GP0352

LB 8200

Operation manual
Issue 10/2006
Date of printing 10.2006
Language EN
From machinenumber (PSN) GR000154
Referencenumber VGG0610GR(3)EN
 Identification of the machine
To support you as soon as possible your dealer requires several details of your machine.
Please enter the information here.

Designation LB 8200

PIN GR.......

Mounted options

Dealer's address

Manufacturer's Kverneland Group Geldrop BV

address Nuenenseweg 165
5667 KP Geldrop
The Netherlands

Phone +31 40 2893300

Kverneland Group Geldrop BV, retains all copyrights and rights of usage. The contents of this operation manual are subject to change without
notice. All rights reserved. The right to technical revision is reserved.
 Table of contents
Table of contents

Preface.............................................................. 6 Preparation at the field ................................. 55

Target group of this operation manual 6 Safety 55
Symbols used 7 Performing settings 55
Prior to baling 55
Safety instructions .......................................... 8
Gauge wheels 56
For your safety 8
Pick-up working height 56
Safety decals 9
Crop guard 56
Who is allowed to operate the machine? 12
Hitching the machine 13 Use at the field............................................... 58
Hydraulics 14 Safety 58
Road transport 15 Prior to baling 59
Working with the machine 16 Pre-chamber density setting 59
Unhitching the machine 18 Switching knives on and off 62
Care and maintenance 19 Bale length setting 63
Further prescriptions 20 Driving 65
Warranty 21 Bale growth 67
Rebaling bales 67
Acquaintance with the machine................... 22
End of baling 67
Destination of the machine 22
Cleaning the press chamber 68
Characteristics of the machine 22
Description of the parts 23 Autoform ....................................................... 70
Technical specifications 24 Electronic control system 70
Sensors 70
Delivery and preparation .............................. 26
Working 74
Checking the delivery 26
User functions 81
Hitching the machine .................................... 27 Dealer functions 85
Safety 27 Factory functions 90
General 27
Cleaning and caring ...................................... 94
Hitching 28
Safety 94
Support jack 30
Cleaning 94
Coupling the pto drive shaft 31
Preparing for winter 94
Installation control box 32
Winter storage 94
Connections 33
Caring 95
Safety brake for unhitching 36
Rear step 36 Storing the machine...................................... 96
Running 37 Safety 96
Unhitching and securing of the machine 96
Preparation for use........................................ 38
After the season 97
Safety 38
General 39 Maintenance................................................... 98
Lateral doors 39 Safety 98
Adjustment gauge wheels 40 Check at beginning of the season 98
Pick-up working height 40 General 100
Pick-up suspension 40 Pto drive shaft 105
Pick-up raising speed 41 Lubrication 106
Opticut cutting system adjustment 42 Gearboxes 117
Exchange of knives by dummy knives [+] 43 Hydraulic system 120
Changing press chamber height [+] 44 Wheels/axle 121
Twine installation 47 Chain tension 125
Windrow dimensions 51 Cutting unit 126
Packer system 127
Road transport............................................... 52
Packer timing 128
Safety 52
Pre-chamber 136
Before road transport 53
Binding system 140
Checking the machine 54
Knotters 144
Road transport 54

3
Table of contents

Needles 152
Plunger 160
Brakes 162
Sensors 165
Hydraulic diagrams 170
Optional equipment..................................... 175
General 175
Changing press chamber height 175
Knotter fans 175
Centralised knotter greasing 175
Automatic grease lubrication system 176
Bale ejector 176
Roller chute 176
Following tandem axle 177
Dummy knives 177
Twine release 177
Troubleshooting .......................................... 178
General electronics 178
Autoform 179
Security systems 185
Pre-chamber overload 189
Disposal of the machine ............................. 200
EC Certificate of conformity ....................... 201
Index ............................................................. 202

4
Table of contents

5
Preface
Preface

Target group of This operation manual is meant for those concerned with the control,
use and maintenance of the machine. It contains all data required for
this operation a safe handling, use and maintenance of the machine.
manual For your safety
Before starting to adjust and use your machine, familiarise yourself
with this operation manual. By doing so your safety and the best per-
formance are assured. It is very important to read this manual carefully
before using the machine and to keep it handy. In this way, you will
• avoid accidents
• respect the warranty conditions
• always have a functional machine in perfect working order

For the employer

All personnel are to be trained in the use of the machine regularly (at
least once a year) in accordance with employers’ liability insurance as-
sociation guidelines. Untrained or unauthorised individuals are not
permitted to use the machinery.
You are responsible for the safe operation and maintenance of your
machine. You must ensure that you and anyone else who is going to
operate, maintain or work around the unit be familiar with the operat-
ing and maintenance procedures and related safety information con-
tained in this manual.

6
 Preface

Symbols used In this operation manual the following symbols and terms are used:

• A bullet stands at enumerations

> A triangle stands at steps, which you must do

→ An arrow shows cross-references at other text passages

[+] The plus sign shows that it handles about optional equipment,
which does not belong to the standard model.

Besides these symbols, pictograms are used, which will help you with
locating of text passages:

TIP The word “Tip“ shows tips and advices to the use.

The triangle refers to danger at assembling or (adjusting) work.

The key refers to tips at assembling or adjusting work.

8 The star shows examples, which are needed for a better understand-
ing.

All directional rotations are to be interpreted when facing in direction

of travel.

7
Safety instructions
Safety instructions

For your safety This chapter contains all general safety instructions. Subject-specific
safety instructions are located per chapter.

This chapter contains all general safety instructions. Subject-specific

safety instructions are located per chapter. Take care of the safety in-
structions
• because of your own safety
• because of the safety of your fellow man
• to guarantee the machine safety

When handling agricultural machinery, wrong behaviour can lead to a

lot of danger. Therefore work with special care and never under pres-
sure of time.

For the employer

Inform the one who works with this machine frequently about these
safety instructions and according to the legal regulations.

8
 Safety instructions

Safety decals The installed warning and advisory signs give important hints for a
safe operation; adhering to serves your own safety. Keep safety de-
cals and signs clean and legible at all times. Replace safety decals
and signs that are missing or have become illegible. If original parts on
which a safety decal or sign was installed are replaced, be sure that
the replacement part also displays the current decal or sign.

9
Safety instructions

Meaning of the safety de-

cals
Shut off engine and remove key
Shut off engine and remove key before performing maintenance or re-
peair work.

Block knotters before any repair work or maintenance

Block knotters with the trip mechanism of the needle drive before any
repair work or maintenance.

Stay clear of the bale chute

Stay clear of swinging area of implements.

Place chocks at a parked machine

Always place chocks if the machine is parked on a non-horizontal
plane.

Do not enter machine components before it has completely

stopped
Wait until all machine components have completely stopped before
touching them.

10
 Safety instructions

Stay clear of pto drive shaft

Stay clear of danger area of pto drive shaft. Do not work with a pto
drive saft if protection is damaged or not present. Personal injuries can
occur.

Stay clear of a moving pick-up

Stay at a safe distance of a rotating pick-up. The pick-up tines may
grab your clothes if you come close to it and pull you inside the ma-
chine. Serious or deadly injuries can occur.

Read the operation manual carefully

Read the operation manual carefully before taking the machine into
operation.

Keep away from the rotating driveline

The rotating driveline may grap clothes, etc. if you come close to it and
pull you to or inside the machine: stay at a safe distance of a rotating
driveline.

Apply flywheel brake before maintenance or repair work

Before maintenance or repair work, the flywheel brake must be ap-
plied.

Accumulator stays under high pressure

Never do maintenance or repair work to the accumulator. The accu-
mulator stays under high pressure (> 90 bar). Squirting hydraulic oil
can cause serious injuries.

11
Safety instructions

Who is allowed to Authorised people only

The machine may only be used, maintained or repaired by authorised
operate the ma- people who have been informed about the dangers when handling the
chine? machine.
Usually such persons have an agricultural or equal intensive educa-
tion.

General Safety is your responsibility

Apply and insist upon application of the safety instructions. Most acci-
dents are avoidable. Do not run the risk of serious or fatal accidents
through ignorance of these safety instructions.

Wear close fitting clothing

Avoid wearing loose fitting clothing.
Loose clothing can get stuck between rotating parts. Danger of seri-
ous injury.

Keep the machine clean

Always keep the machine clean to avoid fire risk.

Fire extinguisher
Carry a fire extinguisher at all times, especially when operating in dry
crop materials. This should be a multi-purpose ABC rated extinguisher
with a 10 kg capacity, approved by the appropriate authority.

Good operating condition

Always check that
• the tractor is in good operating condition
• the tractor brakes are powerful enough for the combination of trac-
tor and machine

Use a proper tractor

Make sure the tractor is in safe operating condition with adequate
braking capabilities for a machine of this weight.
→ the tractor’s technical details

No running in a closed area

Do not run the machine in a closed area. Exhaust fumes collect with-
out being noticed. Exhaust fumes can cause serious or deadly inju-
ries.

Never work on a running machine

Never work on the machine while it is running. A running machine has
several moving parts which can not be seen. These moving parts can
cause serious injuries.

No modification of the machine

Do not modify the machine in any way. Unauthorised modifications
may impair the function and/or safety and could affect the life of the
machine. All warranty will be reduced to nil and void.

12
 Safety instructions

Hitching the ma- Increased danger of injury

While hitching the machine onto the tractor an increased danger of in-
chine jury occurs. Therefore:
• prevent the tractor from rolling away, shut down the engine and re-
move the ignition key
• never stay between tractor and machine during hitching
• mount and secure the pto drive shaft at the pto
In case of negligence damages to the machine or serious personal in-
juries can occur.

Pto drive shaft

Only use the pto drive shaft complying with the manufacturer’s speci-
fication. Other pto drive shafts with slip clutches can permit higher
torques. Higher torques can damage the machine.

Pto drive shaft operation manual

Regard to the operation manual of the pto drive shaft manufacturer.
Here you find instructions for correct handling of the pto drive shaft.
Negligence can lead to damages at the pto drive shaft and to the ma-
chine.

Fix and check pto drive shaft protection

The rotating pto drive shaft is secured by a pto drive shaft protection.
Take care that the pto drive shaft protection is not damaged. Pto drive
shaft protection must be fixed through the chains, both at tractor and
machine side. Unprotected pto drive shafts can cause serious person-
al injuries.

Pto speed 1000 rpm

The prescribed pto speed of maximum 1000 rpm may not be exceed-
ed. Higher pto rpm can cause damages to the machine.

13
Safety instructions

Hydraulics Hydraulic couplings only pressureless

Only couple the hydraulic hoses to the tractor when both tractor and
machine hydraulics are pressureless. Hydraulics under pressure can
cause accidental movements of the machine.

High pressure in the hydraulic system

The hydraulic system is under high pressure. All tubes, hoses and
couplings must be controlled regularly for leaks and external damag-
es. Only use suitable tools when searching for leaks. Immediately re-
pair damages. Leaking oil can cause injuries and fire. When having in-
juries visit a doctor immediately.

14
 Safety instructions

Road transport Pay attention to a road-safe condition

When driving on the local roads, the machine must correspond to the
current traffic prescriptions. To which e.g. belongs:
• mounting of lighting, warning and protection installations
• comply with the permittable transport dimensions and weights,
maximum permissible axle loads, tyre carrying capacity, total
weights and national speed limits
• taking care of the maximum permitted speed
In case of negligence, driver and owner of the machine are fully liable.

Check tyre pressure

Check the tyre pressure regularly. Wrong tyre pressure decreases the
life of the tyres and can cause unstable driving characteristics and ac-
cidents.

Prohibition of transporting people on the machine

Nobody and nothing shall be transported on the machine during trans-
port. Transporting of people or objects on the machine is perilous and
prohibited.

Changed driving and braking handling

Because of the hitched machine the driving and braking handling
changes. Especially when driving curves the dimensions and mass of
the machine have to be taken into account. A not adapted driving style
can lead to accidents.

Adapted driving speed

Under bad road circumstances and at high driving speeds very high
crafts can appear, which load or overload the tractor and machine to
much. Adapt the driving speed according to the road circumstances.
A not adapted driving speed can lead to accidents.

Do not transport bales in the press chamber

Never transport bales in the press chamber. Transporting a bale influ-
ences the tractor’s steering and braking capacities. Personal or ma-
chine damages can occur.

15
Safety instructions

Working with the First use only after instruction

The machine may at the first time of use only be brought into use by
machine employees of the dealer, factory representatives or employees of the
manufacturer. False use after bringing the machine into use without in-
structions can cause damages to the machine or accidents.

Take care of technical correct condition

Only bring the machine into use in a technical correct condition. Check
all important parts and replace defective parts before use. Defective
parts can cause material or personal damages.

Do not remove protective covers

The protective covers should not be removed or evaded. Check all
protective covers before using. Unprotected machine parts can cause
heavy or deadly accidents.

Prohibition of transporting people on the machine

Nobody and nothing shall be transported on the machine during trans-
port. Transporting of people or objects on the machine is perilous and
prohibited.

Check the direct surroundings

Before driving and bringing into use of the machine the direct sur-
roundings must be checked. Take care of sufficient view. Only start
driving when no persons or objects are in the direct surroundings. Per-
ilous injuries can occur.

Tighten bolts and nuts

Check bolts and nuts regularly for being tight and tighten if necessary.
Because of using the machine bolts can get loose. Damages to the
machine or accidents can be caused.

Behaviour at troubles
At functional troubles stop and secure the machine immediately. Rem-
edy the trouble immediately or commission a workshop. Continuing
working with the machine cause accidents or damages.

Pto rotates after disengaging

After disengaging or switching off the pto, the machine will continue
running because of inertia. Keep a safe distance to the machine until
the pick-up and the moving parts really stand still.

Cornering or manoeuvring
When cornering, anticipate centrifugal forces caused by the distance
of the centre of gravity of the machine behind the tractor. Beware of
the turning radius and the inertia of the machine.

Bale ejection
Keep clear of the bale ejection area. Danger of crushing. Which can
cause severe injuries. Never stay behind the machine when a bale is
coming out.

16
 Safety instructions

Drive adapted to ground conditions

Always drive with caution on sloping or moving ground. Respect the
maximum load permitted per axle and the total working weight autho-
rised.

Blockage of a security device

In case of a blockage or operation of a security device, never work on
the machine without
• disengaging the tractor pto first
• switching off the electronic control system
• stopping the engine and removing the ignition key
Never be tempted to hand feed or unblock the machine while it is run-
ning. Serious or deadly injuries can occur.

17
Safety instructions

Unhitching the ma- Increased danger of injury

While unhitching the machine from the tractor an increased danger of
chine injury occurs. Therefore:
• prevent the tractor from rolling away, shut down the engine and re-
move the ignition key
• never stay between tractor and machine during unhitching
• take care of a level and secure surface for the machine
• take care of a secure lock of the jack stand
• place the pto drive shaft at the support or hang it in the chain
• prevent the machine from rolling away
• only disconnect the hydraulic hoses when the hydraulic system at
both tractor and machine is pressureless
In case of negligence heavy or deadly injuries can be the conse-
quence.

18
 Safety instructions

Care and mainte- Observe the care and maintenance intervals

Observe the prescribed intervals and those stated in the operation
nance manual for recurring checks and inspections. In case of negligence of
the intervals damages to the machine or accidents can be caused.

Use original parts only

Lots of components have special properties which decides for the sta-
bility and the function of the machine. Only the parts and options de-
livered from the manufacturer have been tested and released. Other
products can interrupt the function of the machine or can harm the se-
curity. When using not original parts the warranty and liability of the
manufacturer reduces to nil and void.

At all care and maintenance work:

• switch off the pto
• make the hydraulics pressureless
• unhitch the tractor if possible
• switch off the engine and remove the ignition key
• make sure the tractor and machine are positioned on a firm and
level area, support if necessary
• do not use parts of the machine as climbing help, use suitable
climbing helps on the contrary
• prevent the machine from rolling away
Only when observing these prescriptions a secured working during
care and maintenance work is guaranteed.

Interrupt electric power supply

Before working on the electrical device, separate this from the electric
power supply. Supplies being charged can cause material or personal
damages.

Exchange hydraulic hoses

Hydraulic hoses can age without external recognizable indications.
We therefore recommend to exchange all hydraulic hoses every six
years. Defective hydraulic hoses can cause heavy or deadly injuries.

19
Safety instructions

Careful when cleaning with high-pressure cleaner

The machine can be cleaned with water or steam. Clean bearings,
plastic parts and hydraulic hoses with low pressure only. Too high
pressure can damage these parts.

No aggressive wax additives

When cleaning do not use aggressive wax additives. Bright metal sur-
faces can get damaged.

Before welding work

Before welding to the hitched machine, disconnect the tractor’s bat-
tery and the dynamo. Therefore you will avoid damages to the electri-
cal installation.

Tighten bolted links

After care and maintenance work all loose bolted links must be tight-
ened. Because of loose bolted links material damages can be caused.

Further prescrip- Observe the prescriptions

Please observe besides these safety information
tions • the accident prevention prescriptions
• the general accredited safety-technical, industrial medicinal and
road traffic law rules
• the tips in this operation manual
• the work, care and maintenance prescriptions

20
 Safety instructions

Warranty Disregard of the 'Safety instructions', inadequate maintenance, use of

the machine other than for its intended purpose, overloading or unau-
thorised modification of the machine, renders the manufacturer's war-
ranty and responsibility void.

21
Acquaintance with the machine

This chapter contains general information about your machine and in-
Acquaintance with the machine

formation about:
• characteristics
• technical specifications

Destination of the This machine is exclusively appropriate designed for collecting of cut
non or insignificantly ligneous plants, mainly grasses, from the ground,
machine feeding them through pick-up and cutting unit and consequently form-
ing a square bale inside the press chamber, taking into account all pre-
scriptions, procedures, etc. as stated herein and/or through decals or
other signs on the machine.

Intended use of the This machine shall be exclusively used for the normal agricultural
work.
machine Any use beyond the one stipulated above requires written authoriza-
tion of the manufacturer, this may be required for baling unusual, non-
grass plants as well.

Characteristics of The pick-up picks up the crop from the ground to the intake rotor. The
intake rotor forwards the crop to the pre-chamber. Eventually it will be
the machine cut. The crop is fed into the pre-chamber. Where it will be compressed
to the set density. This pre-set density is controlled by the measuring
plates. Then it will be fed into the press chamber. In the press cham-
ber, the bale is formed. When the bale has reached its desired length
and density, it will be tied with twine.

22
 Acquaintance with the machine

Description of the
parts
Knotters Bale chute

Press
chamber

GP0352
Drawbar Pick-up Pre-chamber Axle

23
Acquaintance with the machine

Technical specifi-
cations
Weight

Weight empty (kg) 7900

Length (m)

Overall length bale chute folded up 8.00

Overall length bale chute extended 8.85

Width (m)

Maximum width (depending on tyre size) 2.45 (2.64)

Height 2.60

Tandem axle 16.0/70-20 12 PR

Tandem axle 500/55-20 12 PR

Single axle 500/60-22.5 12 PR

Single axle 600/50-22.5 12 PR

Tandem axle 560/45-22.5 146D

Single axle 710/40-22.5 158A8

Maximum hitch load (kg) 1.500

Bale dimensions (m)

Width 0.80

Height 0.70 - 0.80 (depending on model)

Length adjustable from 0.60 to 3.00

Pick-up

Collecting width (m) 2.10

Reel diameter (m) 0.30

Number of tine bars/tines 4/112

Space between tines (cm) 6.1

Lift/lower hydraulic

Gauge wheels 2 wheels

Feeding rotor with integrated augers and auto-

matic overload clutch

Forced packer with 5 tines

Pre-chamber with feedback volume/

density measurement

Security: Automatic phased torque lim-

iter

Baling

24
 Acquaintance with the machine

Plunger cycle (strokes/min) 45

Plunger stroke (cm) 69,5

Width x length of the press chamber (m) 0.80 x 2.75

Density control hydraulic system - 3 pressure shutters

Hydraulic pressure adjustable by the

operator from the tractor cab

Security: main driveline protection

through an automatic clutch, freewheel
clutch and slip clutch

Binding

Number of knotters 4 (type Raussendorf)

Space between twines (cm) 18

Number of twine spools 20

Recommended twine (m/kg) 130-150 (synthetic)

Tractor requirements

Pto horsepower (kW / hp) 70 / 90

Pto speed (rpm) 1000

• 12 V (DC) coupling for control box

(DIN 9680)
Electric supply • 12V (DC) knotter fans security [+];
DIN 9680)

12 V (DC) coupling for road lighting

(DIN ISO 1724)

Hydraulics 1 single acting control valve

1 brake connection to ISO 5676

bale chute/ last bale ejection [+] 1 double acting control valve

steered tandem [+] 1 single acting control valve

Pneumatics 2 connections for pneumatic brakes

25
Delivery and preparation
Delivery and preparation

Checking the de- Completely delivered

The machine is delivered completely. In case parts are not mounted,
livery please contact your dealer.

