Big Pack 88 / MultiCut Big Pack 127 / MultiCut Big Pack ... Manuals/596_3_EN BP 88... · Here are...

Big Pack 88 / MultiCutBig Pack 127 / MultiCutBig Pack 128 / MultiCut

(from machine no.550 000)

Operating Manual No. 596-3 GB

Big Baler

We

declare under our sole responsibility, that the product

to which this declaration relates corresponds to the relevant basic safety and healthrequirements of the Directive 89/392 (EEC) and to the requirements of the other relevantDirectives:

Heinrich-Krone-Str. 10, D-48480 Spelle

Maschinenfabrik Bernard Krone GmbH

Spelle, 01.11.2002(Dr.-Ing. Josef Horstmann, Board of Directors)

(ppa. Dr.-Ing. Klaus Martensen, Manager of the engineering and design dep.)

(Wolfgang Ungruh, Quality assessment manager)

EC Declaration of Conformityaccording to Directive 89/392/EEC

Dear customer,

Here are the operating instructions for the KRONE product youpurchased.

These operating instructions contain important information for theproper use and safe operation of the machine.

If these operating instructions have for any reason becomecompletely or partially redundant, you can obtain replacementoperating instructions for your machine with the specificationnumbers listed overleaf.

Krone-Big BalerModels: Big Pack 88 / MultiCut; Big Pack 127 / MultiCut

Big Pack 128 / MultiCut

1

List of contents

List of contents1 General Information .............................................................................. I - 11.1 Designated Purpose ..................................................................................................... I - 11.2 Technical Data ............................................................................................................. I - 11.2.1 General Information ...................................................................................................... I - 11.2.2 Manufacturer's Address ................................................................................................ I - 11.2.3 Certification .................................................................................................................. I - 11.2.4 Identification ................................................................................................................. I - 11.2.5 Data Required for

Inquiries and Orders ..................................................................................................... I - 11.2.6 Designated Use............................................................................................................ I - 21.2.7 General Technical Data................................................................................................ I - 21.2.8 Technical Data ............................................................................................................. I - 3

2 Safety ..................................................................................................... II - 12.1 Identifying Safety Instructions in the Operating Manual ............................................... II - 12.2 Safety Instructions and Accident Prevention Regulations ........................................... II - 12.2.1 Personnel Qualification and Training .......................................................................... II - 12.2.2 Failure to Follow the Safety Instructions ...................................................................... II - 12.2.3 Working in a Safety Conscious Manner....................................................................... II - 12.2.4 Safety Instructions and Accident Prevention Regulations ........................................... II - 22.2.5 Trailer Implements ....................................................................................................... II - 3 2.2.6 Power Take-Off Operation ........................................................................................... II - 32.2.7 Hydraulic System ........................................................................................................ II - 32.2.8 Tyres ........................................................................................................................... II - 42.2.9 Maintenance ................................................................................................................ II - 42.2.10 Unauthorized Modification and Manufacture of Replacement Parts ............................ II - 42.2.11 Prohibited Modes of Operation .................................................................................... II - 42.3 Introduction .................................................................................................................. II - 62.3.1 Location of Safety Decals on the Machine................................................................... II - 62.4 Overview of the Big Pack Baler with Tandem Axle (Left Side) .................................... II - 82.5 Overview of Big Pack Baler with Tandem Axle (Right Side) ....................................... II - 92.6 The BIG PACK Baler Working Method ...................................................................... II - 10

3. Preparing the Big Pack Baler ............................................................ III - 13.1 Special Notes on Safety ............................................................................................. III - 13.2 Adjusting the Height of the Swinging Drawbar ........................................................... III - 13.3 Adapting the Main PTO Shaft ..................................................................................... III - 33.4 Putting the Big Pack Baler into Operation .................................................................. III - 43.4.1 General ....................................................................................................................... III - 43.4.2 Attaching the Big Pack Baler to the Tractor ................................................................ III - 53.4.3 On-Board Hydraulics .................................................................................................. III - 93.4.4 Road Journeys ......................................................................................................... III - 103.4.5 Detaching the Big Pack Baler................................................................................... III - 113.4.6 Maintenance Platform............................................................................................... III - 133.4.7 Fire Extinguisher ...................................................................................................... III - 143.4.8 Shunting Without an Air Brake Connected ............................................................... III - 14

