If an accident occurs, call for a doctor immediately.

Any fluid injected in the skin must be surgically

removed within a few hours. If not, gangrene may

result. Doctors unfamiliar with this type of injury

should reference a knowledgeable medical source.

CLEANING THE BALER

1. Remove all the crop left in the machine to

facilitate cleaning.

2. Clean the interior and exterior of the baler

thoroughly because any chaff and dirt left in the

machine will attract moisture and cause rust.

NOTE:

• Avoid pressure washing at ambient temperatures below 10!C (50!F) or when the machine is wet. Place the machine in a heated workshop or dry barn for at least 24 hours, and clean it only when fully dried.

• Avoid to direct water jets onto electric equipment, bearings, seals, gearbox, oil tank filler caps.

• When using a high pressure washer spray:

- Keep a minimum distance of 30 cm (11in)

between the spray gun and the surface to be

cleaned.

- Spray under an angle of minimum 25° (do not

spray in perpendicular direction).

- Maximum water temperature: 60°C (140°F).

- Maximum water pressure: 60 bar (870 psi).

Do not use chemicals.

ACCESSORIES (WHERE FITTED)


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PICK-UP STOP KIT

Should it be necessary at any time to replace a hose

or repair a leak in the pick-up stop system it will

require bleeding proceeding as follows.

Bleeding the pick-up stop system.

Run the baler, with the Baler monitor ON.

In Manual operating mode, set a density pressure on the

gauge around 50 bar (725 psi).

Disengage the PTO, shut the tractor down, but

leaving the monitor under power, so the density

pressure is maintained in the system.

Disconnect the hydraulic hose elbow at the cylinder port

and have a clean oil can to catch the oil.

On the monitor, select the ”Service mode”, ”Diagnostics Output”, ”Pick-up stop”, select ”Digital” read-out.

Switch the valve ON and back OFF until the hydraulic

hoses are filled with oil.

Reconnect the elbow to the cylinder, switch the valve ON

and OFF until the oil is free from air bubbles.

Tighten the elbow at the cylinder and switch the monitor

off.

Top up the hydraulic oil reservoir with the lost oil.

194 BALE WEIGH SYSTEM - CALIBRATION

NOTE: To do this calibration the machine has to be equipped with the software version 3.6.8.0 or later, the bale weighing system with the software 1.2.0.0 or later.

There are two calibrations that need to be done, if

both need to be done start with the calibration of the

Accelorometer.

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NOTE: Before starting the calibrations switch on the machine electrical system for minimum 15 minutes to warm up the electronics. Perform the calibration of the load cells within 60 minutes.

1. Accelero-meter

1. Place the machine on a horizontal flat ground

with the rear part of the roller bale chute open in

a lateral horizontal position using the machine

hydraulic system.

NOTE: Refer to operation in this manual.

2. In the monitor, select ”Diagnosis inputs”.


3. Select the ”bale weight system”.

195

4. Enter the calibration mode by selecting again

”Diagnosis inputs” button

196

5. Select the Accelerometer button (AJ) to start the

calibration.

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6. Remove the bolts (AN) from the accelerometer

(AL) at the bottom end of the roller bale chute.

180° = position 1, and reinstall it hand tight on the

other side of the support reusing one bolt (AN).

NOTE: Make sure the accelerometer is perfectly turned 180! measure if neccessary

180° = position 1, and reinstall it hand tight on the

other side of the support reusing bolts (AN).

200

7. If two holes foreseen, turn the accelerometer (AL) 198

If three holes foreseen, turn the accelerometer (AL) 199


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8. Confirm the position 1 by selecting the green V

mark button (AI).

9. The calibration will start and takes a few seconds

the status ”busy” will appear on the screen. Wait

at this time.

NOTE: Do not move the roller bale chute during calibration.

201

10. When this screen appears, loosen the bolts (AN).

Turn the accelerometer (AL) and reinstall it in its

original place = position 2, reusing the bolts (AN).

11. Confirm the position 2 by selecting the green

Vmark button (AI).

the status ”busy” will appear on the screen. Wait

at this time.

NOTE: Do not move the roller bale chute during calibration.

13. When the status ”Calibration done” appears, the

second value is saved and the date will be

entered. This calibration is now done.

203

2. Load cells

1. Place the roller bale chute in the normal working

position.


2. At the bottom of the bale weighing frame (1) there

are two brackets (AR) through which you can fit a

bar (AS).

3. Have three calibration weights (AU) at hand with

a weight including the bar (AS) and the support

(AT) if necessary. 204

12. The calibration will start and takes a few seconds, 202


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Low weight 80-100 kg (176.4-220.5 lb)

Medium weight 200-300 kg (440.9-661.4)

High weight 400-500 kg (882-1102 lb)

NOTE: Weigh the three weights separately (up to one decimal) exactly on a balance. The exactness of the value of the weights determines the precision of the system.