The machine must be checked after delivery. The machine is

equipped with:
• Operation manual
• Spare parts manual
• Pto drive shaft assembly
• Hydraulic hoses with couplings
• Electronic control system (control box, fixing brackets, power ca-
ble)
• Lighting cables
• Mechanical brake cord
• Number plate board
• Pick-up gauge wheels
TIP Some accessories are packed and located in the twine boxes.

Knotter cleaning fans > Mount the panel to the supporting frame with the fans towards the
knotters
[+]
→ assembly instruction in this kit
Fan Power cable Frame
> Connect the plug to the socket
> Connect the power cable to the tractor

Plug Socket Supporting

frame

26
 Hitching the machine
Hitching the machine

Safety Increased danger of injury

• Prevent the tractor from rolling away
• Never stay between the tractor and the machine during hitching
In case of negligence serious or deadly injuries can occur.

Use a proper tractor

Make sure the tractor
• is in safe operating condition
• has adequate braking capabilities for this machine
• is suitable for carrying and transporting this machine
Using a tractor which is not suitable can cause serious personal and
material damages.

General The machine is ex works provided for hitching onto the tractor’s hook.
To prepare the machine for hitching, the following items are neces-
sary:

• Both tractor and machine must be placed on a firm level

• The drawbar must be adjusted
• The hitch eye must be adjusted
• The pto drive shaft must be coupled
• The electronic control box must be installed
• The parking brake [+] must be installed
• The hydraulic hoses must be coupled
• The pneumatic hoses [+] must be coupled
• The lighting cables must be coupled

27
Hitching the machine

Hitching Remove tractor lower links

Remove the tractor lower links to avoid them touching the drawbar.
During turning, the lower links can touch the drawbar and the machine
can tip over. Personal or machine damages can occur.

Rotatable hitch eye

A rotatable hitch eye may never be used in combination with a rotat-
able tractor towing hook. Personal or machine damages can occur.

Before the machine can be hitched onto the hook, the correct height
of the hitch eye to the tractor’s clevis must be determined.
> Place both tractor and machine in line on a firm level, with a dis-
tance between clevis and hitch eye of about 15 cm

Both drawbar and hitch eye can be turned upside down. Doing this the
drawbar can be set for high and low attachment.

Drawbar adjustment The machine must be placed in a horizontal position:

> Turn handle to the left: drawbar goes upwards
or
> Turn handle to the right: drawbar goes downwards
> Check the height of the tractor’s clevis
Pin
The drawbar height can be changed by
Handle • moving the drawbar
• moving the hitch eye

Support jack Select the correct position in accordance with your tractor in order to
have tractor and machine lined up correctly.

28
 Hitching the machine

Moving the drawbar The drawbar can be adjusted to both a low and a high hitch, within the
following height ranges:
Hitch type Height range
low hitch = 38 - 70 cm
high hitch = 84 - 115 cm
115

84 > Secure the drawbar by placing it in a well suited hoist

70 > Loosen bolts and nuts
> Move the drawbar to the desired position
38 Drawbar
GP0440
> Tighten bolts and nuts
→ Tightening torques, page 104
> Remove the hoist
The drawbar must always be fitted with a minimum of 4 bolts and nuts
per side. The bolts and nuts must be distanced as far from each other
as possible, with a minimum overlap of 5 holes.

Moving the hitch eye > Loosen bolts and nuts

Hitch eye > Move the hitch eye to the desired position
> Tighten bolts and nuts
→ Tightening torques, page 104

115

84
70

38
GP0440

29
Hitching the machine

Support jack

Mechanical support > Level the drawbar to the correct height using the handle
jack > Attach the machine onto the tractor
> Fully retract the support jack using handle
> Remove spring clip
> Remove pin
> Fold up the support jack completely
Pin > Place pin
> Lock the pin with spring clip
Handle
> Place the handle in its support

Support jack

Hydraulical support > Use the hydraulic valve to lift or lower the support jack and level the
drawbar to the correct height
jack [+]
> Hitch the machine onto the tractor
Support jack > Use the hydraulic valve to fully lift the support jack
> Put the valve in pick-up position
Pick-up

Valve
GP0395

> Remove the spring clip

> Remove the pin
> Fold up the support jack completely
> Place the pin
> Lock the pin with the spring clip
Pin

Support jack

30
 Hitching the machine

Coupling the pto Do not use a hammer

The pto drive shaft may not be mounted using a hammer or other
drive shaft equivalent tools. Using these, the pto drive shaft can get seriously
damaged. A damaged pto can cause both machine and tractor dam-
ages.

> Check, before coupling the pto drive shaft, if the pto drive shaft has
to be shortened
> Shorten the pto if necessary
→ Pto drive shaft, page 105
> Ensure the tractor pto is clean and greased
> Couple the pto drive shaft at both tractor and machine side
> Ensure the shaft sliding ring catches with the slot of the pto
> Fit the chains to rigid positions at both tractor and machine to pre-
vent the protection covers from turning with the pto drive shaft

31
Hitching the machine

Installation con- Correct connection of the electronic control system

Never connect the cable to the cigarette lighter because of interfer-
trol box ence risk. Always connect the cable directly to the interference-free
power source. Therefore check the functioning of the fuses on the
power cables.

The control box must be installed on a support or holder in the tractor

cab.

Take care of the following:

• Ensure the control box is installed in good manual and visible
reach of the operator
• Do not mount the control box onto a part that is subject to strong
vibrations
• Ensure the control box is in an area with less dust
• Do not install the control box where bright sun or rain may reach it

Electrical connec- > Connect the main power cable of the machine box directly to the
12V battery of the tractor
tions control box
Colour Pole
Brown +
Blue -

Some tractors are standardly equipped with a direct power connection

from the battery
> Connect the 7-pin connectors of the control box and machine box
to each other

32
 Hitching the machine

Connections

Hydraulic connec- Hydraulic coupling only pressureless

Only couple the hydraulic hoses to the tractor when both tractor and
tions machine hydraulics are pressureless. Hydraulics under pressure can
cause accidental movements of the machine.

Avoid oil mixture

When using the machine in combination with different tractors, im-
proper oil mixture can take place. Improper oil mixture can destroy
tractor parts.

Avoid entering of dirt into the hydraulic system

The hydraulic system can get seriously damaged. Personal injuries or
material damage can be caused.

Check hoses and couplings

Before connecting, prove all hydraulic hoses for damages. After con-
necting check all hydraulic couplings for tight connection. Defective
hydraulic hoses or bad connected hydraulic couplings can cause inju-
ries or unforeseen movements of the machine.

Secure tractor hydraulic devices

In transport position tractor hydraulic devices must be secured against
unintentional movements. Unintentional movements of the hydraulic
device can cause serious injuries or unforeseen movements of the
machine.

Take care of the correct laying of hydraulic hoses

Hydraulic hoses may not stick or tighten. Take care of sufficient free
space. Worn or stuck hydraulic hoses can cause heavy damage to the
machine or severe injuries.

33
Hitching the machine

Coupling All hydraulic hoses with connection to the tractor are marked with co-
loured rings. The meaning of the colours is indicated on the decal,
Brakes Steered Flywheel
placed at the support at the drawbar.
axle brake
Colour Meaning
Red Brakes
Blue Bale ejector [+] / bale chute [+]
Green Steered axle
Yellow Pick-up / hydraulic support jack
Bale ejector / Pick-up /
bale chute support jack White Flywheel brake [+]

> Ensure the quick couplers are clean

> Make sure the control valves are pressureless
> Couple the red marked hydraulic hose for the hydraulic brakes to
a single acting control valve
> Couple the blue marked hydraulic hose for the bale ejector [+] and
the bale chute [+] to a double acting control valve
> Couple the green marked hydraulic hose for the steered tandem
axle to a single acting control valve
> Couple the yellow marked hydraulic hose for the pick-up and the
hydraulic support jack to a single acting control valve
> Couple the white marked hydraulic hose for the hydraulic flywheel
brake [+] to a single acting control valve

Hydraulic brake • When plugging-in the quick-disconnect plug of a hose always en-
sure the socket is not pressurised!
• Ensure sockets are clean!

> Connect the hose to the tractor's trailer brake valve

> Attach the cord to the machine parking brake and to a fixed point
at the tractor

34
 Hitching the machine

Pneumatic connec- Avoid entering of dirt into the pneumatic system

The pneumatic system can get seriously damaged. Personal or mate-
tions rial damage can be caused.

Check hoses and couplings

Before connecting, prove all pneumatic hoses for damages. After con-
necting check all pneumatic couplings for tight connection. Defective
pneumatic hoses or bad connected pneumatic couplings can cause
injuries or unforeseen movements of the machine.

Take care of the correct laying of pneumatic hoses

Pneumatic hoses may not stick or tighten. Take care of sufficient free
space. Worn or stuck pneumatic hoses can cause heavy damage to
the machine or severe injuries.

Pneumatic connections are only available if the machine has been

provided with pneumatic brakes.
> Ensure the quick couplers are clean
> Connect the quick couplers of the pneumatic hoses to the pneu-
matic receptacles of the tractor

Pneumatic brake [+] > Pull the ring to drain the tank from possible fluid
Tank > Perform a brake test before transport

Before moving the machine without a tractor:

> push the valve downwards
The brakes are free now, the machine can be moved.
Afterwards:
> push the valve upwards
The brakes are blocked now.

Ring Valve

Coupling > Ensure that the valves at the tractor are open
> Couple the red quick coupler to the corresponding tractor valve
> Couple the yellow quick coupler to the corresponding tractor valve

Electric lighting > Fit the number plate board if necessary

> Connect the 7-pin plug to the trailer lighting socket on the tractor

35
Hitching the machine

Safety brake for A safety brake for unhitching provides the machine from keep on mov-
ing after an undesired unhitching from the tractor during working or
unhitching road transport.

To mount the safety brake for unhitching

> attach the cable from the lever to a fixed point at the tractor
In case of undesired unhitching during working or road transport, the
cable pulls the lever. The machine will come to a standstill.

Lever Cable

Rear step > Fix the rear step for access to the platform

36
 Hitching the machine

Running > Run the tractor pto at idle

• Check correct operation of the components
• Check if there are no unusual noises
> Run the machine at 1000 rpm for some minutes
> Switch off the pto
• Check the tightness of the hardware
• Check the tension of the chains

During the running-in period, a specific maintenance must be done,

confer to maintenance chart
→ Maintenance intervals, page 101

37
Preparation for use
Preparation for use

Safety Obey safety instructions

Obey the safety instructions at the execution of all work. Ignoring the
safety instructions can lead to serious or deadly injuries.

Guarantee correct hydraulic coupling

Check before using if all hydraulic couplings are coupled correct to the
single and double acting valves. Not correct coupled hydraulic cou-
plings can cause unpredictable movements of the machine.

Never work on the machine while it is running

Never carry out adjustment work while the machine is running.
• Pto must be switched off
• Tractor engine must be switched off and the ignition key must be
removed
• Electronic control box must be switched off
In case of negligence, serious or deadly injuries can occur.

No persons in turning area

During work, no persons may be within the turning area of the ma-
chine, including the satellite area. Serious personal injuries can be
caused.

Secure the machine

During adjustment, an increased danger of injury exists. Therefore
• secure the machine from accidental commencement of operations
and rolling away (use wheel chocks)
• the machine must have a level, secure position and must be sup-
ported during working if necessary
Unsecured or not supported machines can lead to accidents.

Wear safety shoes

During all work at the machine never bring your feet under the ma-
chine and always wear safety shoes. Wearing safety shoes prevents
or decreases the risk of serious injuries.

Guarantee correct hydraulic coupling

Check definitely, before using the machine, if the hydraulics for the
pick-up, the tailgate and the cutting system are coupled to the correct
single or double acting valves. Not correct coupled hydraulic hoses
can cause accidental movements of the machine.

38
 Preparation for use

General For the realization of all preparations counts:

• Secure the machine

The following settings have to be realized before using the machine:

• gauge wheels adjustment
• pick-up safety chains
• pick-up suspension
• Opticut cutting system adjustment
• twine installation

Lateral doors The lateral doors can be opened for

• filling the twine boxes
• adjustment
• care and maintenance

Opening the lateral > Use a 13-mm wrench to unlock the lock
doors > Pull up the bracket to open the lateral door

Lateral Bracket Lock

door

Closing the lateral Carefully pull down lateral door

Be careful when pulling down the bracket to close the lateral door. The
doors lateral door is spring loaded to close on the last part of the stroke. Per-
sonal injuries can occur.

> Pull down the bracket to close the lateral door

The lateral door locks automatically.

39
Preparation for use

Adjustment gauge The working height adjustment of the pick-up tines is determined by
the height of the gauge wheels on both sides of the pick-up.
wheels
Spring clip Gauge wheel The mentioned height of 2 - 3 cm above the ground is just a recom-
mendation since the correct value depends much on ground and crop
conditions.

The adjustment of the gauge wheels is carried out by placing the

bracket in different vertical positions. Hereby the brackets shall be set
to the same position at both sides of the pick-up.
Adjust as follows:
> Raise the pick-up fully
> Close the valve
GP0413

> Remove the spring clip

Bracket > Place gauge wheel with help of bracket at the desired position
2 - 3 cm
> Replace the spring clip

TIP Removal for road transport

→ Gauge wheels, page 54

Pick-up working The adjustment of the pick-up working height is determined by the
length of the chains on each side of the machine.
height > Attach the chain to the desired working height on both sides at the
Support support

Chain

Pick-up suspen- Two springs, located on the pick-up hydraulic cylinders, ensure sus-
pension of the pick-up.
sion
Adjust the spring tension on both sides of the pick-up as follows:
> Raise the pick-up fully
> Close the valve
> Move locking plate to the left: increase spring tension
or
> Move locking plate to the right: decrease spring tension
The pick-up is correctly adjusted when it can be lifted by hand at the
GP0415

front of the flanks.

Locking
plate

TIP Make sure that the spring tension is the same on both sides of the
pick-up.

40
 Preparation for use

Pick-up raising The pick-up raising speed may be adjusted using the flow limiter locat-
ed under the drawbar.
speed Adjust the flow limiter as follows:
Knurled knob > Loosen the locking screw
> Turn the knurled knob to the desired speed
> Tighten the locking screw

Locking
screw

Flow limiter

41
Preparation for use

Opticut cutting Wear safety gloves

Cutting knives are very sharp. Always wear safety gloves when han-
system adjust- dling cutting knives. Not wearing safety gloves can cause serious in-
ment juries.

• The pto must be switched off

• The electronic control system must be switched off
• The tractor engine must be stopped; the ignition key must be re-
moved
• Apply the flywheel brake
• Shut-off the selector valve prior to working on the cutting system

Removing the knives All the knives can be individually removed.

> Switch on the pto
> Switch on Autoform control box

> Push to swing out the cutting unit

> Wait until the knife symbol has disappeared

> Close the valve at the hydraulic block on the right side

Valve

> Turn the lever downwards

> Seize the knife by its end and take it out towards the rear

Always keep the cutting knives sharp. Sharp knives save power and
provides a higher capacity.
→ Knife sharpening, page 126

Lever

42
 Preparation for use

Installing the knives > Slide the knives at the slotted holes over the knife carrier shaft
> Seize the knives by their ends and push towards the front to install
them
> Turn the lever upwards

Lever

> Open the valve at the hydraulic block on the right side

> Push to swing in the cutting unit

> Switch on the pto
> Wait until the knife symbol has appeared

Valve

Cutting length The cutting length can be chosen as desired, by varying the amount
and the position of the knives.
Minimum cutting length with 10 knives: about 75 mm.
All crop will be cut, even in difficult circumstances.

Exchange of Once the knives are removed, they can be replaced by dummy knives.
Which helps to
knives by dummy • keep the knife slots clean
knives [+] • ensure an uniform crop flow over the cutting unit floor

> Switch off the knife guide cleaning

→ Knife guide cleaning [+], page 83

To install the dummy knives

→ Installing the knives, page 43

43
Preparation for use

Changing press With suitable lifting equipment only

Carry out this operation using suitable lifting equipment. Severe per-
chamber height [+] sonal injuries can occur.

The press chamber height can be changed according to the desired

bale height, 70 or 80 cm.

Proceed as follows:
> Clean out the press chamber
→ Cleaning the press chamber, page 68
> Turn the flywheel by hand to the right to put the needle frame in the
bottom dead position (rest position)
> Turn the flywheel by hand to the right to put the plunger under the
opening at the top of the press chamber
> Remove the plunger extensions, located at the top of the plunger
> Loosen the knotter drive shaft
> Detach the connecting telescopic rod

Filler plate > Connect the knotter frame to a hoist

> Partially unscrew the 4 bolts in the slotted holes, which connect the
80 cm
knotter frame to the press chamber
> Unscrew the other 8 bolts that hold the knotter frame
80 cm > Move the knotter frame to the position corresponding with the de-
sired press chamber height
Depending on chamber height:
> fit or remove the filler plate
> Fit and tighten all bolts again
70 cm

44
 Preparation for use

> Untighten the needle frame brake

Needle
frame brake > Connect the needle frame to a hoist
> Partially unscrew the 2 bolts in the slotted holes of the brackets that
hold the needle frame at each side of the press chamber
> Unscrew the other 3 bolts
> Move the brackets to the position corresponding with the desired
press chamber height
GP0472
> Fit all bolts
> Retighten all bolts

Lateral
Reposition the density cylinder support of the top pressure door to the
top plate selected position:
depending on chamber height:
> move the lateral top plates in the correct position
70 cm

Cylinder
support

80 cm

Lateral
top plate
GP0470

Plunger extension > Fit the plunger extensions corresponding to the chosen press
chamber height:
70 cm • 80 cm: 5 extensions: 3 central + 2 lateral ones
80 cm • 70 cm: 5 extensions: 3 central + 2 lateral ones

45
Preparation for use

> Move the needle frame buffers in correct position corresponding to

the chosen press chamber height

80 cm
Needle
frame buffer

70 cm
GP0471

Adjustments Carry out the following adjustments:

• Check and carry out the adjustment of the tucker fingers
→ Tucker finger adjustment, page 159
• Check the needle centering
→ Centering the needles, page 152
• Check the needle height
→ Adjustment of needle height to knotter, page 153
• Check the needle throw
→ Needle throw, page 154
• Check the needle / plunger timing
→ Needle/plunger overlap timing - check, page 156
• Check the needle frame brakes
→ Adjustment of the needle frame brake, page 158
• Check the position of needle frame buffer
→ Adjustment of needle frame buffer stops, page 158
• Check the trip mechanism
→ Trip mechanism adjustment, page 140

46
 Preparation for use

Twine installation Before guiding the twine or carrying out any work on the knotters:
> Switch off the pto
> Stop the tractor engine
> Remove the engine key
> Block the flywheel using the flywheel brake
> Place the locking lever of the trip mechanism at the needle drive in
the stop position

Trip mechanism lock To work safe on the knotters, use the locking lever to lock or unlock
the trip mechanism at the needle drive.
The trip mechanism lock is placed near the starwheel.