2

List of contents

4. Comfort Controls ................................................................................ IV - 14.1 Special Notes on Safety ............................................................................................ IV - 14.2 General Description................................................................................................... IV - 14.3 Mounting .................................................................................................................... IV - 24.4 The Control Box ........................................................................................................ IV - 34.5 Ready Status ............................................................................................................. IV - 44.6 Basic setting .............................................................................................................. IV - 54.6.1 Pmax mode ............................................................................................................... IV - 54.6.2 Automatic mode......................................................................................................... IV - 64.6.3 Open Bale Channel ................................................................................................... IV - 74.6.4 Bale Counter ............................................................................................................. IV - 84.6.5 Information ................................................................................................................. IV - 84.6.6 Alarm Messages ........................................................................................................ IV - 94.6.7 Blade Check on the Cutting Mechanism (Special Equipment) .................................. IV - 94.6.8 Electric bale length indication (optional) .................................................................. IV - 104.7 Miscellaneous ......................................................................................................... IV - 10

5. Working with the Big Pack Baler....................................................... V - 15.1 Special Notes on Safety ............................................................................................. V - 15.2 Basic Setup for the Big Pack Baler ............................................................................. V - 15.2.1 Pick Up ....................................................................................................................... V - 15.2.2 Pack Chute ................................................................................................................. V - 35.2.3 Regulation of the Baling Thrust .................................................................................. V - 35.3 Adjusting the Length of the Big Packs ........................................................................ V - 45.4 Twine ......................................................................................................................... V - 45.4.1 General ....................................................................................................................... V - 45.4.2 Inserting the Twine ..................................................................................................... V - 55.4.3 Electric Twine Fault Display ....................................................................................... V - 75.4.4 Initiating the Binding Process Manually ...................................................................... V - 75.5 Emptying the Bale Channel ........................................................................................ V - 8

6. Settings ............................................................................................... VI - 16.1 Special Notes on Safety ............................................................................................ VI - 16.2 Adjusting the Needles ............................................................................................... VI - 16.2.1 Lateral Adjustment of the Needles ............................................................................. VI - 16.2.2 Height of the Needles on the Knotter ......................................................................... VI - 26.2.3 Needles' Upper Dead Centre .................................................................................... VI - 26.2.4 Needles in Idle Position............................................................................................. VI - 36.2.5 Needles Relative to the plunger ................................................................................ VI - 46.3 Twine Bar (Single knotter) ......................................................................................... VI - 56.3.1 Adjusting the Twine Bar ............................................................................................ VI - 56.4 Adjusting the twine brake (Single knotter) ................................................................. VI - 66.5 Plunger Setting .......................................................................................................... VI - 76.6 Setting the packer Relative to the Baling Ram .......................................................... VI - 86.7 Setting the clutch ....................................................................................................... VI - 96.8 Damper equipment .................................................................................................... VI - 96.8.1 Lateral setting of the damper equipment .................................................................... VI - 96.8.2 Setting the damper equipment ................................................................................... VI - 96.9 Setting the sensibility of the actuator ....................................................................... VI - 106.10 Adjusting the Flywheel Cleaning Mechanism (only Big Pack 88) ........................... VI - 10

3

List of contents

6.11 Location of the sensors ............................................................................................ VI - 116.12 Adjusting the Sensors ............................................................................................. VI - 136.13 Basic adjustment of the flywheel brake ................................................................... VI - 146.14 Installing the flywheel brake .................................................................................... VI - 15