4. In the monitor, select ”Diagnosis inputs”.


5. Select ”bale weight system”.

205

6. Enter the calibration mode by selecting again the

”diagnosis inputs” button.

206

7. Select the weight field (AK).

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8. Fill in the weight of the ”low weight”, the ”medium

weight”, and the ”high weight” you have at hand

using the numeric key pad.

9. Select the weight button (AL) to start the 208

calibration.

10. Confirm the weights you have already entered by 209

selecting the green V mark (AI).

210

11. When this screen appears, remove the

”lowweight” on the bar (AS).

NOTE: Hang the weights free in the middle of the roller bale chute, do not move the chute anymore.

12. Select the green V mark button (AI), at the screen

with the status ”busy” will appear, wait at this

moment.

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13. When the screen appears, remove the

”lowweight” and hang the ”medium weight” on the

bar (AS).


14. Again select the green V mark button (AI) on

thescreen with the status ”busy” will appear, wait

at this moment.

weight” and hang the ”high weight” on the bar

(AS).


16. Again select the green V mark button (AI) on

thescreen with the status ”busy” will appear, wait

at this moment.

213

17. The calibration was performed succesfully

whenthe status ”Calibration done” appears, the

values are saved and the date will be entered.

18. Remove the weights and the bar (AS) from

thebale frame.

19. Test the bale weighting systemNOTE: Refer to

operation in this manual.

BALE LENGTH KIT ELECTRIC

CALIBRATION

Select the "Field setting" icon (S) on the "Main screen"

in the monitor.

214

15. When the screen appears, remove the ”low 212


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Put the "Bale length" and "Measured bale length" on the same value using the numeric keypad.

Take the mean value of those bales and fill in that

value in the "Measured bale length" field using the

numeric keypad. Now the calibration is done.

216

DIAGNOSTIC INPUTS

Inputs from sensors and other sources can be

displayed, which are used for Dealer guidance and

correction.

These inputs can be viewed through the error

overview screen by selecting the diagnosis input icon

and screen. Follow the on screen prompts where

displayed.

Example of input items that can be checked, and if

sensor controlled can be adjusted:

Make five bales and measure their separate lengths. 215


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Controller voltage

Battery voltage

10v reference voltage



Moisture sensor - A2

Flywheel brake - B1

Mistie 1 - B5

Mistie 2 - B4

Mistie 3 - B3

Mistie 4 - B2

Mistie 5 - B6

Mistie 6 - B21

Knotter gearbox - B7

Pick up speed - B8

Feeder shearbolt - B9

Cutter status - B10

Bale drop - B11

Needle carriage - B12

Feeder channel - B13

Fan shield - B14

Greasing sensor - B15

Oil pressure - B16

Load sensor - B17

Bale chute - B18

Bale length I - B19

Bale length II - B20

Needle yoke - B12

Moisture sensor - A2

217

An example of an input diagnosis is: Main power relay

as shown here where the relay can be viewed to see

if it is okay to use or defective.

With power ON the active voltage is shown as 11.67

volts which is correct for operation.

Should this drop too low the relay will not react

correctly and errors will be reported; check the relay

and/or lines.

Adjustments can be made by selecting the input field

using the soft key or rotary encoder, touch screen.

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Another example of inputs could be Misties, when the

signal is not correct which case repair the fault or

change the sensor.

Where a new sensor is fitted adjust as discussed in

”Sensor adjustment” move the sensor in or out to

achieve the correct reading.

As in the case of the optional bale length system

which can be checked in the same way and

adjustments made, by selecting the input field using

the soft key or rotary encoder, touch screen.

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DIAGNOSTIC OUTPUTS

Outputs for solenoids and other sources can be

displayed, which are used for Dealer guidance and

correction.

NOTE: Relay output is only possible when the output is in off state. In the on state it is not possible.

Not possible also for the density valve and pick-up stop since they are directly controlled by the processor board (not relays).

These can be viewed through the error overview screen using the diagnosis output icon.

Shown below are examples of outputs that can be

checked, by selection of the switch ICON (1). For

example in this screen and with operating lights

selected, these can be switched On and OFF using

the monitor.

221

Main power relays - K1, K2

Main power relay - K3

Knotter fans - K21

Flashing light - K11

Operating lights - K31

Grease pump - K12

Accessory 2 - K14

Density valve - Y2

Chain oiling pump - K13

Pickup stop (where fitted) - Y4

Bale electric trip system (where fitted) - K15

Stuffer light - K31

Density sensor - Y2 222

Bale weigh system (where fitted)

setion 4 ‐ luriation and maintenane -...

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