TIP Arrow = direction of drive.

Proceed as follows:
> Move locking lever to the right to lock the trip mechanism
> Move locking lever to the left to unlock the trip mechanism

> Make sure the trip mechanism is unlocked before operating the
machine

Working Locked
position position

47
Preparation for use

Passing the twine

To needle 1 To needle 2

2 1 5 6 7

3 4 R R 8

GR0401
TIP Arrow = direction of drive.

Needle 1 Needle 2

Spools (1)-(2)-(3)-(4) Spools (5)-(6)-(7)-(8)

Pass the twine in such sequence that there are 4 spools per needle.
Nb: R = spare

Indication:
• with 1x9 kg spool (150 m/kg), for bales of 2.5 m long; approximate-
ly 200 bales
• with 4x9 kg spools (150 m/kg), for bales of 2.5 m long; approxi-
mately 800 bales

48
 Preparation for use

Guiding the twine

Eye of the
needle

Twine brake
(inside the
twine boxes)

2
1 Middle twine
Upper twine
guides
guides

Lower twine
guides

Tensioning
arms GP0408

For both left and right side of the machine:

> Put the twine spools in the twine boxes
> Pass the twine through the twine brakes (inside the twine boxes)
> Pass the twine through the middle twine guides
> Pass the twine through the lower twine guides
> Pass the twine through the tensioning arms
> Pass the twine through the upper twine guides
> Pass the twine through the eye of the needle
> Attach the end of the twine to the lower press chamber beam at
both sides and not under any circumstances to the needle frame
> See next page

49
Preparation for use

Eye of the
needle

Twine brake
(inside the
twine boxes)

2
1 Middle twine
Upper twine
guides
guides

Lower twine
guides

Tensioning
arms GP0408

> Switch on the pto drive shaft and run machine at 1000 rpm
> Turn the trip lever to the left
→ Trip mechanism lock, page 47
> Switch off the pto drive shaft as soon as the tying cycle is finished
> Lock the binding mechanism trip using the lever
> Check for the presence of twine at the knotter twine disc holders
> Remove any twine remaining in the bill hooks and attached to the
beam

50
 Preparation for use

Twine brakes The twine brakes must be adjusted in two ways:

• basic adjustment
• twine force
After the basic adjustment has taken place, the twine force has to be
checked.

Basic adjustment The basic adjustment of the spring length N of the twine brakes, only
Nuts if there is twine between the brake plates: 30 + 5 mm.
It is possible to adjust this length according to the twine used.
> Check the spring length N is 30 + 5 mm
> Loosen the nuts to decrease the spring length
N
> Tighten the nuts to increase the spring length

Twine force The twine force must be 60 - 80 N (6 - 8 kg).

Twine end Needle Check the twine force as follows:
> Attach a steelyard to the end of the twine at one needle
> Pull the steelyard until the tension arm is completely up
The twine force must now be 60 - 80 N (6 - 8 kg).
If necessary
> adjust the twine force by the twine brake
> Adjust the twine force for each needle

Tension arm

Windrow dimen- A constantly built windrow allows crop collection at a constant speed
and avoid shocks to the machine. Its shape, volume and moisture di-
sions rectly affects the output of the machine.
The machine can take in windrows according to the following dimen-
sions:
width (m) 1.20 - 1.80 maximum
height (m) 0.40

A windrow with a larger height than 0.40 m risks being caught by the
drawbar and so
• creating an irregular feed to the pick-up
• upsetting the normal rhythm of the machine
• risking the overload of the feeding system during baling

51
Road transport
Road transport

Safety Before road transport will take place, please read the following safety
information. The compliance is prescribed and helps you to avoid ac-
cidents.

Close valves
Before road transport close all valves. With open valves and false op-
eration the lifting cylinder can be lowered. Traffic accidents can be
caused.

Clean the machine before road transport

Clean the machine, before every road transport, from crop residues
and heavy dirt. Crop or dirt, falling at the road, can cause a slippery
state of the road. This can lead to fatal accidents.

Tractor rear wheels may not touch the drawbar

During driving through curves the tractor rear wheels may not touch
the drawbar. The tractor rear wheels can touch the pto drive shaft. Se-
rious machine damages can be caused.

Do not transport bales in the press chamber

Never transport bales in the press chamber. Transporting a bale influ-
ences the tractor’s steering and braking capacities. Personal or ma-
chine damages can occur.

Guarantee correct hydraulic couplings

Before preparing the machine, strictly check if the hydraulic couplings
are coupled correctly to a single acting hydraulic valve. Not correct
coupled hydraulic couplings can cause unpredictable movements of
the machine. Personal or machine damages can occur.

Adapted driving speed

Under bad road circumstances and at high driving speeds very high
crafts can appear, which load or overload the tractor and machine to
much. Adapt the driving speed according to the road circumstances.
A not adapted driving speed can lead to accidents.

52
 Road transport

Before road trans- Road transport must be done in transport position. To bring the ma-
chine into transport position, the following steps are necessary:
port
• the pick-up must be fully lifted
• the press chamber must be empty
• the bale chute must be fully lifted and locked
• the gauge wheels can be removed
• the road lighting must be connected properly to the tractor
• the braking system must be connected properly to the tractor
• the tyre pressure must be checked
• the wheel nuts must be tightened
• crop residues and heavy dirt must be removed

Pick-up When the machine is transported by road, the pick-up must be fully lift-
ed to maximum height.
> Lift the pick-up to maximum height
> Close the isolating valve on the hydraulic hose at tractor side
> Secure the pick-up in the highest position by holding the chains
tight in the retainer located on each side of the machine

Press chamber The press chamber must be empty before road transport may take
place. If necessary, the last bale must be tied and ejected.

Bale chute The bale chute must be fully lifted.

> Fold up the bale chute by hand
> Secure the bale chute by the chains on both sides

Chain

Roller chute [+] The roller chute must be fully lifted.

> Fold up the roller chute hydraulically
> Secure the roller chute by the chains on both sides
GP0394

Chain

53
Road transport

Gauge wheels The gauge wheels can be removed before road transport.
Gauge wheel Bracket
> Remove the spring clip
> Move the bracket forwards
> Turn the gauge wheel until the bolt is in the hole
> Pull out the gauge wheel
> Replace the spring clip
> Place the gauge wheel inside the press chamber

Spring clip Bolt

Tyre pressure > Check the tyre pressure

→ Tyre pressure, page 122

Tightness of wheel > Check tightness of wheel nuts

nuts → Tightness of wheel nuts, page 121

Checking the ma- Check the machine before road transport by the checklist:
•
chine •
Bale chute fully lifted and locked completely?
Electronic control switched off?
• Tractor hydraulic switched off?
• Pto switched off?
• All valves closed?
• Correct tyre pressure?
• Crop residues and heavy dirt are removed?
• Road lighting is connected and is working properly?
• The braking system is connected properly?
• Cables and lines are placed in that way they will not tension or get
in touch with the tractor rear tyres during curve driving?

Road transport • Before starting driving, check the close environment. Always take
care of a clear view and especially at children in the working envi-
ronment of the machine.
• Lock hydraulic valves of the tractor before road transport
• Do not transport any persons or objects at or inside the machine
• Adapt the drive speed to the road conditions
• Do not exceed the maximum speed, subject to local regulations in
force. Obey the national and local speed limits.
• Pay attention to sufficient driving and braking capacity. Then driv-
ing and braking capacity are influenced by the attached machine;
longer braking paths because of larger propulsion.

54
 Preparation at the field
Preparation at the field

Safety Obey the safety information

Obey the safety information at the execution of all work. Ignoring the
safety information can lead to serious or deadly injuries.

Secure tractor and machine

• Switch off and secure the tractor
• Prevent the machine against accidental commencement of opera-
tions
Unsecured machines can lead to accidents.

Do not compress the pto drive shaft

In no working or transport position may the pto drive shaft be com-
pressed. Compressed pto drive shafts can cause damages to the trac-
tor or the machine.

Performing set- The settings to the machine must be performed in working position.
They are described in the next sections:
tings • Gauge wheel adjustment
• Pick-up working height
• Crop guard adjustment

Prior to baling Before baling can start, the following has to be checked:
• Has the twine been guided completely?
• Has the bale length been set?
• Are the gauge wheels mounted?
• Has the pick-up been positioned at the desired height?
• Has the bale density been adjusted?
• Has the crop guard been set?
• Has the electronic control box been switched on?
• Is the bale chute fully lowered?
• Has the pto been switched on at low rpm and increased to 1000
rpm?
• Has the hydraulic density pressure been adjusted?

55
Preparation at the field

Gauge wheels The gauge wheels must be mounted after road transport.

Mounting If the gauge wheels are removed before transport, they must be
mounted before working.
Gauge wheel Bracket

> Remove the spring clip

> Place the gauge wheel
> Turn the gauge wheel until the bolt is in the hole
> Move the bracket backwards
> Replace the spring clip

Spring clip Bolt

Adjustment For gauge wheel adjustment

→ Adjustment gauge wheels, page 40

Pick-up working For pick-up working height

→ Pick-up working height, page 40
height

Crop guard The crop guard favours a good crop feed. Especially in short crop and
windy weather.

Adjustment small The bottom side of the crop guard must just touch the windrow.
The crop guard may only be used in the most forward pivot point.
windrow
Pivot point Adjust the crop guard as follows:
> Adjust the crop guard through bolts (four positions)
> Also use chain to prevent the crop guard from sinking
Chain

Bolts

Crop guard
GP0404

56
 Preparation at the field

Adjustment thick The bottom side of the crop guard must just touch the windrow.
The crop guard may only be used in the most forward pivot point.
windrow
Pivot point Adjust the crop guard as follows:
> Adjust the crop guard through bolts (four positions)
The bottom side of the crop guard must just touch the windrow.
Chain > Also use chain to prevent the crop guard from sinking
Bolts

Crop guard GP0405

57
Use at the field
Use at the field

Safety Never work on the machine while it is running

It is prohibited to do adjustments on a working or moving machine.
• The pto must be switched off
• The tractor engine must be switched off and the ignition key must
be removed
• The electronic control box must be switched off
In case of negligence, serious or deadly injuries can occur.

Driving along at the machine prohibited

It is not allowed that people or objects drive along at the machine.
Driving along at the machine is perilous and prohibited.

No persons in the turning area

Take care of no people be in the turning and working area of the ma-
chine. People can get grabbed or hit by the machine. Serious or dead-
ly injuries can occur.

Maximum pto speed 1000 rpm

The pto speed may not exceed 1000 rpm and must be adapted to the
condition of the crop. A higher rpm can cause damages to the ma-
chine.

58
 Use at the field

Prior to baling Before baling can start, the following has to be checked:
• Has the twine been passed?
• Has the bale chute been lowered?
• Has the flywheel brake been released?
• Has the electronic control box been switched on?
• Has the pre-chamber setting been adjusted?
• Has the bale length been set?
• Has the pto been switched on at low rpm and increased to 1000
rpm?
• Has the hydraulic density pressure been adjusted?
• Has the pick-up been positioned at the desired height?

Pre-chamber den- Dependent on the crop conditions and the desired bale density, the
crop density can be set in the pre-chamber. The crop density is influ-
sity setting enced by changing the pressure of the measuring plates. The level
and the density in the pre-chamber determine when the packer will put
the crop before the plunger in the press chamber. That way the crop
package fed in front of the plunger will always have a constant re-
quired volume for a regular bale shape.

Differences between In automatic setting (standard setting), the measuring plates move
backwards until the desired density and volume are reached. Then the
automatic and 1:1 crop is fed into the press chamber.
setting In 1:1 setting, the measuring plates are completely moved backwards
and are locked in this position. Now each plunger stroke a filling stroke
takes place.

59
Use at the field

Automatic setting Never work on a machine while it is running

Due to its inertia, the pto continues to rotate after disengaging. Stay
Measuring
clear of the machine until it has come to a complete stop.
plate
> Apply the flywheel brake
Upper
lever To place the measuring plates in the automatic setting, proceed as fol-
lows:
> switch off the pto
> Move the lower lever in the uppermost position
Spring > Move the upper lever upwards in the horizontal position
> Lock the upper lever with the spring clip

Recommended adjustment pre-chamber density:

> Place the lower lever in the uppermost position
If necessary:
Lower > move the lower lever downwards to increase the crop density
lever

TIP If the packer overload clutch is running, the pre-chamber density is set
too high.
→ Packer clutch, page 109
> Decrease the pre-chamber density by moving the lower lever up-
wards

60
 Use at the field

1:1 setting Never work on a machine while it is running

Due to its inertia, the pto continues to rotate after disengaging. Stay
Measuring clear of the machine until it has come to a complete stop.
plate

> Apply the flywheel brake

To place the measuring plates in the 1:1 setting, proceed as follows:

Upper > Switch off the pto
lever
> Move the lower lever in the uppermost position
> Move the upper lever fully downwards
Spring > Lock the upper lever with the spring clip

Lower
lever

61
Use at the field

Switching knives The cutting length is dependent on the number of knives. When all
knives are switched on, the crop will be cut to a length of 90 mm (10
on and off knives).

The knives can be switched on and off using the electronic control
box.

> Switch on the pto

> Let the machine run at 1000 rpm
The preset pressure value must been reached.

> Push

If the LED above this button is illuminated, the knives are in or come
into cutting position. When the knives are in cutting position, a knife
symbol appears on the display under the baling pressure value.

62
 Use at the field

Bale length setting Never adjust the bale length on a moving machine!

The bale length must be set

• mechanical, at the machine
• electronical, via Autoform, in order to control eventual alarms
The bale length can be set from 0.60 m to 3.00 m.

Mechanical bale length Set the mechanical bale length as follows:

setting > Loosen the knurled knob
Knob
> Move the arrow by turning the knob until the desired bale length is
reached
• Moving arrow up = decrease bale length
• Moving arrow downwards = increase bale length
> Tighten the knurled knob

After setting the bale length, the electronic bale length setting must be
adapted to the set mechanical bale length.
GP0417

Arrow Knurled
knob

Electronical bale length Set the electronical bale length as follows:

setting → Electronic bale length setting, page 81

63
Use at the field

Density pressure set- • The maximum permissible density pressure is 180 bar!
ting • Wait till the desired density pressure has been reached through let-
ting run the tractor pto for a few minutes without baling!
Actual density pressure • The preset pressure value must never be exceeded.

The automatic density pressure control is normally switched on to au-

tomatic control. The indicator light above the concerning button is on
when the automatic density pressure control is active.
When the pto is switched on, the electronic control system Autoform
automatically switches to the preset density pressure.

The actual density pressure must be approximately equal to the preset

Plunger load Preset density value. Therefore it will constantly be measured and adjusted.
indication pressure

The pressure control can also be operated manually

→ Manually setting the density pressure, page 65

The electronic control system regulates the density pressure between

0 bar and the preset value. In the event of a plunger overload the hy-
draulic pressure in the cylinders of the press chamber guide will auto-
matically be reduced. After the load on the plunger is reduced, the
density pressure is automatically built up to the preset value.

The density pressure must be adapted according to the working con-

ditions, like type of crop, crop humidity, twine resistance, etcetera.

> Push to switch on manual or automatic density pressure control

TIP If the LED above the button is on, automatic density pressure control
is switched on. Start at 50 bar.

> Push to increase the density pressure until the desired bale weight
has been reached
> Wait until the desired density pressure has been reached

64
 Use at the field

Manually setting the den- In manual mode, the density pressure is directly determined. The pre-
sity pressure set pressure value (= desired pressure value) on the screen is re-
placed by the symbol of a hand. The plunger load is displayed with a
Plunger load Actual density growth bar; the bar height indicates the load.
pressure
The density pressure can be set between 0 and 180 bar.
> Switch on the pto
The display shows the density pressure value.

> Push to decrease the density pressure

Manual control
> Push to increase the density pressure

Driving Never switch off the pto during feeding in

It is vital to let the machine run at 1000 rpm speed during use. Dam-
ages to the feeding and to the binding system can occur.

Please take care of the following during use:

• the pto must be switched on
• drive at the correct working speed, between 4 and 15 km/h, adapt-
ed according to the crop

Pto The pto may only be switched on at low motor rpm.

> Switch on the pto

65
Use at the field

Driving speed Use an adequate forward speed to ensure the crop is fed uniformly
and constantly into the machine.
> Adjust the driving speed according to
• crop amount
• windrow volume
• ground conditions

To achieve maximum bale density, the separate wads in the bale must
not be thicker than 5 cm.
Adapt the forward speed to the number of compression strokes per
bale. The working screen showing the plunger strokes per bale is a
good visible tool.
> Start slowly straight on the windrow
The electronic bale length must be in accordance with the number of
Plunger load Preset density
plunger strokes. The number of plunger strokes can be displayed in
indication pressure the lower right corner of the display.

Actual density pressure

8
Bale length (cm) 80 120 160 180 220 260
Number of plunger strokes per bale 16 24 32 36 44 52

> Maintain 1000 rpm at windrow end so that pre-chamber is empty

and eventually operate a binding cycles

66
 Use at the field

Bale growth In the working screens, the display always shows the bale growth.
This value matches the actual length in metres of the bale that is being
Actual bale length produced. When a bale is being tied, the actual bale length on the
screen is set to 0.

Set bale length

Rebaling bales Pto must be switched on during tying

Never stop the pto during the tying process. The needles and knotters
can get damaged.

When rebaling bales, make sure:

• the bales are clear of all twine
• the material has been spread to avoid an overload of the pick-up
or the feeder fork

End of baling At the end of the job:

• the press chamber must be cleaned
• a binding of the last bale must be operated
• the density pressure must be set to zero
• the pto must be switched off
• the control box must be switched off
• the bale chute must be folded up

67
Use at the field

Cleaning the press Never work on a machine while it is running

Due to its inertia, the pto continues to rotate after disengaging. Stay
chamber clear of the machine until it has come to a complete stop.

> Apply the flywheel brake

Before the machine can be transported on the road, before changing

field or crop, both the pre-chamber and the press chamber can be
cleaned.

Cleaning the pre- The pre-chamber can be cleaned as follows:

chamber > Place the lower lever in the uppermost position
> Move the upper lever downwards
Measuring > Switch on the pto
plate
The packer will now empty the pre-chamber.
> Switch off the pto
> Move the upper lever back in the horizontal position
Upper
lever

Spring

Lower
lever

68
 Use at the field

Cleaning the press When the pre-chamber has been cleaned, the press chamber can al-
so be cleaned.
chamber
> Switch on the pto
> Push to drop the density pressure to 0 bar

As soon as there is no more crop to bale:

> bind the last bale
> If a bale ejector [+] is mounted
→ Ejecting the last bale (bale ejector [+]), page 69
> Switch off the pto
> Stop the tractor engine
> Remove the ignition key
Wait until the machine has come to a complete stop!
> Put the trip mechanism lever at the needle drive in the locked po-
sition
> Remove the bale(s)

Ejecting the last bale When finished, the last bale has to be cleared out.
(bale ejector [+]) > Switch on the pto
> Let the machine run at 1000 rpm
> Start a tying process
> Lower the pto to 500 rpm
> Push to drop the density pressure to 0 bar
> Switch off the pto
> Bring the concerned hydraulic valve on the tractor in working posi-
tion
> Use the lever to eject the bale
> Put ejector in the most forward position after ejecting the last bale

Lever

69
Autoform
Autoform

Electronic control The machine is equipped with the Autoform electronic control system.
This control system controls and monitors the growing bale, the tying
system and clearing out of the bale. Furthermore the system also provides er-
ror indicating functions.

All dimensions are given in metric values.

Sensors The machine is equipped with sensors (proximity switches, rotational

and analog sensors).