7. Care and Maintenance ..................................................................... VII - 17.1 Special Notes on Safety ........................................................................................... VII - 17.2 General ..................................................................................................................... VII - 17.3 Cleaning ................................................................................................................... VII - 27.4 Tyres ........................................................................................................................ VII - 27.5 Opening the Front Guard Plate ................................................................................. VII - 27.6 Hydraulics ................................................................................................................ VII - 37.6.1 Special Notes on Safety ........................................................................................... VII - 37.6.2 On-Board Hydraulics ................................................................................................ VII - 37.6.3 On-Board Hydraulic Circuit Diagram ........................................................................ VII - 47.7 Changing and Checking the Oil in the Gearboxes ................................................... VII - 57.7.1 General ..................................................................................................................... VII - 57.7.2 Main Gearbox ........................................................................................................... VII - 67.7.3 Feed packer Gearbox ............................................................................................... VII - 67.7.4 Transfer Gearbox ...................................................................................................... VII - 67.7.5 Pick Up Gearbox ...................................................................................................... VII - 77.7.6 Cutting system gearbox for Big Pack MultiCut .......................................................... VII - 77.8 Compressed Air Unit ................................................................................................ VII - 87.8.1 General ..................................................................................................................... VII - 87.8.2 Compressed Air Reservoir Tank .............................................................................. VII - 87.8.3 Brake Cylinders ........................................................................................................ VII - 97.9 Replacing the Guide Rollers on the Packers ............................................................ VII - 9

8. Lubrication .........................................................................................VIII - 18.1 Special Notes on Safety .......................................................................................... VIII - 18.2 General .................................................................................................................... VIII - 18.3 Lubrication ............................................................................................................... VIII - 18.4 Central grease lubrication system ........................................................................... VIII - 78.4.1 Method of operation of the BEKA-MAX central grease lubrication system: ............. VIII - 78.4.2 Design of the BEKA-MAX central grease lubrication system: .................................. VIII - 78.4.3 Function description, central lubricating pump EP-1: .............................................. VIII - 88.4.4 Lubrication scheme Big Pack 88 ............................................................................. VIII - 98.4.5 Lubrication scheme Big Pack 127 / 128 ................................................................ VIII - 108.4.6 Method of operation of progressive distributors MX-F:........................................... VIII - 118.4.7 Description of control ............................................................................................. VIII - 128.4.8 Technical details: .................................................................................................. VIII - 138.4.9 Signals of control ................................................................................................... VIII - 14

9. Knotter ................................................................................................. IX - 19.1 Special Notes on Safety ............................................................................................ IX - 19.1.2 Start up ...................................................................................................................... IX - 19.2 The Knotter Hook ...................................................................................................... IX - 19.3 The Twine Retainer ................................................................................................... IX - 29.4 The Blade Lever ........................................................................................................ IX - 29.5 Adjusting the blade Lever .......................................................................................... IX - 4

4

List of contents

10. Over the Winter .................................................................................... X - 110.1 Special Notes on Safety ............................................................................................. X - 110.2 General ....................................................................................................................... X - 1

11. Putting into Operation Again ............................................................ XI - 111.1 Special Notes on Safety ............................................................................................ XI - 111.2 General ...................................................................................................................... XI - 111.3 The Overload Coupling on the Flywheel ................................................................... XI - 1

12. Special Equipment ............................................................................ XII - 112.1 MultiCut cutting system ............................................................................................. XII - 112.1.1 Special notes on safety ............................................................................................ XII - 112.1.2 General ..................................................................................................................... XII - 112.1.3 Setting the cutting length .......................................................................................... XII - 112.1.4 Changing blades ...................................................................................................... XII - 312.1.5 Blade stop ................................................................................................................ XII - 412.1.6 Setting the blade control shaft sensors ..................................................................... XII - 512.1.7 Setting the blade protection system .......................................................................... XII - 512.1.8 Locking the free-wheel ............................................................................................. XII - 512.2 Compressor .............................................................................................................. XII - 612.3 Swath Distributor ...................................................................................................... XII - 712.3.1 Assembly Instructions ............................................................................................... XII - 712.4 Hydraulic folding bale chute with rollers ................................................................... XII - 912.5 Wide pick-up........................................................................................................... XII - 1112.6 Further coupling options ......................................................................................... XII - 1212.6.1 Pivoting drawbar eye .............................................................................................. XII - 1212.6.2 Hitch Coupling ........................................................................................................ XII - 1212.7 Double knotter ........................................................................................................ XII - 1312.7.1 System operation .................................................................................................... XII - 1312.7.2 Tying process ......................................................................................................... XII - 1312.7.3 Inserting the twine (Double knotter) ........................................................................ XII - 1412.7.4 Twine flow display .................................................................................................. XII - 1612.7.5 Settings .................................................................................................................. XII - 1712.8 Trouble-shooting for the double knotter .................................................................. XII - 19