Overview main parts

Hydraulic Pressure sensor Punger load sensor Machine box Fill sensor Knotter fans
block

Knotter hood
sensor

Bale
length
sensor

Bale
chute
sensor
Control
box

Power cable
knotter fans Tying
Power Connec- Flywheel Rotor Knife position Feed sys- Twine sensor
cable tion cable brake sensor sensor tem over- detec-
sensor load tion Needle
sensor sensor frame
shearbolt
sensor

70
 Autoform

Control box The control box enables supervision of the total baling procedure from
the tractor cab. Especially the following functions can be monitored:
• Bale length indication
• Plunger load
• Density pressure
• Overload packer
• Twine tension detection and functioning of the tying system
• Relation of filling strokes to plunger strokes
• Bale counters: 25 day counters and 1 total counter
• Knife position indication of the Opticut cutting system

Control box front

Display

Control box lower side

71
Autoform

Buttons (Re)Start button

To (re)start the electronic control system.

Stop button
To stop, interrupt a procedure, return to the starting position. Activity
is interrupted.

No function
This button has no function.

Registration button
Registration of bales and time per field.

Function button
To move to the next function of adjustment position.

Flywheel brake button [+]

Activating the flywheel brake reduces the rpm more quickly.

Auto / manual button

Selection of automatic or manual density pressure control.

Delete (clear) button

E.g. for the last bale: reduce density pressure to 0 bar.

Increase value button

To increase the selected value.

No function
This button has no function.

72
 Autoform

Knives button [+]

Switching knives on or off.

Confirm / save button

The value blinks no longer after confirming / saving.

Decrease value button

To decrease the selected value.

Main switch
Position Function
1 On
0 Off
2 Override control

No function
This switch has no function.

Override control switch

To override density pressure.

73
Autoform

Working
> Push to 1

The screen displays the load display.

Load display

Then the screen automatically switches to the basic display.

Basic display

The basic display is the starting display which also shows when a
function is interrupted by the Stop-button.
When the basic diplay shows, no active controls are possible (safety
position).

> Push, if required, to select manual or automatic mode

Automatic mode is standard setting.

> Push to show the working display

Through this display the working is monitored.

74
 Autoform

The vertical bar displays the plunger load. The numbers at the lower
left display the preset density pressure. The numbers at the upper left
display the actual density pressure. The number at the upper right dis-
plays the actual bale length. The number at the lower right displays the
pre-set bale length.
Work display

Push to show the different working displays

> The numbers at the lower right display the relation between the
number of filling strokes to the number of plunger strokes

Filling strokes : plunger strokes

• Filling strokes per bale of the most recently produced bale

Filling strokes

• Bales made per hour

Bale counter

75
Autoform

• Bale counter (number of bales for the job chosen)

Bale counter

• Actual tractor pto speed

Tractor pto
speed

76
 Autoform

Bale counters The number of produced bales can be shown on the display.

Bales per hour The number of produced bales per hour can be shown as follows:

> Push when in the working display or in the basic display

At the lower right corner shows the hour counter. This counter can not
Bales per hour counter be cleared to zero.

Bales per job The number of produced bales per job can be shown as follows:

> Push when in the working display or in the basic display

At the lower right corner the counter shows. This counter can be
Total bales counter cleared to zero.

Control of cutting mech- Using the Knife-button, the cutting mechanism is (de)activated.
anism (Opticut)
> Push to switch on or off the cutting mechanism

As soon as the knives are in cutting position, a knife symbol appears

in the lower middle of the display.
When the knives are coming into cutting position, the LED above the
button is on.

77
Autoform

Manual and automatic The system starts in automatic mode. Manual mode is used when au-
mode tomatic density pressure control is not desired or not possible.
In manual mode the indicator light above the button will be on. Stan-
dard setting is automatic mode.

When the working display shows you can select this mode as follows:

Manual / automatic control

> Push to select manual or automatic mode

In manual mode the automatic density pressure control is not desired

or not possible.
In manual mode, the display shows at the lower middle a hand instead
of the word AUTO. Also the LED over the button is on.
In manual mode, the density pressure can be set as follows:

> Push to decrease the density pressure

> Push to increase the density pressure

The maximum permissible density pressure is 180 bar!

78
 Autoform

Why working in manual Manual mode can be used for a short period:
mode? • if one or more connections are faulty
• if one or more sensors are defective
That way a field can be completed.

If the alarm keeps recurring, it can be deactivated by switching off the

concerning sensor(s)
→ Dealer functions, page 85

If the Rotor, FF, P or ML sensors (display F+08) are deactivated, the

operating settings switches to manual mode until the sensor has been
switched on and works properly. For the other sensors it remains pos-
sible to work even if the automatic density pressure control is switched
off.

TIP Manual mode is confirmed by the symbol of a hand on the display. In

addition, a wrench is shown on the right of the display (defective sen-
sor).

As soon as a defective connection or an alarm is shown, the cause

must be traced and remedied.

As long as the connection has not been repaired, the alarm symbol will
be displayed as long as the system is on.

When a connection failure occurs:

> Trace the cause
> Remedy as soon as possible

Proceed as follows:
100 150
> Observe the pressure values when the hydraulic pressure sensor
is switched off (indicated on the pressure gauge at the front of the
50 200
machine)

When the plunger overload sensor has been switched off, the elec-
Bars
tronic control system no longer registers the plunger load. In this case
GP0459

the alarm message "plunger overload" will not be shown.

In any event the overload limit will be the flywheel safety or a twine fail-
ure on ejection of the bale from the press chamber.

79
Autoform

Registration function This function is used for storing baling activities data.

The machine must be stopped completely!

> Push to switch on the Autoform electronic control system

The basic display appears. All other functions are blocked now.

Proceed as follows:
> Push to call up the registration function from the basic screen

> Push to scroll through (select) the displays J 01 to J 25

8 The selected screen (J06) can be allocated to a client or a field (06) to

subsequently register the duration (00:31) and the number of bales
(29).

> Push to reduce the registered time and number of bales

> Push to reset the registered time and number of bales (to 0)
or
> Push simultaneously to reset the registered time and number of
bales (to 0)

> Push to confirm

> Push to restore the previous value

or
> Push to restore the previous value
The previous value can be restored as long as the indicator light is
blinking.

80
 Autoform

User functions

Electronic bale The actual bale length is set mechanically. Autoform monitors and
controls the electronic bale length.
length setting

Setting the automatic

bale length control > Push to call up the main function immediately from the basic
screen
The factory setting is 2.0 m.
> Push to increase the bale length setting

Preset bale length

> Push to decrease the bale length setting
The setting range is 0.5 m to 3.0 m.
> Push to confirm
The bale length value stops blinking.
> Push to exit a function immediately
The bale length is set mechanically
→ Mechanical bale length setting, page 63

Knotter cleaning fans The knotters can be cleaned by optional cleaning fans.
[+]
> Push, when in the basic screen, until display F02 is entered

> Push to switch on the knotter cleaning fans

> Push to switch off the knotter cleaning fans

> Push to confirm

81
Autoform

Knotter cleaning The knotters can be cleaned by an optional cleaning compressor.

compressor [+]
> Push, when in the basic screen, until display F03 is entered

> Push to switch on the knotter cleaning valve

> Push to switch off the knotter cleaning valve

> Push to confirm

Oil lubrication [+] The chains can be automatically lubricated with oil by an optional oil
lubrication system.

> Push, when in the basic screen, until display F04 is entered

> Push to switch on the oil lubrication system

> Push to switch off the oil lubrication system

> Push to confirm

Grease lubrication A number of grease lubrication points can be automatically lubricated

with grease by an optional grease lubrication system.
[+]
> Push, when in the basic screen, until display F05 is entered

> Push to switch on the grease lubrication system

> Push to switch off the grease lubrication system

> Push to confirm

82
 Autoform

Knife guide cleaning Applies for machines with Opticut only: when the knives are not used,
locked in the lower position, the knife guide slots can be dirty. There-
[+] fore the knife guide slots must be cleaned regularly. Cleaning takes
place by swinging the knives automatically into cutting position for a
pre-set time.
Knife guide cleaning function can only be set when
• the pto is switched on
• the preset density pressure is reached
> Let the machine run at 1000 rpm

> Push, when in the basic screen, until display F06 is entered

> Push to switch on the knife guide cleaning function

> Push to switch off the knife guide cleaning function

> Push to confirm

Display contrast The display contrast can be set between 35% (dark) and 80% (pale).

> Push, when in the basic screen, until display F07 is entered

> Push to increase the display contrast

> Push to decrease the display contrast

> Push to confirm

83
Autoform

Volume level of the The volume level of the buzzer can be set between 0% (silent) and
100% (loud).
buzzer
> Push, when in the basic screen, until display F08 is entered

> Push to increase the volume level of the buzzer

> Push to decrease the volume level of the buzzer

> Push to confirm

84
 Autoform

Dealer functions Dealer functions are functions meant for reading and adjustment es-
pecially by a dealer, but also by the end user.

> Push to go to the basic display

> Push simultaneously to call up the first display F+01

> Push to scroll through and select the displays and adjust any set-
tings

Correction bale The bale growth per bale length sensor pulse can be corrected here.
length sensor
> Push to go back to the basic display

> Push simultaneously to enter the dealer functions

The display F+01 shows.

Default value is 15 mm bale growth per pulse.
> Push to correct the value
Set a value for the coefficient of variation between the actual value
and the displayed value.

8 Actual value (measured): 2.0 m,

Displayed value: 2.4 m;
> Reduce the preset value (15 mm / pulse) to: 15 x 2.0 / 2.4 = 13 mm
/ pulse

> Push to confirm

The displayed value no longer blinks.

Time setting pneu- Set at 1 sec cleaning and 10 sec pause.

matic knotter clean- > Push, when in the basic screen, until display F+02 is entered

ing
> Push to increase the time setting pneumatic knotter cleaning

> Push to decrease the time setting pneumatic knotter cleaning

> Push to confirm

85
Autoform

Time setting auto- The lubrication time can be set from 30 until 180 sec. The fix pause
time is 180 sec.
matic oil lubrication
> Push, when in the basic screen, until display F+03 is entered
system
The smaller the time setting is, the more oil will be put through.

> Push to increase the time setting oil lubrication system

> Push to decrease the time setting oil lubrication system

> Push to confirm

Time setting auto- Set at 20 sec. lubrication and 99 sec. pause.

matic grease lubrica- > Push, when in the basic screen, until display F+04 is entered

tion system
> Push to increase the time setting grease lubrication system

> Push to decrease the time setting grease lubrication system

> Push to confirm

Time setting auto- Set at 20 sec. cleaning and 5 min pause.

matic knife cleaning > Push, when in the basic screen, until display F+05 is entered

> Push to increase the time setting knife cleaning

> Push to decrease the time setting knife cleaning

> Push to confirm

86
 Autoform

Adjustment pressure The pressure sensor must send accurate information to the electronic
system. If not, the sensor must be calibrated.
sensor

Checking pressure sen- Check correct operation of the pressure sensor as follows:
sor
> Push to set the pressure to 150 bar
Upper value

> Push, when in the basic screen, until display F+06 is entered
> Read out the upper value
A value of 625 + 20 should appear. If not, calibrate the pressure sen-
sor.

Calibration pressure sen- Calibrate the pressure sensor as follows:

sor > Push to reduce the density pressure to zero

> Push, when in the basic screen, until display F+06 is entered

> Push twice

> Push to confirm

87
Autoform

Bale dimension ad- The bale dimension in cm is set, depending on the machine specifica-
tions, to:
justment
• 80 x 80 - 70
• 120 x 80 - 70
• 120 x 90 - 80

> Push, when in the basic screen, until display F+07 is entered

> Push to return to the basic screen

Total number of bales Can not be reset.

produced on the ma-
> Push, when in the basic screen, until display F+08 is entered
chine
> Push to return to the basic screen

Total baling time Can not be reset.

> Push, when in the basic screen, until display F+09 is entered

> Push to return to the basic screen

Switching rotor/ff/ In case of a sensor alarm, one or more sensor(s) can be switched off.
The alarm, caused by this sensor, will temporarily disappear.
pressure/ml sensors Proceed as follows:
on/off
> Push, when in the basic screen, until display F+10 is entered

> Push to switch on the sensor

> Push to switch off the sensor

> Push to confirm

If one or more of these sensors is switched off, the system goes to

manual mode.

88
 Autoform

Switching twine/bind/ In case of a sensor alarm, one or more sensor(s) can be switched off.
The alarm, caused by this sensor, will temporarily disappear.
starwheel/oc sensors Proceed as follows:
on/off
> Push, when in the basic screen, until display F+11 is entered

> Push to switch on the sensor

> Push to switch off the sensor

> Push to confirm

If one or more of these sensors is switched off, the system goes to

manual mode.

Switching chute/fly- In case of a sensor alarm, one or more sensor(s) can be switched off.
The alarm, caused by this sensor, will temporarily disappear.
wheel brake/needle Proceed as follows:
shearbolt/filling sen-
sors on/off > Push, when in the basic screen, until display F+12 is entered

> Push to switch on the sensor

> Push to switch off the sensor

> Push to confirm

If one or more of these sensors is switched off, the system goes to

manual mode.

89
Autoform

Factory functions These functions can be used to

• read out values
• test functions
> Switch off the pto before entering the factory functions

> Push to go to the basic display

> Push simultaneously to call up the basic display

In the basic display can be chosen between ‘Test menu’ and ‘Settings
menu’.

> Push to scroll through (select) the displays and adjust any settings

> Push to exit the factory functions at any moment

All data remain stored in the system (through battery).

Test menu

Voltage digital connector 1 D12V = voltage measured on

connector
11.7 V = current voltage

V2 = knives in 1 = active
V3 = knives out 0 = inactive
V4 = hydraulic flywheel brake
(V = valve)

Pneumatic knotter cleaning 1 = active

Automatic grease lubrication 0 = inactive
Automatic oil lubrication

Spare valve 2 1 = active

V5 = proportional valve 0 = inactive
V1 = pump selector valve

TMO Not used

Spare motor Not used

90
 Autoform

Inputs:
Flywheel brake sensor 0 = no signal
Fill sensor 1 = signal
Spare 3

Inputs:
Spare 4 Not used
Spare 5
Spare 6

Electric fans knotter cleaning = clockwise

stop = deactivate
= counterclockwise

Voltage analog 5 V and 12 V sensors + digitalIf value = 0, there is a system

12 V sensors on connector 2 short-circuit
A5V = 5 V (not used)
A12V < 9 V = alarm
D12V < 9 V = alarm
Test analog sensors:
P = Pressure sensor P = 459 -> current value
TW = Twine sensors TW = 0 -> current value
ML = Plunger load sensor ML = 373 -> current value

Testing analog inputs 4, 5 and 6 Not used

Test input:
Bind = Bale counter + resetting bale length 0 = no signal
ROT = rotor sensor 1 = signal
FF = feeder fork sensor

Test input:
OC = knife position sensor 0 = no signal
SW A = bale length sensor A 1 = signal
SW B = bale length sensor B

Test input:
Needle frame shearbolt sensor 0 = no signal
Bale shute position sensor 1 = signal
Fan emergency switch

Keyboard test screen for keys and LED’s > Push any button
The button number appears on
the display and the LED will go
out.
> Push any button twice to re-
turn to the basic screen

91
Autoform

Settings menu In the basic display can be chosen between ‘Test menu’ and ‘Settings
menu’.
> Push to scroll through (select) the displays and adjust any settings

> Push to exit the factory functions at any moment

The settings may not be changed.

Onboard computer software version V1.07 19 - 07 - 00 = software

version

Machine software version V1.04 23 - 11 - 05 = software

version

PIN code Not applicable

ML- offset 15 = current sensor counts

170 = setting for ML sensor if no
load

ML- maximum setting 14 = current sensor counts

500 = growth bar fully black at
500 counts

ML alarm setting 14 = current sensor counts

600 = setting for plunger load
alarm

Total number of bales produced on the ma-Can not be changed

chine

Total baling time of the machine Can not be changed

Current time Can not be changed

Current date Can not be changed

92
 Autoform

Electronic emer- In the event of an electronic problem, the machine offers a possibility
to control the density pressure manually.
gency control density
pressure The emergency control makes it possible to continue work despite
electronical defects. In all cases it is important to remedy the problem
quickly. Working quickly and accurately with the machine requires that
the machine is in automatic mode.

> Push to II

> Push to operate the pump

> Repeat this procedure every 30 sec, depending on the frequency
of reading the manometer
Now the desired pressure can be read from the pressure gauge.
GP0460

Hand wheel
> Rotate the hand wheel of the proportional valve to set the density
pressure
Setting the density pressure by rotating the hand wheel must never be
performed during work!

93
Cleaning and caring
Cleaning and caring

Safety For all cleaning and caring activities applies:

Do not penetrate bearings and hydraulic parts

Be careful when cleaning with a high-pressure cleaner. Bearings,
sealings and bolted joints are not waterproof. To avoid machine dam-
ages never penetrate bearings, sealings and bolted joints with water.

Do not clean bearings and hydraulic parts with high pressure

Do not clean bearings and hydraulic parts with a high-pressure clean-
er. Bright metal parts will get degreased and start rusting. After every
cleaning grease the bearings and grease bright metal parts.

Cleaning After every time of using the machine:

> Empty and clean the machine of all accumulated crop
Cleaning can be done with low pressure with the high-pressure clean-
er. Do not clean bearings, electronic and hydraulic parts with the high-
pressure cleaner.

Preparing for win- > Remove the control box from the tractor cab

ter
> Store the control box it in a dry place
> Empty and clean the machine of all accumulated crop
> Grease all greasing points
> Oil all chains
> Pump the tyres to a minimum pressure of 2.5 bar, depending on
the type of tyres

Winter storage When you observe the rules below, you will have a fully operational
machine at the start of the next season.
• Consult your dealer if you have any questions
• Before taking into use again, all adjustment activities described in
the operation manual must be carried out.

> Remove the twine

> Grease all the components of the machine (pivot points, cylinder
rods, etc.), oil the chains
> Protect the inside of the press chamber (antirust, spray with mix-
ture of diesel and oil)
Check
• the condition of the machine and
• the tightness of the hardware
> Replace any damaged parts

94
 Cleaning and caring

Electric lighting When the machine is unhitched from the tractor, put the plugs on the
support at the drawbar.

Automatic lubrica- The grease pump should be filled with grease as recommended.
tion system [+] > Let the pump work for a few minutes to ensure there is grease ev-
erywhere in the system

Support jack For a long storage, support the machine by a support under the hitch.

Caring > Protect all bright metal parts with an oil film. Only use authorized
biological oil, like rape oil
> Repaint any paint damages

95
Storing the machine
Storing the machine

Safety Obey the safety instructions

Obey the safety instructions at the execution of all work. Ignoring the
safety information can lead to serious or deadly injuries.

Machine is no toy
Store the machine in an area away from human activity. Never allow
children to play on or around the stored machine. Metal edges and
parts of the machine can lead to serious injuries.

Unhitching and se- > Place the bale chute fully up

curing of the ma-

> Lock the bale chute on both sides with the chains
> Place the machine on a dry and stable ground
chine > Secure the tractor from rolling away

> Disconnect the hydraulic connections and store them in the sup-
port at the drawbar
> Disconnect the electronic connections and store them in the sup-
port at the drawbar
> Uncouple the pto drive shaft and place it on the support provided

Machine with mechanic support jack

> Use the handle to lower the support jack fully

Machine with hydraulic support jack

> Put the valve in support jack position
> Open the shut-off valve at the quick coupler

Parking brake A parking brake provides the machine from rolling away when parked.

To use the parking brake

> Pull lever forwards

> Store the control box in a dry and dust-proof room free from ro-
dents, insects and martens
> Unhitch the machine from the towing hook of the tractor

Lever

96
 Storing the machine

After the season After the season and at longer storage periods, the following work
must be performed:
> Block the flywheel with the brake
> Tighten the machine parking brake
> Put the wheel chocks in place, depending on the version
> Thoroughly clean the machine
→ Cleaning, page 94
> Check all bolted joints and torque them
> Repair or replace damaged parts
> Repaint any paint damages
> Lubricate the machine
> Check the tyre pressure

97
Maintenance
Maintenance

Safety For all maintenance work applies:

Take care of the safety information

Definitely take care of the safety information during all work. In case
of negligence of the safety information serious or deadly accidents can
occur.