13. Faults, their Causes and Elimination .............................................XIII - 113.1 Special Notes on Safety .......................................................................................... XIII - 113.2 Needle Yoke Does Not Go Up ................................................................................ XIII - 113.3 Packer Drum............................................................................................................ XIII - 213.4 Failure of Regulation of the Baling Thrust ............................................................... XIII - 213.5 Further Faults .......................................................................................................... XIII - 313.6 Finding Errors in the Central Lubrication System .................................................... XIII - 7

A1 Integrated Diagnostic Program – Comfort Controls........................ A -1A1.1 General Information ..................................................................................................... A -1A1.2 Sensor Test ................................................................................................................. A -2A1.2.1 Auto Sensor Test ......................................................................................................... A -2A1.2.2 Manual Sensor Test .................................................................................................... A -3A1.3 Valves Test.................................................................................................................. A -4A1.3.1 Auto Valves Test ......................................................................................................... A -4A1.3.2 Manual Valves Test ..................................................................................................... A -5A 1.4 Electrical Circuit Diagram Big Pack 88/127/128 .......................................................... A -8A1.5 Alarm and Error Messages Big Pack 88/127/128 ...................................................... A -15

I - 1

General Information

1.2.4 Identification

The machine data are listed on the identification plate(1). This is located on the right inner side of themachine under the angle gear.

1.2.5 Data Required forInquiries and Orders

When making inquiries concerning the machine orordering replacement parts, be sure to provide typedesignation, vehicle ID number and year of manu-facture.

Genuine replacement parts andaccessories authorized by themanufacturer help ensure safety.Use of other parts may void liabilityfor damage which results.

The entire identification plate re-presents a legal document and shouldnot be altered or rendered illegible!

Type

Year

VehicleID no.

1 General Information

The operating manual contains basic instructions to beobserved when attaching, operating and doingmaintance work. Therefore it is imperative that theoperating personnel have access to and read thisoperating manual before putting into operation andusing the implement.

Follow both the general safety instructions contained inthe section on safety and the specific safetyinstructions contained in the other sections.

1.1 Designated Purpose

The big square balers Big Pack 88 / MultiCut, Big Pack127 / MultiCut and Big Pack 128 / MultiCut are pick-upbalers with the „Variable Feeding System“.They produce highly compressed and consistent bigsquare bales with a length from 1.0 to 2.5 m and 1.2 or0.8 m width. The big square balers are fitted asstandard with a tying unit and a two-part bale chute.

1.2 Technical Data

1.2.1 General Information

This operating manual is valid for the Big Baler BigPack 88 /MultiCut, Big Pack127 /MultiCut and BigPack 128 /MultiCut from machine-no. 550 000

1.2.2 Manufacturer's Address

Maschinenfabrik Bernard Krone GmbHHeinrich-Krone-Straße 10D-48480 Spelle (Germany)Telephone: (49) 0 59 77/935-0Fax: (49) 0 59 77/935-339E-mail: [email protected]

1.2.3 Certification

Declaration of Conformity (requirements of the ECMachine Directive 89/392/EEC; 3. amending directiveof 22.7.93 has been fulfilled.)See reverse side of title page

Maschinenfabrik Bernard Krone GmbHHeinrich-Krone-Str. 10 D-48480 Spelle

Made inGermany

I - 2

General Information

1.2.6 Designated Use

The Big Baler Big Pack 88 / MultiCut; Big Pack 127 /MultiCut and Big Pack 128 / MultiCut is designed forstandard agricultural use only (intended use).