Conditions for maintenance work

Only carry out maintenance work if you do dispose of the necessary
professional knowledge and of the suitable tools. Missing professional
knowledge or unsuitable tools can cause accidents or damages.

Use original parts

Use original parts for safety relevant components. Dimensions,
strength, and material quality must be guaranteed. Building in of not
original parts the warranty reduces to nil and void.

Protect the machine against unintentional use

Carry out general repairs, maintenance and repair of function troubles
at the hitched machine, in principle with switched off pto, switched off
engine and removed ignition key. At unintended taking into use seri-
ous accidents can be caused.

No modifications on the machine

Never carry out modifications on the machine without prior consent of
the manufacturer. Unauthorised modifications can interrupt the function
of the machine or can harm the security. Unauthorised modifications
reduces the warranty and liability of the manufacturer to nil and void.

Welding work
Before welding work at the tractor and the machine in principal the
electronic circuit must be interrupted. Otherwise damages to the elec-
tronic can not be excluded.

Check at begin- • Check the slip clutch

→ Slip clutch, page 107
ning of the season

98
 Maintenance

Protection measures Additives in oil and lubricants can have, under circumstances, harmful
effects to health. Because an indication according to the danger order
in contact with oil or is not necessary, therefore in principle please pay attention to:
lubricants
Avoid skin contact
Avoid skin contact with these oil and lubricants. Protect your skin by
skin protection creams or oil-resistant gloves. Skin contact can lead to
skin diseases.

Do not use oil for cleaning

Never use oil and lubricants for hand cleaning! Chips and waste in this
oil and lubricants can extra lead to injuries.

Change dirty clothing

Change extremely filthy oiled clothing as soon as possible. Oil can
cause health injuries.

TIP • Waste oil must be collected and recycled

• in case skin diseases by oil or lubricants occur, immediately visit a
doctor

99
Maintenance

General All grease nipples must be greased with multipurpose grease. Accord-
ing to NLGI, class 2.
Except the grease nipples of the packer clutch
→ Packer clutch, page 109
These grease nipples must be greased with lithium grease type EP2.

This information is related to all maintenance work. At all maintenance

work the machine must be secured in working position. In case the
transport position is necessary for maintenance, you will find suitable
tips to the maintenance work.

Information of direc- Information of directions (left, right, front, rear, above, below) are to be
seen in the direction of travel.
tions The direction of rotation has been defined as follows:

Direction Description

Left counterclockwards

Right clockwards

Front in the direction of travel

Rear in the direction of travel

Rotation around a horizontal axis as seen at right angles to the direction of travel from left to right

Rotation around a vertical axis as seen from top to bottom

Rotation from bolts, nuts, etcetera always as seen from the operating side

100
 Maintenance

Maintenance inter- Before doing any maintenance, the following must be obtained:
vals • Empty the press chamber before doing any repair work
• Never work on a machine while it is running
• Pto must be switched off
• Electronic control system must be switched off
• Tractor engine must be stopped; ignition key must be removed
• Apply the flywheel brake
• Clean the machine with an air jet

Every 150 working hours

Every 250 working hours
Every 500 working hours
Every 10 working hours
Every 50 working hours

Centralised greased [+]

After 10 working hours

Automatic greased [+]

Change
Grease

Check

Clean

Page
Oil
Lubrication
Pto drive shafts • • • 106
Freewheel pto drive shaft • • 106
Overload clutch • • 106
Slip clutch • • 107
Pick-up overload clutch • • 107
Intake rotor bearing (left side) • • • • 107
Intake rotor bearing (right side) • • • • 108
Couplings gearbox shaft • • 108
Drive shaft bearing intake rotor • • • • 108
Rotor clutch (right side) • • 108
Rotor drive chain • • • • • • 109
Pick-up drive chains • • • • • • 109
Packer clutch • • 109
Main packer shaft bearing (left side) • • • • 109
Top hinge • • • • 110
Cylinder pivot • • • • 110
Swing shaft hinge • • • • 110
Locking mechanism • • • • 110
Measuring plates • • • 111
Plunger rods (both sides) • • • • 111
Plunger rollers • • • • 111
Needle frame drive • • • 111
Ratching pin • • • 112
Needle carrier connector rod • • 112
Needle extractor lever, hub and rod • • 112
Needle carrier pivots (both sides) • • • 112
Knotter drive shaft • • 113
Tucker finger shaft bearings • • • • 113
Knotters - top • • • • 113
Knotters - bottom • • • • 113

101
Maintenance

Every 150 working hours

Every 250 working hours
Every 500 working hours
Every 10 working hours
Every 50 working hours

Centralised greased [+]

After 10 working hours

Automatic greased [+]

Change
Grease

Check

Clean

Page
Oil
Centralised knotter greasing [+] • • 114
Automatic grease lubrication system [+] • • 115
Gearboxes
Front binding gearbox • • • 117
Front binding gearbox • • • 117
Rear binding gearbox • • • 118
Packer gearbox • • • 118
Packer gearbox • • • 118
Main gearbox • • • 119
Main gearbox • • • 119
Hydraulic system
Oil • • • 120
Oil • • 120
Filter • • 120
Wheels/axle
Wheels • • • 122
Hinges • • 123
Pivot pin • • 123
Brake lever single axle • • 123
Brake lever tandem axle • • 123
Pivot single axle • • 124
Chain tension
Rotor chains • • 125
Pick-up drive chains • • 125
Cutting unit
Knife sharpening • • 126
Packer system
Packer system • • 127
Checking the packer timing • • 128
Setting the packer timing • • 129
Tension cylinders packer • • 132
Timing rod • • 133
Pre-chamber
Pre-chamber • • 136
Cable measuring plates • • 138
Binding system
Trip mechanism adjustment • • 140
Anti-return for needle frame adjustment • • • 141
Timing of the needle extractor curve • • 142
Finger of the trip arm spring • • 143
Adjustment of the needle frame brake • • 158

102
 Maintenance

Every 150 working hours

Every 250 working hours
Every 500 working hours
Every 10 working hours
Every 50 working hours

Centralised greased [+]

After 10 working hours

Automatic greased [+]

Change
Grease

Check

Clean

Page
Oil
Plunger
Plunger roller adjustment • • 160
Plunger knife adjustment • • 161
Crop deflectors • • 161
Knotters
Overlap between needles and knotters • • 147
Overview knotters • • • 144
Checks knotters • • • 145
Bill hook • • • 146
Adjustment twine retainer disc • • • 147
Stripperarm • • 148
Knotter knife • • 148
Knotter environment • • 113
Twine release [+] • • 151
Sensors
Bale length sensor • • 165
Tying sensor (BIND) • • 165
Rotor sensor (ROT) • • 166
Feeder fork sensor (FF) • • 166
Fill sensor • • 166
Bale chute sensor (Chute) • • 167
Flywheel brake sensor • • 167
Needle frame shearbolt sensor • • 168
Knives position sensor (OC) • • 168
Knotter hood sensor • • 168
Plunger load sensor (ML) - check • • 169
Plunger load sensor (ML) - calibration • • 169
Twine detection sensor • • 169
Needles
Adjustment of the needles • • 152
Drawbar
Hitch eye • • • 124

103
Maintenance

Tightening torques All screwed joints on this machine must be torqued in accordance with
the values given in this table below unless indicated otherwise.
On this machine, 8.8 is both standard and minimum quality used. If not
indicated anyhow use this quality for determination of torque (in most
cases the quality can be found on the head of the respective bolt).

Thread Torque value Size of jaw*

8.8 10.9 12.9

Nm mm

M3 1.3 1.8 2.1 6

M4 2.9 4.1 1.9 7

M5 5.7 8.1 9.7 8

M6 9.9 14 17 10

M8 24 34 41 13

M10 48 68 81 17 (15)

M12 85 120 145 19 (17)

M14 135 190 225 22 (19)

M16 210 290 350 24 (22)

M18 290 400 480 27

M20 400 570 680 30

M22 550 770 920 32

M24 700 980 1180 36

M27 1040 1460 1750 41

M30 1410 1980 2350 46

M33 1910 2700 3200 50

M36 2450 2546 3063 55

M39 3200 4500 5400 60

* Values in brackets = size of jaw of lock bolts and nuts with toothed
flange are given in brackets if different from standard.

TIP • The listed values are applicable for dry or slightly oiled joints
• Do not use plated bolts/screws/nuts without grease
• When a stiff grease is applied decrease the given value by 10%
• In case lock nuts, lock screws or lock bolts are used increase the
given value by 10%

104
 Maintenance

Pto drive shaft The length of the pto drive shaft can be adapted. This depends on the
distance between tractor and machine.
Protection tube Profiled tube

Profiled tube Protection tube

Checking length of Correct length

To long a pto drive shaft may seriously damage drive bearings of both
the pto drive shaft tractor and machine. Which is beyond any warranty.
min. 5 cm min. 37 cm
Prior to coupling the pto drive shaft check the length:
> Correctly line-up tractor and machine
> Ensure the tractor pto is clean and greased
> Fit both pto drive shaft halves (not connected!)
> Hold both pto drive shaft halves together, ensure
• the protection tube shall be at least 5 cm shorter
A min. 5 cm • the overlap of the profiled drive tubes shall be at least 37 cm

Shortening the pto > Exactly determine the correct length of the shaft
drive shaft > Shorten the protection tubes
> Shorten the profiled drive tubes
The length of both cut-off ends shall be identical.
> Clean cut ends of both protection tubes and profile tubes to ensure
they are all smooth and clean
At the tractor side the pto drive shaft has a wide angle joint enabling
an angle of up to 80°. Ensure the joints are not destroyed due to bot-
WD0410

A=B toming of the shaft halves in sharp turns.

105
Maintenance

Lubrication

Lubrication marks
Grease / oil Specification
Oil API-GL-3 / 20W50
Grease NLGI 1-2, DIN 51818 lithium

Pto drive shafts The tube of the pto drive shaft, on tractor side, is equipped with
5 grease nipples.
The second pto drive shaft, on machine side, is equipped with
2 grease nipples.
> Disconnect the pto drive shaft
> Grease the grease nipples
> Grease the tubes of all pto drive shafts
• before using the machine and then
• every 10 hours
> Check every 10 hours that the tubes of pto drive shaft are sliding
Grease nipples correctly
> Grease the 2 joints of pto drive shaft largely before commissioning
the machine

Freewheel pto drive Do not grease the nipples excessively since grease could enter the
clutch.
shaft The clutch will not function properly. The machine can seriously get
damaged.

> Grease the nipple of the freewheel pto drive shaft

Grease
nipple
0354

Overload clutch > Grease the nipples of the overload clutch

Grease nipples
0354

106
 Maintenance

Slip clutch Prior to beginning the new season, the correct function of the slip
clutch in the pto drive shaft must be checked. This clutch is placed
Drum
nearby the gearbox, in front of the flywheel.

Proceed as follows:
> Untighten all eight nuts
> Rotate the clutch by hand
The clutch must rotate freely.
> Tighten all eight nuts so much, that the drum can just rotate
GP0418

Nuts

Pick-up overload > Raise the pick-up in the maximum position

clutch > Grease the grease nipple

Grease nipple

Intake rotor bearing > Grease the grease nipple at the back side of the sprocket
(left side)

Grease nipple

107
Maintenance

Intake rotor bearing > Grease the grease nipple at the back side of the sprocket
(right side)

Grease nipple
GP0356

Couplings gearbox > Grease the grease nipple

shaft

Grease nipple

Drive shaft bearing > Grease the grease nipple at the back side of the drive shaft
intake rotor

Grease nipple

Rotor clutch (right > Grease the grease nipple

side)

Grease nipple
GP0356

108
 Maintenance

Rotor drive chain > Grease or oil the chain

> Check the chain tension
→ Chain tension, page 125

Oil

Pick-up drive chains > Grease or oil the chain

> Check the chain tension
→ Chain tension, page 125

Oil
GP0357

Packer clutch > Grease the grease nipple with maximum 10 cc lithium grease type
EP2

Grease nipple

Main packer shaft > Grease the grease nipple on the bearing housing
bearing (left side)
Grease nipple

109
Maintenance

Top hinge > Grease the grease nipples at both sides

Grease nipples

Cylinder pivot > Grease the grease nipples at both sides

Grease nipples

Swing shaft hinge > Grease the grease nipples at both sides

Grease nipples

Locking mechanism > Grease the grease nipples

Grease nipples

110
 Maintenance

Measuring plates > Grease the grease nipples

Grease nipples

Plunger rods (both > Grease the grease nipples

sides)
Grease nipples

Plunger rollers > Grease the grease nipples at both sides

Grease nipples

Needle frame drive > Grease the grease nipple

Grease nipple

111
Maintenance

Ratching pin > Grease the grease nipple

Grease nipple

Needle carrier con- > Grease the grease nipple

nector rod

Grease nipple

Needle extractor le- > Grease the grease nipples

ver, hub and rod

Grease nipples

Needle carrier pivots > Grease the grease nipples

(both sides)
GP0366

Grease nipple

112
 Maintenance

Knotter drive shaft > Grease the grease nipples

Grease nipples

Tucker finger shaft > Grease the grease nipples on both sides
bearings

Grease nipple

Knotters - top > Grease the grease nipples

Grease
nipples

Knotters - bottom > Grease the grease nipples

Grease
nipples

113
Maintenance

Centralised knotter The knotters can be greased via a centralised grease lubrication sys-
tem. Then the following points will be greased:
greasing [+]
• tucker finger shaft bearings on both sides
• knotters
• needle carrier pivots on both sides

Filling > Connect a grease pump to the monobloc grease nipples, which are
located in front of and above the knotters
Overload valve Grease nipple
> Pump slowly to give the grease enough time to get into the tubes
A quickly pumping increases resistance of the system and does not
save any time.

> Regularly check the right working of the grease lubrication system
for cut or obstructed tubes
GP0433

Monobloc

Working When the monobloc is working, the indicator pin moves slowly in and
out.
GP0433

Indicator pin Monobloc

114
 Maintenance

Automatic grease lu- The machine can be equipped with an automatic grease lubrication
system.
brication system [+] The automatic lubrication system is controlled by Autoform.

Nearly all the greasing points of the machine are lubricated fully auto-
matically.

The system can be filled

• with a standard grease cartridge
• by grease gun/volume filler

Procedure filling by using > Clean the pump unit

a standard grease car- > Move up the black cap at the front of the lid and withdraw the rod
tridge and the rubber plunger
Black cap > Remove the dust covers of the grease cartridge
> Insert the grease cartridge
The largest opening should be upper most.
> Insert the rubber plunger into the cartridge
Rubber > Move the rubber plunger down until the cartridge is empty
plunger
> Remove the empty grease cartridge
> Replace the black cap at the front of the lid

Procedure filling by
grease gun/volume filler The pump should not be filled higher than 15 mm from the top of the
reservoir tube!

> Attach a power grease gun to the nipple

> Pump until the grease pump has been filled until the grease level
is 15 mm under the lid

Nipple

115
Maintenance

Working When the grease pump and/or divider blocks are working, the indica-
tor pins move slowly in and out.

Indicator pin

Indicator
pin

116
 Maintenance

Gearboxes

Contents
Gearbox Content Type Specification
Main gearbox (l) 25 B 80W90 API GL-4
Front binding gearbox (l) 3.3 ISO VG 100 DIN 51517-3
Rear binding gearbox (kg) 0.8 NLGI OEP
Packer gearbox (l) 4 ISO VG 100 DIN 51517-3

Front binding gear-

box

Checking the oil level > Remove the check level plug
If oil comes out the gap, the level is ok.
Check level plug Fill plug > Replace the check level plug
If no oil comes out, the gearbox must be filled.
→ Filling the front binding gearbox, page 117
GP0501

Discharge plug

Filling the front binding > Remove the check level plug
gearbox > Remove the fill plug
> Insert oil via the opening of the fill plug, until a little oil comes out
the gap of the check level plug
> Replace the check level plug
> Replace the fill plug

117
Maintenance

Rear binding gearbox

Checking the grease > Remove the check level plug

level If grease comes out the gap, the level is ok.
> Replace the check level plug
If no grease comes out, the gearbox must be filled.
→ Filling the rear binding gearbox, page 118

Discharge plug Check level plug /

Fill plug

Filling the rear binding > Remove the check level plug
gearbox > Insert grease via the gap of the check level plug, until a little grease
comes out the gap
> Replace the check level plug

Packer gearbox

Checking the oil level If oil is visible via the window of the check level plug, the level is ok.
If no oil is visible, the gearbox must be filled.
Fill plug
→ Filling the packer gearbox, page 118

Check level plug Discharge plug

Filling the packer gear- > Remove the fill plug

box > Insert oil via the opening of the fill plug, until oil is visible via the win-
dow of the check level plug
> Replace the fill plug

118
 Maintenance

Main gearbox
Fill plug

Check level plug

Discharge plug

Checking the oil level If oil is visible via the window of the check level plug, the level is ok.
If no oil is visible, the gearbox must be filled.
→ Filling the main gearbox, page 119

Filling the main gearbox > Remove the fill plug

> Insert oil via the opening of the fill plug, until oil is visible via the win-
dow of the check level plug
> Replace the fill plug

119
Maintenance

Hydraulic system

Oil
Content (l) Standard Thickness
Hydraulic system (l) 9 ISO 6743/4 22/32

Check the level via the gaugeglass:

• with 0 bar pressure
Gaugeglass
• with the press chamber cylinders in
The oil level is correct when the top of the oil is at the top the gauge-
glass.
GP0466

Change the hydraulic oil every 150 hours (or every year).

Filter Change the hydraulic oil filter every 150 hours (or every year).
The oil filter must, when fitted, be tightened by hand without using a
wrench.

Filter
GP0468

120
 Maintenance

Wheels/axle Correct repairwork only

Repairwork on wheels and tyres must only be carried out
• by professionals
• with the correct fitting equipment
Mounting wheels and tyres requires sufficient knowledge and avail-
ability of prescribed tools and equipment being in perfect condition.
Serious personal injuries or machine damages can occur.

Tyre dimensions as described

Do not fit other tyre dimensions than prescribed. Fitting other tyre di-
mensions can cause accidents. Personal or machine damages can
occur.

Pre-scribed tyre pressure only

Only use the pre-scribed tyre pressure. Using the false tyres pressure
can cause serious personal or machine damages or traffic accidents.

When working on the wheels make sure that the machine

• has been placed on the ground safely (use support jack)
• is secured by chocks against unintentional rolling

Tightness of wheel Tighten the wheel nuts:

nuts • after the first 10 working hours
• every 150 working hours
• after every tyre / wheel renewal
Tightness of wheel nuts is 270 Nm.
GP0367

121
Maintenance

Tyre pressure

Gauge wheels Tyre pressure pick-up gauge wheels

Tyre size Pressure
15 x 6.00 - 6 1.75 bar

> Check the tyre pressure regularly: ensure prescribed value

GP0437

Wheels When working on the wheels make sure that the machine
• has been placed on the ground safely with use of the support jack
• is secured by chocks against unintentional rolling
Mounting and repairing wheels and tyres requires
• sufficient knowledge
• availability of prescribed tools
• equipment being in perfect condition
Do not fit other tyre sizes as prescribed. Severe injuries can occur.
WA99101

Check the tyre pressure regularly: ensure prescribed value

Speed
Tyre size 25 km/h 40 km/h 60 km/h
500/55-20.0 12PR 1.2 bar 1.5 bar -
500/60-22.5 12PR 2.0 bar 2.5 bar -
16.0/70-20.0 12 PR 1.6 bar 2.0 bar -
560/45-22.5 146D 1.0 bar 1.5 bar 2.5 bar
600/50-22.5 12PR 2.0 bar 2.5 bar -
710/40-22.5 158A8 1.4 bar 1.6 bar -

122
 Maintenance

Hinges > Grease the grease nipples on both sides

Grease nipples

Pivot pin > Grease the grease nipple on both sides

Grease nipple

Brake lever single > Grease the grease nipples

axle

C
MONRO

Grease nipple

Brake lever tandem > Grease the 2 grease nipples on both sides
axle

Grease nipples

123
Maintenance

Pivot single axle > Grease the grease nipples

GP0370
C
MONRO

Grease nipples

Drawbar

Hitch eye The hitch ring in the hitch eye is fitted with a wearing sleeve. It must
be changed as soon as wear appears.
> Grease underside of the hitch ring every 500 bales

Handle support jack Grease the handle of the support jack from time to time with oil.
> Use the hole on the handle

124
 Maintenance

Chain tension

Rotor chains The automatic chain tensioner of the rotor drive is at the right side of
the machine.
Correct the chain tension as follows:
D > Loosen or tighten nut until a spring length D of 165 mm has been
reached

Nut

Pick-up drive chains The automatic chain tensioner of the pick-up drive is at the left side of
the machine.
E
Pick-up drive:
• 1x left side: compression spring (1”)
• 1x left side: automatic tensioner (3/4“)
Correct the chain tension as follows:
> Loosen lock nut
> Loosen or tighten nut until a spring length E of 140 mm has been
reached
> Tighten lock nut
E
GP0513

> Check for wear on the tensioner pads on a regular base

Nut

125
Maintenance

Cutting unit

Knife sharpening Wear protective goggles

Always wear protective goggles when sharpening the knives. Flying
around sparks can cause serious injuries.

Never sharpen the undulated side of the cutting edge because of ex-
cessive wear.

Proceed as follows:
WA0474

> Remove the knife

→ Removing the knives, page 42
> Clamp the knife in the vice
Ensure the knife is not getting hot during sharpening, since that may
weaken the steel! It is better to grind more frequently than a lot at
once.
> Sharpen the knives every 10 working hours on the smooth side,
using a grinder
> Reinstall the knife
→ Installing the knives, page 43

126
 Maintenance

Packer system
Measuring
plates

Main crank

Hook

Pin

Cable
Lock pin

The measuring plates measure

• the level of the crop
• the density of the crop
The position of the measuring plates is transferred by the cable. When
the lock pin is activated, the pin is caught by the hook. The transport
movement of the packer is converted into an input movement.

127
Maintenance

Packer timing

Checking the packer

timing
L

Main crank

Timing plate

Bolt

Checking plate

Nut

The timing can be checked by comparing the packer position relative

to the plunger position.
> Turn the flywheel by hand to the right until the main crank is just
before the forward dead centre
> Place the checking plate on the bolt and the nut
The front plunger roller center must be in the middle of the hole of the
timing plate.
The distance L from the center of the front plunger roller to the end of
the rails must be 170 + 5 mm.

128
 Maintenance

Setting the packer

timing
L

Main crank

Timing plate

Bolt

Checking plate

Nut

If distance L from the center of the front plunger roller to the end of the
rails is not 170 + 5 mm, this must be readjusted.
Before setting the packer timing:
> Check the packer timing
→ Checking the packer timing, page 128
> Turn the flywheel by hand to the right until the main crank is just
before the forward dead centre
> Place the checking plate on the bolt and the nut
> Block the flywheel using the brake
> Remove the duplex chain
> Unblock the flywheel brake
> Turn the flywheel by hand to the right until the middle of the front
plunger roller is in the middle of the hole of the timing plate
Distance L must be 170 + 5 mm, measured from the front plunger roll-
Duplex er to the end of the plunger rails.
chain Hereby the plunger must just before the forward dead centre.
> Block the flywheel using the brake
> Fit the duplex chain
> Unblock the flywheel brake
Some angle displacement between the sprockets is allowed as long
as the plunger remains within the prescribed distance. If necessary,
the sprockets may be moved by the splines of the axle.

129
Maintenance

Checking the synchroni-

zation of the hook
Hook Lock nut Bolt

Arm

Non-visual line

G
Lock pin Pin A

The packer system must be checked every 3000 bales.

Checking may only happen, if the system is at the beginning of the fill-
ing stroke. This is achieved, if a non-visual line can be seen (as shown
in the graphic).

Distance G, on both sides, must be approximately 497 mm when

• the hook is over pin A
• the arm is in line with pin A
When hook moves down over pin A, it must go down in a smooth mo-
tion. Whereby pin A must be in the middle of slotted hole of hook.
> Loosen the lock nut
> Adjust distance G by turning the bolt
> Tighten the lock nut
In this position, the head of the bolt must touch the arm on both sides.
Difference in length on the left and on the right side is possible!

TIP To be able to move hook, lock pin must be pulled out by cable. Pro-
ceed as follows:
> Place the lower lever in the uppermost position
> Move the upper lever downwards
Upper lever The lowering of the hook is now possible.

Lower
lever

130
 Maintenance

Adjustment of the hook

Hook Lock nut Bolt

Arm

Non-visual line

G
Lock pin Pin A Pin B

Checking may only happen, if the system is at the beginning of the fill-
ing stroke. This is achieved, if a non-visual line can be seen (as shown
in the graphic).

TIP To be able to move the hook, the lock pin must be pulled out by the
cable. Proceed as follows:
> Place the lower lever in the uppermost position
> Move the upper lever downwards
The lowering of the hook is now possible.
> Turn the flywheel to the right till
• the hook moves over pin A
• the small crank and pins A and B are in line
> Turn the bolt at the right side fully in
> Turn the bolt at the left side as far as necessary in or out, till pin A
is in the middle of slotted hole of hook
> Lock the bolt with the nut at the left side
Measuring
plate > Turn the bolt at the right side till it slightly touches the arm
> Lock the bolt with the nut at the right side
> Let the machine run for a few moments and
Upper
lever > Check for a fluent downward movement of the hook
> Move the upper lever upwards
> Lock the upper lever by the spring clip
> Move the lower lever in the preferred position
Spring

A too wide or too small distance G may seriously damage the mecha-
nism!

Lower
lever

131
Maintenance

Tension cylinders packer

Tension cylinder

No maintenance of the cylinder allowed

It is not allowed to maintain or repair the cylinder. The tension cylin-
ders are under high pressure. Outcoming oil can cause severe inju-
ries.

The tension cylinders at both sides are maintenance-free.

Repair work may only be done by qualified, skilled personnel.

132
 Maintenance

Timing rod
Checking timing rod

K
Ring

Checking
plate

Crank

Roll Hook

If hook moves up after a filling stroke

• distance K between the tip of hook and roll must be 0 mm and
• the slotted hole must just be visible under the ring

The position of the crank to the hook is important. Check this position
as follows:
> Place the checking plate
> Check if distance K = 0 mm
> Check if distance X = 0 - 0.5 mm

The crank must move backwards and have moved through the top
dead center.

TIP The timing rod must be checked every 3000 bales!

133
Maintenance

Adjustment timing rod

K
Ring

Checking
plate

Crank

Roll Hook

The crank must move backwards and have moved through the top
dead center.

> Use the checking plate

Adjust distance K by turning the rod.
> Loosen the lock nuts
> Turn the rod that far, so the tip of the hook slightly touches the roll
> Turn the rod, seen from above, 6 complete turns to the left
That will make the rod 3 mm longer. Distance K is still 0 mm and dis-
tance X is 0 - 0.5 mm.
> Tighten the lock nuts
> Switch on the pto and let the machine run at stationary rpm
> Check if the stop bolts touch the arm without excessive noise
> If necessary, change the length of the rod
> Complete the entire feeding cycle; check if the hook moves up flu-
ently

Setting the rod too short or to long, will cause damage to the mecha-
nism!

134
 Maintenance

Spring setting hook

Screw-clip

Nuts

Plate

GP0377
Hose
Spring

The upper part of the spring must be fully against the plate.
Make sure the spring is not rotating during tightening the nuts.
> Tighten the nuts
> Fit the hose tightly at the spring
> Tighten the screw-clip

135
Maintenance

Pre-chamber

Buffers measuring
plates

Checking buffers mea-

suring plates

Measuring plate

Support
Upper lever

Nut

Buffer
Lower lever

The two buffers, to stop the measuring plates in the rearmost position,
must touch the measuring plates at the same time.
> Move lower lever fully up
> Move upper lever fully down
> Pull the measuring plates by hand against the buffers
The buffers must be positioned against the measuring plates at the
same time. If not, adjust the buffers
→ Adjustment buffers measuring plates, page 137
> Put back upper lever
> Put back lower lever

136
 Maintenance

Adjustment buffers mea-

suring plates

Measuring plate

Support
Upper lever

Nut

Buffer
Lower lever

> Move lower lever fully up

> Move upper lever fully down
> Pull the measuring plates by hand against the buffers
When the measuring plates are not against the buffers at the same
time, one or more washers must be added between the buffer and the
support.
Adjust the buffers as follows:
> Loosen nut
> Add or remove washers to effect both buffers touch the measuring
plates at the same time
A minimum of two washers must be mounted between the buffer and
the support.
> Tighten nut
> Move down upper lever
> Move up lower lever

137
Maintenance

Cable measuring
plates

Checking cable length

measuring plates

Measuring plate

Upper lever

Buffer
Lower lever

K
The signal from the measuring plates that is sent to the lock pin goes
via a cable.
> Move lower lever fully up
> Move upper lever fully down
Lock pin > Distance K must be 34 + 1 mm
> Move back upper lever
> Move back lower lever

Nuts

138
 Maintenance

Adjustment cable length

measuring plates

Measuring plate
Upper lever

Buffer
Lower lever

Nuts

K
The signal from the measuring plates that is sent to the lock pin goes
via a cable.
> Move the lower lever fully up
> Move the upper lever fully down
Lock pin > Adjust the cable length by turning the nuts, till length K is 34 + 1 mm
> Move back the upper lever
> Move back the lower lever

Nuts

139
Maintenance

Binding system

Trip mechanism ad-

justment
Wheel Rod Nut Lock nut Trip lever

GP0380
Arm Roller Roller A

The distance A between the trip lever and the roller must be between
3 to 5 mm when the lever is being reset and drops.
Adjust distance A as follows:
> Trip the mechanism
> Turn the flywheel by hand to the right until the arm with the roller is
at the wheel radius
> Loosen the nut
> Remove the lock nut
> Take off the rod
> Turn the rod to the left or to the right to adjust distance A
> Place the rod
> Mount and tighten the lock nut
> Tighten the nut

An incorrect adjustment of the trip mechanism may lead to

• variation in the bale length
• undesired tying cycles take place

140
 Maintenance

Anti-return for needle

frame adjustment
Anti-return strip Bolts

90°
Knotter frame Screw

GP0381
Crank

After each knotting cycle, the anti-return strip must be in contact with
the crank.

> Put the crank in the rest position; a 90° angle appears between the
Crank
crank and the knotterframe
Knotter In rest position, the crank and the rod must be in line. This can be ad-
shaft
brake
justed by changing the knotter shaft brake force.
→ Knotter shaft brake adjustment, page 146
> Loosen bolts
Rod
Adjust the position of the anti-return strip as follows:
Needle > Turning screw clockwards:
frame
> Tighten bolts
> Run the pto at 1000 rpm
> Check that anti-return strip butts against the crank

141
Maintenance

Timing of the needle ex- > Turn the flywheel to the right until
tractor curve • the crank has passed the forward dead centre and
Curve Marks • both marks on the plunger are visible through both holes in the
side-frame
Hereby the curve must be in line with the slotted hole.

Slotted hole Crank

Adjustment of the needle Distance B between the peak of the curve and the bearing on the
extractor crank lever must be between 0.2 and 0.5 mm.
Hereby the needles must be in rest position.
Adjust as follows:
> Change the length of the link, until distance B has been reached

Link Curve Bearing

142
 Maintenance

Finger of the trip arm

spring
Finger

Pin

Spring

GP0382
Nut Lock nut
B

The pin must be at the end of the slot in the finger. This corresponds
with a spring length B of 58 ± 1 mm.
Adjust the spring length as follows:
> Untighten the lock nut
> Turn the nut to the left or to the right until spring length B has been
reached
> Tighten the lock nut

143
Maintenance

Knotters Stop the knotter fans while carrying out maintenance in the knotter ar-
ea.

> Push
TIP Each knotter fan has a 15 A fuse.

Overview knotters
Knotter disc Knotter body Tap washer Nut, hook
spanner

Bill hook gear

Twine disc
gear

Compression Stripper arm

spring (twine
retainer)
Twine retainer

Stripper plate

Clamping
Compression segment

GP0449
GP0448

spring (bill
hook) Worm gear Worm Nut, hex.
Bill hook 25 Nm

144
 Maintenance

Checks knotters
Knotter disc Tap washer Nut

Bill hook gear

GP0448

Bill hook

TIP In order to assure a trouble-free functioning of the tying process, reg-

ular visual inspection of the knotter is indispensable!

Axial play knotter disc > Check axial play A of the knotter disc
> Adjust axial play if required
Adjust as follows:
The distance between the edge of the sliding ring of the knotter disc
and the sliding surfaces of bill hook and twine catching gear may be
maximum 0.2 mm for one of the gears. In that case, a distance of max-
imum 0.6 mm is effective for the other gear.
> Check this
> Correct the distance if required.
This can be done by using nut, finally secure the nut using tap washer.

Knotter shaft brake check- To check the correct operation of the knotter shaft brake:
ing > Trip the knotter drive mechanism several times at 1000 rpm with
an interval between each operation
The ratchet
• must stay in contact during the rotation of the knotter shaft with the
stop on the annulus of the drive sprocket
• releasing must be clean

145
Maintenance

Knotter shaft brake ad- To adjust, use the bolts keeping the springs at an equal length C = 48
justment + 0.5 mm.

C Check the spring tension regularly. A false spring tension means that
the needle frame does not come back in its home position.
Replace the brake linings as soon as they are worn.
Never grease the brake discs.
> Loosen or tighten the nut to adjust the spring tension
> Use the set bolts to make sure that the linings are in line
Nut

Springs Bolts
GP0384

Adjustment bill hook Distance A of the bill hook compression spring must be 20 mm.
compression spring Adjust as follows:
> Turn or loosen the bolt

Bolt

Bill hook Distance E of the bill hook (in the knotter) shall be at least 10 mm.
How to check:
> Turn the knotter manually until roll at the bill hook is at the highest
Roll point of the curve
GP0385

146
 Maintenance

Adjustment twine re- Before the twine retainer disc can be adjusted, the following conditions
tainer disc have to complied with:
C • No twine in the twine retainer disc
• Clamping segment sits on the bottom of the twine retainer disc
• Knotter must be in rest position
Distance C between the left corners of the catch slots of the twine re-
tainer and the lips of the clamping segment must be 7 mm.
> Check distance C

If distance C is not 7 mm, the twine retainer disc should be adjusted.

Proceed as follows:
> Slacken nut
> Release worm of shaft cone (by cautiously tapping at the shaft
Worm Shaft Nut Worm end)
gear end
> Rotate worm gear until distance C (7 mm) has been obtained
Condition: teeth of worm and worm gear
• must touch in drive direction and
• must be turned until they fit tight
> Tighten nut
> Torque nut to 25 Nm

Clamping force of twine > Check correct adjustment of clamping force of twine retainer spring
retainer spring Standard spring length D is 38 mm, measured along the outer surfac-
es. The final adjustment of the twine retainer shall be carried out when
machine is in use.
The twine retainer shall keep the twine without fraying or flattening be-
cause of too high a tension.

Twine retainer
spring

147
Maintenance

Stripperarm Check that comb of stripperarm slides in the middle along the bill hook
just touching it. If this is not the case it can be seen by irregular wear
of radius A of the stripperarm.
> Bend the stripperarm slightly to correct this

GP0448

Stripper-
arm

The stroke length C of the stripperarm at the bottom of the bill hook
GP

shall be about 15 mm. If not, the twine will be damaged and the prob-
lem must be solved.
> Replace a damaged bill hook or stripperarm

Knotter knife Carefully handle the knife! Danger of severe physical injuries.

Ensure the knotter knife is sharp at all times.

> Replace a dull of damaged knife

Knotter knife

148
 Maintenance

Disassembly of knotter
Tap washer Breaking Nut Bolts Lubrication
lines tube

GP0451
GP0450

Do not tap strongly on the metal in order to avoid pieces of metal flying
around! Work safely by wearing safety spectacles!

Because of the breaking lines in the knotter body a single knotter can
be disassembled easily.
Proceed as follows:
> Slacken nut
> Remove lubrication tube
> Remove both bolts
> Break the knotter body into two parts by hammering on the two
breaking lines using a sharp chisel and a hammer
> Remove the knotter
> Perform required repairs or place a new knotter by parting into two
parts in the same way
It may be necessary to remove the worm gear also in order to enable
removing the knotter.

149
Maintenance

Tap washer Breaking Nut Bolts Lubrication

lines tube

GP0451
GP0450

> Install the knotter

Ensure the body parts are correctly reassembled (the two parts shall
not be turned 180° with respect to each other).

> Tighten both bolts (48 Nm)

> Reinstall lubrication tube and worm gear (if required)
> Check free-turning at knotter around knotter-flanges
> Turn/install the knotter in the working position
> Tighten nut and lock it with the tap washer
If the worm gear has been removed, ensure it has been reset into the
correct timing
→ Adjustment twine retainer disc, page 147

150
 Maintenance

Twine release [+]

Curve

Nuts Roll

Highest point

Pin
Frame

Arm
Nut

Bolt
A

Distance A between the side of the arm and the right side of the frame
must be 0.5 - 1 mm.
Distance B between the arm and the pin must be 2 - 3 mm.

Adjust distance A as follows (per arm):

> Loosen the nut
> Loosen the bolt
> Move the arm laterally until distance A is 0.5 - 1 mm
> Tighten the bolt
> Tighten the nut

Adjust distance B as follows:

Before adjusting distance B, make sure the curve is at the highest
point to the roll.
> Turn the nuts to adjust distance B

151
Maintenance

Needles Adjusting the needles requires a fixed procedure. This procedure is as

follows:
• the needles must be centered
• the distance between needle and knotter must be set
• the needle throw must have been adjusted

Adjustment of the Before any adjustments to the needles can be done, they must be in
the top dead centre.
needles Adjust as follows:
> Trip the tying mechanism
→ Trip mechanism lock, page 47
> Turn the flywheel by hand to the right to raise the needles to the
top dead centre

Centering the needles Distance A between the side of the needle and the knotter frame must
A be 0 mm (slightly touching).
> Loosen bolts and nuts
> Turn sleeve nut to adjust
> Tighten bolts and nuts
> Recheck distance A
> Check if the needles are centered to its slot in the press chamber
Needle

Sleeve Nuts
nut
GP0432

Bolts

152
 Maintenance

Adjustment of needle The distance between the needle and the twine retainer disc must be
height to knotter 12 + 0.5 mm.
Check this distance as follows:
> Place a round bar, with a diameter of 12 mm, between the needle
Knotter and the knotter frame
> Check distance
If the bar fits exactly, the needle height is set correctly.

If not, the needles must be adjusted as follows:

> Move each needle vertically to adjust to 12 mm
> Loosen bolts and nuts
12 mm > Turn sleeve nut to adjust
Needle Bar
> Tighten bolts and nuts
> Recheck distance

Sleeve nut Nuts

GP0432

Bolts

153
Maintenance

Needle throw

Crank

Line Needle

Twine retainer disc

Needle rod

Only adjust the needle throw

• when the needle frame is supported by a gantry and
• while the drive rod is disconnected and
• when the crank and the needle rod are in line

To put needles in the top position, proceed as follows:

> Trip the mechanism
> Turn flywheel by hand to the right until crank is in top position and
in line with needle rod
In rest position, the crank and the rod must be in line. This can be ad-
justed by changing the brake force.
Needle
rod

Needle
frame
brake
Needle
Fork frame

Pin

154
 Maintenance

Crank

Line Needle

Twine retainer disc

Needle rod

Distance H between the twine retainer disc and the centre of the nee-
dle roller must be 150 + 5 mm.
Needle Adjust as follows:
rod > Support the weight of the needle frame and the needles
Needle > Loosen lock nut at the needle rod
frame > Remove pin
brake
> Disconnect fork
Needle
Fork frame > Turn fork to increase or decrease the length of needle rod
> Connect fork
Pin
> Replace pin
> Check the adjustment
> Tighten lock nut at the needle rod

155
Maintenance

Needle/plunger overlap
timing - check

Knotter drive
shaft

Plunger

The needle/plunger overlap (distance C) must be 0 - 35 mm.

Check distance C as follows:
> Trip the mechanism
→ Trip mechanism lock, page 47
> Turn the flywheel to the right until the needle tips are flush with the
bottom of the press chamber
> Check distance C is 0 - 35 mm

156
 Maintenance

Needle/plunger overlap
timing - adjustment

Knotter drive
shaft

Plunger

Before adjusting the needle/plunger timing

• the tractor pto must be switched off
• the engine must been stopped
• the ignition key must been removed
• the needle throw must have been adjusted

Adjust the needle/plunger timing as follows:

> Turn the bale length star wheel until lever is pulled forward in its
opening
> Turn the flywheel to the right until the needle tips are flush with the
bottom of the press chamber
> Disconnect the knotter drive shaft on front of the machine
> Turn the flywheel to the right
> Stop turning the flywheel as soon as the front of the plunger passes
the needle tips by 0 - 35 mm (distance C)
> Block the flywheel using the brake
> Connect the knotter drive shaft
> Turn the flywheel to the right until a complete plunger cycle has tak-
en place
> Recheck the overlap

157
Maintenance

Shearbolt needle frame The needles are protected by a shearbolt, located in the needle frame
drive rod drive rod.
For correct shearbolts
→ see Spare parts manual

Shearbolt

Adjustment of the needle To adjust, use the bolts keeping the springs at an equal length C = 48
frame brake + 0.5 mm.

C
• Check the spring tension regularly.
A false spring tension means that the needle frame does not come
back in its rest position.
• Replace the brake linings as soon as they are worn
• Never grease the brake discs
Nut
Adjust the brake so that the movement of the needle frame is contin-
Springs Bolts uous
GP0384

> Loosen or tighten nut to adjust the spring tension

> Use the set bolts to make sure that linings are in line

Adjustment of needle frame The needle frame buffers must be aligned with rubber blocks.
buffer stops Adjust as follows:
> Turn the flywheel by hand to the right until the needle frame is in
the lower dead position
Buffer support > Loosen bolts
Bolts > Move the buffer supports so that distance E (35 + 5 mm) is created

158
 Maintenance

Tucker finger
adjustment
Needle B Nuts Base plate

Rod Lock nuts Tucker finger

This adjustment must be done after all needle adjustments are fin-
ished.
The needles must be in the top position, in front of the tucker finger.
Now the tucker finger is in rest position, too (as shown in the figure).

Distance B between the needle and the tucker finger must be 10 - 20

mm.
Adjust as follows:
> Loosen the two nuts
> Move the base plate until the distance B of 10 - 20 mm has been
reached
> Tighten the two nuts
Distance A between the tip of the tucker finger and the side of the base
plate must be 0 - 5 mm.
> Change the length of the rod by means of lock nuts
> Recheck these adjustments after making a few bales

159
Maintenance

Plunger

Plunger roller adjust- Distance B between the top of the rollers and the upper rail along its
length must be between 0.2 - 0.5 mm.
ment
> Use shims to adjust distance B
Bolt Plunger
→ see Spare parts manual
C
Distance C between the rollers and both rails must be 1 + 0.5 mm
along its length.
Adjustment of the lower rail:
> Loosen the bolts holding the rails
> Loosen the front nut
Upper rail B > Loosen the back nut

Adjust distance C as follows:

Roller
> Turn front nut and/or back nut
> Make sure upper rail is free
Lower rail
> Turn the front and/or back nut at the left side to move the plunger
Front nut to the left
> Turn the front and/or back nut at the right side to move the plunger
Back nut to the right
> Tighten the front nut
GP0390

Bolt > Tighten the back nut

> Tighten the bolts holding the rails
> Proceed as above for the upper rail.

> Check that the plunger is not rubbing anywhere in the press cham-
ber

The tighten torque of bolts is 80 Nm.

160
 Maintenance

Plunger knife adjust- Handle the plunger knives with care, they are very sharp. Be careful
not to trap or cut your fingers.
ment

Once the plunger has been adjusted in the press chamber, adjust the 5 plung-
er knives on the lower face of the plunger.
Distance E between the fixed knife and the plunger knives must be be-
Nut tween 1 and 2 mm.
E > Block the flywheel using the brake

GP0490
> Loosen nut
> Add shim(s) to decrease the clearance
Shims Plunger Fixed
knife knife > Remove shim(s) to increase the clearance
> Tighten nut

Crop deflectors Be careful not to trap your fingers between the deflectors and the cross-
member.
Plunger

Distance G between the crop deflectors and the cross member must
be 3 mm.
Adjust as follows:
Bolts
> Loosen bolts
> Reposition the deflector
> Tighten bolts

Crop de- Cross

flector member

161
Maintenance

Brakes

Hydraulic brakes Hydraulic oil is under high pressure! It can cause severe injuries.

Bleeding hydraulic brak- The brake circuit is a hydraulic single acting system connected to the
ing circuit tractor by a hose with a quick coupler.
> Loosen coupling of the hose at the brake cylinder one turn
> Push the tractor’s brake pedal gently
> Repeat this until no more air escapes at the coupling
> Fit the coupling of the hose at the brake cylinder
→ Hydraulical brakes - single axle, page 170

Adjustment brake shoes The brake shoes must not touch/rub against the drums in the rest po-
sition.
Proceed as follows:
> Adjust the position of the brake shoe levers on their splines
> Make a running check by advancing the machine 10 metres

> Frequently clean brake drums and brake shoes

Pneumatic brakes

Adjustment brake shoes The brake shoes must not touch/rub against the drums in the rest po-
sition.
Proceed as follows:
> Adjust the position of the brake shoe levers on their splines
> Make a running check by advancing the machine 10 metres

162
 Maintenance

Flywheel brake The flywheel brake

• provides a quick stop of the rotating parts
• is used to block the machine during maintenance

The flywheel brake can not be adjusted.

163
Maintenance

Automatic grease lu- > Fill the grease pump regularly

brication system [+] Avoid running the pump empty.
> Do not overfill the system
> Keep clean the reservoir tube on the outside, so the level can be
checked
> Clean the filters every 100 machine operation hours

164
 Maintenance

Sensors There are different types of sensors used in this machine:

• Rotational sensor, like the bale length sensor
• Proximity sensors, like the tying sensor

Rotational sensor

Bale length sensor The bale length sensor must send correct information to the electronic
system. If it does not, calibration is required.
After producing a bale of the required length, the length indicated on
the display must match the actually produced length. The actual pro-
duced length is set mechanically.
This procedure must be repeated until the displayed information is
correct.
The bale length is measured by a sensor that runs in a bearing. It is
mounted on the shaft besides the starwheel. This sensor can count
positive as well as negative. If the bale moves backwards and for-
Bale length sensor wards in the press chamber, the measurement will still remain correct.
Each time the needle swing is disengaged, the value will be set to 0.
It can not be adjusted.

Proximity sensors The proximity sensors trace metal objects.Therefore they must be set
according to a certain distance, depending per sensor.
All proximity sensors must have a distance A of 2 - 6 mm.
Proceed as follows:
> Loosen the two bolts
> Adjust the sensor by moving it, until the required distance has been
reached
> Tighten the two bolts

Tying sensor (BIND) The tying sensor

• registrates the number of bales and
• the reset bale length
Situated at the left side of the needle frame.
If the sensor detects metal, the connected sensor indicator light will be
on.

165
Maintenance

Rotor sensor (ROT) The rotor sensor detects the rotation of the rotor.
Situated at the left side of the intake rotor.

Feeder fork sensor (FF) The feeder fork sensor detects the movement of the feeder fork.
Situated at the left side of the machine.

A
GP0461

Fill sensor The fill sensor registrates the filling stroke.

Situated at the left side of the machine.
A

166
 Maintenance

Bale chute sensor The bale chute sensor detects the position of the bale chute.
(Chute)

Flywheel brake sensor The flywheel brake sensor registrates the position of the flywheel
brake.
The connected sensor indicator light will be on if the brake is not used.
The connected sensor indicator light will be off if the brake is used.
Bolts

167
Maintenance

Needle frame shearbolt The needle frame shearbolt sensor registrates a shearbolt breakage
sensor on the needle frame swing.

Knives position sensor The knives position sensor registrates the position of the knives.
(OC) Situated at the knife frame.
Bolts

A
R0414

Knotter hood sensor The knotter hood sensor detects if the knotter hood is closed.

Bolts Knotter hood

sensor

168
 Maintenance

Plunger load sensor (ML) The actual plunger load is measured by this sensor. As soon as the
- check preset maximum value is reached, the electronic control system ad-
justs the proportional valve V5 (see hydraulic diagram). A dropping hy-
draulic pressure of the density pressure opens the three panels of the
Bolts press chamber shortly, reducing the plunger load.
Before checking the plunger load sensor, the plunger must be without
load.

> Push simulteanously to enter the factory functions

> Push to switch on the Settings menu

Plunger overload
sensor
> Push to enter display FS04

> Check if the lower value is 170 ± 5

Plunger load sensor (ML)

- calibration Proceed as follows:
> Push to enter display FS04
It shows the current (upper) value of the ML sensor (in the example
15). It must be 170 if the plunger is free of load.
> Turn the nuts to shift the sensor position

Twine detection sensor The twine detection sensor

• detects the presence of twine and
• the tension of twine
The twine detection sensor is activated by a magnet on the twine arm.
Distance A between the sensor and the magnet must be between 20
and 25 mm with the lever on the stop in the bottom position.
Proceed as follows:
A
> Loosen nuts
> Adjust distance A
Nuts Twine detec- > Tighten nuts
tion sensor

169
Maintenance

Hydraulic dia-
grams

Machine
Press chamber Pressure sensor
0.5 l
P
O D 50 bar
0-180 bar
Density cylinder M
V5

V3
V1

V2

185 bar P T

GR0415
2x

Hydraulical brakes -
single axle
GP0477

Quick coupler Brake cylinders

170
 Maintenance

Hydraulical brakes -
tandem axle

Cylinders

Quick coupler

Pneumatic brakes -
single axle
Quick coupler Hose filter Pressure regulator Check-connection
(yellow) valve

Quick coupler
(red)

Check Brake cylinder

connection

Air tank

Drain valve Brake valve

171
Maintenance

Pneumatic brakes -
tandem axle
Quick coupler Hose filter Pressure regulator Check-connection
(yellow) valve

Quick coupler
(red)

Check Brake cylinder

connection

Air tank

Drain valve Brake valve

Pick-up / support jack

Valve Support jack

Quick coupler Pick-up

cylinders

172
 Maintenance

Bale ejector / roller

chute [+]
Quick coupler Bale ejector
cylinder

Quick coupler Roller chute cylinder

Flywheel brake [+]

GP0481

Quick coupler Flywheel Flywheel

brake cylinder

173
Maintenance

Wheel blockage [+]

Cylinders

GP0482
Quick coupler

174
 Optional equipment
Optional equipment

General Where parts are to be changed, only use genuine original spare parts.
When ordering, quote the machine identification numbers. Trained
people only must carry out the use, maintenance and repair of the ma-
chine. Consult your dealer for any additional advice.
In addition, the warranty will be automatically annulled if the machine
has been equipped with accessories or spare parts not authorised by
the manufacturer.
Attach optional equipment
• in accordance with the mounting instructions
• to the appropriate attaching points only

For details of the optional equipment

→ Spare parts manual

Changing press The press chamber height can be changed, according to the desired
bale height.
chamber height → Changing press chamber height [+], page 44

Knotter fans The knotter fans keep the knotters free of dust.
The system allows to change the direction of rotation of the fan auto-
Fan matically for a few seconds. By this way the section screens of the
knotter fans are cleaned regularly.

Centralised knot- The knotters can be greased via a centralised greasing system. Then
the following points will be greased:
ter greasing • tucker finger shaft bearings on both sides
Grease nipple • knotters
• needle carrier pivots on both sides
→ Centralised knotter greasing [+], page 114
GP0433

175
Optional equipment

Automatic grease The machine can be equipped with an automatic grease lubrication
system.
lubrication system The automatic grease lubrication system is controlled by Autoform.
The automatic grease lubrication system greases fully automatically
nearly all the greasing points of the machine.
→ Automatic grease lubrication system [+], page 115

Bale ejector The bale ejector can be used to eject the last bale.
→ Ejecting the last bale (bale ejector [+]), page 69

Lever

Roller chute The roller chute is used to guide the bales in a quick and smooth way
down.
Roller chute → Roller chute [+], page 53
GP0394

176
 Optional equipment

Following tandem The wheels of the last axle follow the tractor movement exactly.

axle > Connect the hydraulic hose on a single acting spool valve on the
Valve tractor
> Put the valve during baling in floating position

Lock the following tandem axle, using the valve, in every case while
• driving backwards
• during road transport

Hose

Dummy knives Applies for machines with Opticut only: once removed, the knives can
be replaced by dummy knives which will help to keep the slots clean
and ensure an uniform crop flow over the cutting unit floor.
To install the dummy knives, follow the same procedure as for the
knives
→ Installing the knives, page 43

When installing dummy knives, switch off the knife cleaning function
→ Knife guide cleaning [+], page 83

Twine release Twine release reduces the twine tension at the knotter during the knot-
ting process.
→ Twine release [+], page 151

177
Troubleshooting
Troubleshooting

General electron- • Most malfunctions are caused by incorrect connections

•
ics
The machine box may only be opened by people with sufficient ex-
pertise
• Make sure no dirt gets into the opened central operating panel
• Only restart the machine once the cause of the failure has been
identified. Otherwise, parts damaged as a result will not be covered
by warranty.

Problem Cause Solution

No message on the control box No power supply to the control sys- • Switch on the device
tem • Check the system power
• Check fuses

Alarm "no connection" appears on • Control box not equipped with • Switch off and back on at prop-
the display correct eprom er power supply
• No or bad connection between • Check power supply of ma-
control box and machine box chine box
• Switch on control box
• Switch control box off and on

Internal control system problem Consult your dealer

Bale length does not match preset • Incorrect setting increment size • Recalibrate sensor
value • Deviation due to different crop • Correct

Automatic density pressure con- • Faulty operation pressure sen- • Calibrate pressure sensor
trol does not work sor • Check pressure sensor
• Rotor sensor without pulses • Check Rotor sensor
• FF sensor without pulses • Check FF sensor

Defective pto sensor Check adjustment • Check connection

• Change sensor

ML sensor set incorrectly Check the sensor setting Set ML - sensor

Incorrect preset value in computer Switch to manual mode; consult

program dealer

178
 Troubleshooting

Autoform The buzzer warns the operator when an error has occurred. Every er-
ror indication appears separately on the control box display in order of
priority.
If an error occurs:
> Stop baling immediately
> Remedy the error before continuing work
Ignoring the fault message and continuing work may cause consider-
able material and financial damage!

The fault messages are roughly divided into two groups:

• Baling process alarms
• Technical alarms

Baling process If one of the following alarms appears, stop immediately!

alarms

Bale chute alarm This message appears in the working screen when it has been detect-
ed that the bale chute is not yet in baling position.
> Lower the chute

Flywheel brake acti- This message appears when the mechanical flywheel brake is in brak-
vated ing position.
> Switch off the flywheel brake

Emergency stop fans [+] The emergency stop button of the knotter cleaning fans has been
activated pushed or the hood over the knotters is open.
> Close the hood above the knotters

Shearbolt needle frame This message appears when needle frame shearbolt has broken.
failed Probable causes:
• obstructed twine routing
• obstacles in plunger and/or knotter
> Replace the shearbolt
> (Re)activate the tying process

179
Troubleshooting

Plunger overload alarm This message appears when the plunger load becomes too high. In
(ML) that event the density pressure is reduced in 5 bar increments until the
plunger load is back to normal. Then the preset density pressure is au-
tomatically restored.
If the system is in manual mode, the pre-set density value will not be
restored after a plunger load alarm.

If the alarm persists

> reduce the preset pressure or
> reduce the forward speed

When having a plunger overload alarm

• plunger overload calls up a warning on the display
• and activates the buzzer
The automatic density pressure control is disengaged, the pressure
drops in 5 bar increments until the plunger load has reached a normal
level again. This applies to automatic density control only.

Problem Cause Solution

Snapping twine after the bale is Density pressure to high Push to reduce the density
ejected pressure

Frequent activation of the flywheel Plunger overload Push to reduce the density
clutch pressure
Drive slower

> Push rapidly to reduce the hydraulic pressure to 0

The preset pressure remains stored in the memory.
> Push or to activate the preset pressure

Feed system overload When this fault message is repeated, you should reduce the forward
sensor speed. In the event of a constant alarm, check if there is
• a blockage at the rotor
• a blockage in the pre-chamber area
A too high load on the packer disengages the packer camclutch. Au-
toform automatically responds to this by switching off the Opticut
knives [+] and activating the flywheel brake [+].
> Push to switch on the knives

180
 Troubleshooting

Incorrect bale length Bale length does not match value set at "main functions".
> Check the bale length setting
Needle frame shearbolt failed. Find the cause and remedy the prob-
lem.
> Mount new shearbolt

Twine failure message If one or more knotters is not fed with twine or the twine tension is too
low, a warning message appears.
> Remedy the malfunction
The display in this example gives a twine failure message for the left-
hand twine arm and one or more for intermediate twine arms.
> Check twine routing
> Correct twine routing if necessary

Pto alarm (rpm too high) A too high pto rpm increases the risk of damaging the machine. Auto-
form generates an alarm at a pto speed higher than 1100 rpm.
> Decrease the tractor engine rpm

181
Troubleshooting

PTO alarm (rpm too low) If the rpm is too low some machine functions can not respond quick
enough.
> Increase the rpm

Knife position false The knife position is detected differently than set.
Probable causes:
• shut-off valves closed
• obstruction in cutting unit
• pollution
• sensor fault
The knife position alarm can be reset
> by switching the knives off and on or
> by stopping the system and restarting

Fill alarm This display appears if after more than 10 plunger strokes no filling
stroke has taken place while bale growth has been registered.
Probable causes:
• Insufficient crop in feeding channel; drive faster
• Wrong adjustment of the fill sensor or defect
• Because of a mechanical fault the feeder fork does not make a fill-
ing stroke
> Remedy the problem

Timing alarm Per plunger stroke the feeder fork makes 2 filling strokes.
Probable causes:
• Wrong timing adjustment of feeder fork mechanism
• Mechanical fault at timing mechanism of the feeder fork switching
mechanism
> Remedy the problem

Knotter fans alarm This display appears if the knotter fans do not function.
Probable cause:
• The hood above the fans is open
> Close the hood
or
> Adjust sensor under the hood

182
 Troubleshooting

Technical alarms

Bad connection Bad electrical supply or connection(s) between machine box and con-
trol box.
Proceed as follows:
> Check all electrical connections
> Check battery tension (voltage)
> Check software
> Check cables for broken leads

Short-circuit D 12 V con- Short-circuit in the 12 V digital circuit of connector 1 of the machine

nector 1 box (see arrow).

Short-circuit D 12 V con- Short-circuit in the 12 V digital circuit of connector 2 of the machine

nector 2 box (see arrow).

Short-circuit A12 V con- Short-circuit in the 12 V analog circuit of connector 2 of the machine
nector 2 box.

Battery voltage too low The battery voltage is lower than 9 V. When fault messages appear re-
peatedly, function disruptions in the electronic control system may oc-
cur.
> Remedy the function disruption

183
Troubleshooting

No ML sensor No ML sensor is detected, so no plunger load can be indicated.

> Remedy the problem

No rotor sensor No rotor sensor is detected.

> Remedy the problem

Non-confirmable error Strong electromagnetic radiation / fields may generate electronic er-
displays rors. Non-approved transmitters may be the cause.
The system may show not-identifiable errors: if the error cannot be
confirmed/identified at the machine, ignore it and proceed your work.

184
 Troubleshooting

Security systems Before approaching the machine

• switch off the electronic control system
• switch off the pto
• stop the tractor engine; remove the ignition key
• apply the flywheel brake
Do not start up the machine again until the cause of the problem has
been identified and the problem resolved. Otherwise, parts damaged
as a result will not be covered by warranty.

Security systems protect the machine from

• overload
• exceeding the capacity
• damage by foreign objects

Main driveline pro- The main driveline of the machine is protected by an automatic cam-
type clutch.
tection The automatic clutch running can be caused by a too high pre-set bale
density.

> Slow the pto rpm to re-engage the automatic camtype clutch
> If no reclutch, decrease the hydraulic density pressure until restart

Automatic
clutch
0354

Primary drive axles The primary drive axles are protected by a slip clutch.
The slip clutch running can be caused by
protection
• the still active flywheel brake
• a too high plunger load during starting
• a too high pto rpm during starting

Solutions:
> Release the flywheel brake
> Decrease the hydraulic density pressure
> Start at a low pto rpm and slowly increase pto rpm
Slip clutch
0354

185
Troubleshooting

Rotor protection The intake rotor is protected by an automatic camtype clutch.

> Decrease the pto rpm to reengage the drive
> Move 1 or 2 meter backwards to stop the crop flow
> Slowly increase the pto rpm

Camtype
clutch

Packer protection • The overload results from excessive stress on the packer (driving
speed too fast, presence of foreign objects, etc.).
• Stay clear of the hatch when opening. Quick movement of the
hatch by pressed material can cause severe injuries.

The packer is protected by an automatic and phased camtype clutch.

> Decrease the pto rpm to re-engage the automatic torque limiter
In case the overload persists despite forward speed has been re-
Automatic + duced:
phased > Stop the machine
clutch
> Switch off the pto
Do not start up the machine again until the cause of the problem has
been identified and the problem resolved.

To solve the problem, the hatch in the intake channel has to be

opened. And the intake channel has to be cleaned.
→ Pre-chamber overload, page 189

186
 Troubleshooting

Pick-up protection The pick-up protection will operate

• in case of excessive output
• when the pick-up setting is too low or
• when the forward speed is too high

To protect the pick-up in case of an overload the pick-up is protected

by an automatic slipclutch.

> Decrease the pto rpm to re-engage the automatic slipclutch

Automatic
slipclutch Only restart the machine once the cause of the failure has been iden-
GP0397

tified. Otherwise, parts damaged as a result will not be covered by

warranty.

Knotter protection Breakage of the knotter shearbolt is caused by a temporary overload

on that knotter. Clean knotter if necessary of remove damaged parts.
Do not start baling until the cause has been identified and the problem
has been solved!

Each knotter is protected by a shearbolt.

A special wrench is available to turn the knottercam before replacing

the shearbolt. This wrench is placed inside the left lateral door of the
machine, behind the twine box at the left side.

Shearbolt Wrench

187
Troubleshooting

Needle protection The needles are protected by

• a shearbolt located in the needle frame drive rod and
• by a shearbolt in the needle extractor
Only use prescribed shearbolts
→ see Spare parts manual

Needle frame shearbolt A shearbolt in the needle frame drive rod is one of the protections for
the needles in case of an overload.
> Replace the shearbolt if broken

Shearbolt
0464

Needle extractor shear- The needle extractor ensures the return of the needles to rest position.
bolt In case of a failure in the knotter drive
→ Anti-return for needle frame adjustment, page 141

> Check shearbolt every 5 breakages of needles shearbolt protec-

tion
→ Needle frame shearbolt, page 188
> Replace shearbolt in case of wearing
→ Spare parts manual

Shearbolt Needle extractor

188
 Troubleshooting

Pre-chamber over- • Never work on a machine while it is running!

•
load •
Pto must be switched off!
Due to its inertia, the pto continues to rotate after disengaging.
Stay clear of the machine until it has come to a complete stop
• Apply the flywheel brake!

In case of a pre-chamber overload, the pre-chamber can be opened

via a hatch. And the crop can be removed.

Stay besides the machine when opening the hatch. Quick downwards
movement of the hatch by compressed material can cause severe in-
juries.

Proceed as follows:
> Remove the spring clips at both sides
> Remove the pin at the left side
> Remove the pin at the right side
The hatch will fall down by itselves.

> Remove the crop

> Close the hatch
> Replace the pin at the right side
> Replace the pin at the left side
> Replace the spring clips at both sides
Spring clip Pin Hatch

189
Troubleshooting

Main driveline
Problem Cause Solution

Drive line vibration • Flywheel bushing worn Fit new ones

• Flywheel bearings worn

Free play in the transmission pto • Repair/correct it

shaft bottoming out when cornering • Check the hitching to the trac-
tor

Clutch limiter slip Incorrect adjustment Check limiter

Automatic torque limiter of the fly- Bale density too high Reduce the hydraulic pressure
wheel runs too often
Accumulation of dirt in the press Empty and clean the press cham-
chamber ber

Crop flow
Problem Cause Solution

Breakage of pick-up tines Pick-up setting too low Adjust the pick-up height

Suspension incorrectly adjusted Adjust the pick-up suspension

Missing tine guards Replace them

Twine wrapped in the tinebars Clean the pick-up

Noisy pick-up Cam roller broken or missing Replace with new one

Tine guards badly aligned/damaged Correct the tine guard alignment/

replace tine guard if necessary

Twine wrapped in the tinebars Clean the pick-up

Automatic torque limiter of the Too much crop coming into the ma- Reduce forward speed
packer system and or rotor runs chine
too often
Uneven windrows Alter settings of rake making the
windrows

Foreign object in the machine Clean out the machine and re-
move the object

Clutch worn Fit new clutch

Pre-chamber density/volume too Reduce pre-chamber density/vol-

high ume

Noisy packer operation even Packer timing incorrect Check the packer timing and bolt
when machine empty adjustment

190
 Troubleshooting

Plunger
Problem Cause Solution

Plunger noisy Clearance between rail and plunger Adjust the clearance within the
roller too large specified limits

Knives missing Fit new plunger knife sections

Knives dull Sharpen knives

Knive clearance to big Adjust knive clearance

Heating of plunger rollers No clearance between the rails and Adjust the clearance to within the
the plunger rollers specified limits

Accumulation of crop Clean the plunger rollers

Hydraulics
Problem Cause Solution

Hydraulic pressure not increasing Control box not connected Connect control box

Pto does not turn Switch on pto

Shortage of oil Fill up the system

Air in the hydraulic system Bleed the circuit

Air gets into the circuit (hot pump) Verify the hose connections

Dirty oil Drain, clean out the circuit and re-

fill with new oil

Proportional valve not working cor- Check preoportional valve

rectly

Pump not working correctly Check pump

Rotor sensor faulty Renew sensor

Hydraulic pressure drops with Plunger overload switch adjustment Reset to correct adjustment
each plunger stroke incorrect

Electrical circuit problem Consult dealer

191
Troubleshooting

Deformed bales
Problem Cause Solution

"Banana" bales Crop flow into the machine not cen- Drive the tractor straddling the
tralised windrow and along the centre of
the windrow

Uneven hydraulic pressure on the Make a few bales with 0 bar pres-
press chamber shutters sure. Then bleed the hydraulic
system at the shutters and resume
baling at normal pressure

Poor chamber filling (soft top Damp crop Readjust pre-chamber setting
bales)
Packer timing incorrect Readjust packer timing

Build up of trapped material in the Empty and clean out the bale
pre-chamber or press chamber chamber and pre-chamber

Loss of plunger skirt Remedy

Pre-chamber density too low Increase volume/density

Pto rpm not correct 1000 rpm only

Needles / knotters
Problem Cause Solution

Frequent breakage of the needle- Wrong shearbolt used See Spare parts manual
frame shearbolt
Foreign object in the machine Clean out the machine to find the
object

Needles badly adjusted Check the needle adjustments

Needle frame brake badly adjusted Adjust needle frame brake

Needle plunger overlap incorrect Reset

Twine spools tangled up Check the spools of twine and the

twine tensioners

Erratic tripping of the binding sys- Trip lever is not dropping freely Check the clearance between the
tem trip lever and the roller

No tripping of the binding system Seized mechanism Clean and lubricate the trip
mechanism

Trip mechanism locking lever in Put lever in work position

locked position

Wear of the teeth on the trip lever Replace as required

and/or roller

Needle breakage Needle overlap incorrect Reset

192
 Troubleshooting

Knotters
Problem Cause Solution

Twine breaks Density pressure too high Reduce density pressure

Twine inserted wrongly Check twine routing

Bad twine quality Replace by better quality

Contours not smooth Smooth and clean

Twine tension set too high Adjust correctly

Twine tangled in twine box Check and disentangle

The twine end is looped into the Spring tension on hook too low Tighten set nut 1/2 turn
knot
Twine retainer badly adjusted Correct adjustment.

Knotter knife dull or damaged Sharpen or renew knife

Stroke of stripperarm too short Renew stripperarm; check cam of

knotter disc for wear

Frayed or different twine ends Clamping force of twine retainer Increase clamping force by
too low retensioning the spring

Knotter knife dull or damaged Sharpen or renew knife

Twine damaged or broken just be- The twine may get too high a Decrease pressure and/or tension
hind knot tension which increases probability on the knotter disc in order to
of damages. decrease twine tension

The fork-like opening of the strip- Smooth rough edges of stripper-

perarm is rough arm

A knot has been made but the The tucker finger doesn't return to Ensure the tucker finger moves
twine around the bale is broken its idle position. When the needle light. The spring shall return the
returns the twine is positioned over finger into its idle position
the twine finger

The knot is loose The bill hook is worn or damaged Renew bill hook

Too low a pressure on the bill hook Adjust compression spring

of the bill hook accordingly

193
Troubleshooting

Problem Cause Solution

Frequent breakage of knotter Incorrect bolt See Spare parts manual

shearbolts
Twine trapped on the bill hook or Clear out the knotter
twine retainer disc

Shearing of the bill hook roll pin Renew the roll pin

The stripperarm is not clearing the Adjust the stripperarm

knot from the bill hook

A single knot in the needle side During baling the twine is pulled Check and correct adjustment or
end of the knot out of the twine retainer because slightly increase tension of
of too low compression spring compression spring
pressure, or bad adjustment of the
twine retainer or worn twine
retainer parts (although no frayed
twine ends occur)

Twine breaks at twine retainer Correct twine tension, decrease

(twine end frayed) baling pressure. Check twine

Twine brake set too strong Check twine tension

No knot in either twine end Bill hook doesn't open enough Check twine tongue roller and cam
(none of the twine ends frayed) race for wear. Renew damaged
parts

Bill hook doesn't rotate because Renew slotted pin

slotted pin in counter gear has
been blocked

The twine finger doesn't return to its Check twine finger for light
idle position (none of the twine movement
ends frayed)

The twine is clamped in the Check twine retainer adjustment

twine retainer (both ends frayed)

A knot has been made but the Renew knife

twine ends have not been fully cut
(because of dull knife) and
removing action of the knot pulls it
open

Twine has slipped off the back of Due to incorrect guidance the Check alignment of twine guide to
the needle and the twine end is twine doesn't come in the correct needle
tied inside the previous knot position at the back of the needle.
The twine is positioned aside the
slot of the needle and is then
caught by the bill hook

Twine tensioner not adjusted strong Readjust twine tensioner

enough

194
 Troubleshooting

Problem Cause Solution

The knot stays on bill hook - twine Stroke of stripperarm too short Renew stripperarm; check cam on
breaks knotter disc for wear

Too high a tension of the shutter Readjust spring tension

compression spring

The bill hook is rough or grooved Smooth or exchange knotter hook

Bale pressure to low causing the Correct baling pressure

twine not being tensioned sufficien-
ty to enable removal of knot

Dull knotter knife Renew knife

Twine retainer not adjusted cor-
rectly. Correct adjustment of knot
remover mechanism

A single knot on the twine retainer The twine finger does not position Correct adjustment of twine finger
end of the twine the needle end of the twine
adequately to make a knot

The needle end of the twine is not Correct adjustment of twine

caught adequately by the twine retainer and needle
retainer

The twine retainer has not been Correct twine tension

adjusted strong enough

The straw retainer at the channel Remove clogged contamination

top does not move into the baling below straw retainer or renew
channel spring

Twine retainer dirty Clean twine retainer

Twine retainer worn Renew worn parts

Too high a baling pressure Decrease baling pressure

195
Troubleshooting

Problem Cause Solution

The shutter hits the knot remover There is no spring pressure on the Check presence and moveability
mechanism of knotter body roller of the bill hook of all parts as described in sec-
tion "knotter system"

The twine is not fed, knots with 3 Needles badly adjusted Readjust needle stroke, check
twines twine routing

Twine not caught (although not Clamping discs do not catch the Adjust needle height
frayed) twine Adjust groove of retaining discs
and removers

After tying of bale: twine rupture Too high a crop humidity Decrease baling density
upon ejection of the bale
Too high a baling pressure Decrease baling pressure

Too little a crop feed Drive over centre of windrow

Twine quality bad Use better quality of twine

Retaining discs disc tension too Decrease retaining discs tension

high

The twine retainer leaves correct The worm wheel slips on conical Renew worm wheel
setting shaft seat; the hole is too wide

Stripperarm
Problem Cause Solution

Twine stays on bill hook Wear of control roller and/or control Exchange stripperarm
comb

Bend stripperarm

Bearings in pivot point at stripper-

arm

196
 Troubleshooting

Automatic greasing sys-

tem
Problem Cause Solution

The system does not work or Reservoir empty Refill with clean grease
grease escapes from the safety
valve Filter blockage As the pump rotates, check if
grease comes out of the safety
valve or of the primary filter:- If yes:
remove and clean the two filters on
the front of the pump. - If yes: re-
move and clean the reservoir.- If
no: remove the 25 mm blank plug
at the left side of the carcase. Run
the pump for 5 min. If grease does
not appear at the port, remove the
contaminated grease and clean
the primary filter. Refill the pump
with fresh grease

Pump element contaminated Remove the blank plug on the

pump body. Check that the grease
is coming out of the port. If not, re-
place the pump element

Pump is not rotating Check for electrical faults by re-

moving the base cover of the
pump and check the power supply.
If the power is ok, check the output
power from terminal block to the
motor. If the motor is receiving
power but not operating, replace
the motor. Check the self resetable
fuse: turn off the power and wait 1
minute. Turn on the power again
and check the pump. If it operates
for 10 sec, the fuse has reset it
selves. In this case, the source of
the over current must be found
and removed

System operating but overpressure Manually grease each block in

valve of the pump is operating; turn. If all blocks operate freely,
grease deposit at the pump carefully remove feed pipe fitting
on the master block. Replace it by
1/8" grease nipple. If the block will
not work proper, replace the block.
If the block works proper, replace
the overpressure valve

197
Troubleshooting

Centralised greasing
system
Problem Cause Solution

The block does not work proper Blocked grease point Disconnect each pipe on the block
in turn and manually grease each
point to clear the blokkage. Do not
reconnect pipe to blocked point
and do not blank port from block as
this will also stall the system

Burst pipe / pipe blown out of its fit- Replace overpressure valve of the
ting block

Broken pipe Identify the cause of the breakage

and rectify if necessary. Replace
pipe; ensure that the olive crimps
the pipe when the compression fit-
ting is installed

Dry point / port Check for broken pipe work.

Check that the port on the block
delivers grease when the pipe is
removed. If so, manual grease the
point. If the port does not deliver
grease, replace the block

198
 Troubleshooting

Cutting unit
Problem Cause Solution

Crop loss Crumbling crop Reduce the number of knives

Blockage behind the rotor Too short a cutting length Remove one or several knives

Crop wrapping around the rotor Cross scraper support poorly ad- Adjust the cross scraper support
justed

Excessive power requirement of Blunt knives Sharpen knives

the machine
Too low pto speed Increase pto speed

Too high ground speed Reduce ground speed

Cross scraper support • Remove one or several

clogged or dirtied knives
• Open the valves of the hydrau-
lic system
• Check oil level in the reservoir
• Run the machine

The knives cannot be switched off Dirt between or around knife mech- Check the electro-hydraulic circuit
in the cutting position anism, blocking knife movement and the free mobility of the knives
Perform a resetting procedure:
Switch the knives on and off or
switch the Autoform system off
and start it again

No oil or pressure in the density Check shut-off valves of the hy-

system draulic system

Check oil level in the reservoir

Run the machine

The density system does not Wait for the machine to reach the
reach the preset pressure preset pressure

The knives cannot be switched off The oil cannot flow back Check shut-off valves of the hy-
in the lower position draulic system
Run the machine

199
Disposal of the machine

When the real life of the machine has finished, its separate parts must
Disposal of the machine

be properly disposed. Please observe the local current and valid

waste disposal regulations.

Metal parts
All metal parts have to be delivered to a metal recycling company.

Oil
The hydraulic oil must be disposed at a used-oil recycling company.

Plastic parts
All plastic parts can be recycled.

Rubber
Rubber parts, like hoses and tyres, have to be delivered at a rubber
recycling company.

Electronic scrap
Electronic scrap, like the electronic control box and the machine box,
have to be delivered to a specialized company.

200
 EC Certificate of conformity
EC Certificate of conformity

In accordance with EU
Directive, 98/37/EC
We
Kverneland Group Geldrop BV
Nuenenseweg 165
5667 KP Geldrop
The Netherlands

declare under our sole responsibility that the product

LB 8200 and accessories

Type plate
to which this declaration relates, conforms to the relevant basic safety
and health requirements of EU Directive 98/37/EC.

For the relevant implementation of the safety and health requirements

mentioned in the EU Directive, the following standards have been tak-
en into account:

• EN ISO 12100-1;2 (12/2003);

• EN 294 (07/1994);
• EN 704 (04/1999)

Kverneland Group Geldrop BV

Geldrop, 20.10.2006

Casper Böhme
Business unit manager

201
Index
Index

Symbols Pre-chamber density setting 59

Preface
Cleaning and caring
Symbols used 7
Automatic lubrication system 95
Preparation at the field
Gauge wheel adjustment 56
A Preparation for road transport 52
Bale chute 53
Attachment of the machine 38
Preparation for use 32, 35,
Automatic lubrication system
38, 40, 42,
Oil lubrication system 115, 176
51
Check at beginning of the season 107
B Opticut cutting unit 42
Twine installation 47
Bale length setting 63
Windrow dimensions 107
Pto drive shaft 32
C
Cleaning and caring R
Caring 95
Cleaning 94 Road transport 52
Support jack Bale chute 53
95
Before road transport 53
Roller chute 53
D Tyre pressure 54
Dis / engaging knives 62
Disposal of the machine 200 S
Drawbar adjustment
Moving the drawbar Storing the machine
29
After the season 97
Moving the hitch eye 29
Unhitching and securing of the machine 96
Driving 65

E T
Technical specifications 24
EC Certificate of conformity 201
Trouble shooting 178
Electric lighting 35
Security systems 185
Technical alarms 183
M Troubleshooting
Autoform 179
Maintenance 98
General 100
Safety 98 U
Use at the field 59, 62,
O 65
Bale length setting 63
Opticut cutting unit 42
Density pressure setting 64
Removing the knives 42
Dis / engaging knives 62
Optional equipment 115, 175,
Driving 65
176
End of baling 67
Automatic lubrication system 115, 176
Pre-chamber density setting 59
Bale ejector 176
Centralised knotter greasing 114, 175
Prior to baling 55, 59
Rebaling bales 67
Changing press chamber height 44, 175
Knotter cleaning fans 175
Roller chute 176 W
Windrow dimensions 51
P Winter storage 94
Pick-up 40

202