Any use of the machine for other purposes is deemednot to be in accordance with intended use. Themanufacturer bears no responsibility for any resultingdamage - such use is entirely at the operator's risk.

Operation in accordance with intended use also includesobserving the operating, maintenance and serviceinstructions specified by the manufacturer.

Permissible baling material:Grass fodder such as hay, straw and silage.

The collection and baling of othermaterials is permitted only with theprior approval of the manufacturer.Swath form unloading of the balingmaterial and automatic lifting by thepick-up are considered basicprerequisites in any case though.

1.2.7 General Technical Data

• Travelling on public roads is only permissible withempty bale channel and with the bale chute folded in.

• On machines with wide pick-up (optional equipment)the gauge wheels must be moved to transportposition and locked.

• Permissible top speed: 40 km/h (62 km/h).

• Follow the conditions contained in the operatingpermit!

• Respect the maximum permissible load on the tractorhitch as well as the maximum permissible tractiveeffort.

• Switch off the comfort controls during road driving!

All information, illustrations and technicalspecifications in this manual were up to date whenthe manual went to press. We reserve the right tomake design modifications at any time withoutnotice or explanation.

I - 3

General Information1.2.8 Technical Data

Big Pack 88 / MultiCut; Big Pack 127 / MultiCut; Big Pack 128 / MultiCut

Big

Pa

ck

88

Big

Pa

ck

12

7/1

28

Big

Pa

ck

88

av

ec M

ult

iCu

tB

ig P

ac

k 1

27

/12

8a

ve

c M

ult

iCu

tP

ick

-up

with

rolle

r fe

ele

rsIn

div

idual axle

Tandem

Indiv

idual axle

Ta

nd

em

Indiv

idual axle

Ta

nd

em

Indiv

idual axle

Ta

nd

em

40

km

/h4

0 k

m/h

62

km

/h4

0 k

m/h

40

km

/h6

2 k

m/h

40

km

/h4

0 k

m/h

62

km

/h4

0 k

m/h

40

km

/h6

2 k

m/h

Le

ng

th in

Wo

rkin

g P

ositio

n [m

m]

87

00

(S

tand

ard

ch

ute

)

8

80

0 (

ba

le c

hu

te w

ith

ro

llers

)

Length

in T

ransport

Positio

n [m

m]

74

00

(S

tand

ard

ch

ute

)

7

46

0 (

ba

le c

hu

te w

ith

ro

llers

)

Heig

ht

[mm

]2

64

02

74

0

Weig

ht

[kg

]6

28

06

70

06

90

07

32

07

42

08

28

0

Wid

th [m

m] (m

easure

d a

t th

e tyre

s,

possib

ly w

ider

at th

e P

U)

24

20

25

20

26

20

28

60

29

90

29

70

24

20

25

20

26

20

28

60

29

90

29

70

29

00

(wid

e P

ick-u

p)

27

50

(Sta

nd

ard

)

Tyre

s6

00

/50

-22

,57

00

/40

-22

,55

00

/50

-17

50

0/5

0-R

17

60

0/5

0-2

2,5

70

0/4

0-2

2,5

50

0/5

0-1

75

00

/50

-R1

76

00

/50

-22

,57

00

/40

-22

,55

00

/50

-17

50

0/5

0-R

17

60

0/5

0-2

2,5

70

0/4

0-2

2,5

50

0/5

0-1

75

00

/50

-R1

71

5x6

.00

-6

Tyre

Pre

ssure

[b

ar]

1,5

11

,52

1,5

11

,52

1,5

11

,51

,51

,51

1,5

1,5

2,5

Tra

ck W

idth

[m

m]

18

20

24

65

22

20

24

65

18

20

24

65

22

20

24

65

Pa

ck C

ha

nn

el

He

igh

t [m

m]

8

00

80

0

80

0 (

70

0)

12

00

80

0

80

0

80

0 (

70

0)

12

00

Wid

th [m

m]

Pack L

ength

[m

m]

von 1

00

0 b

is 2

50

0 (

infinite

ly v

ari

ab

le)

Pic

k U

p C

olle

ction W

idth

[m

m]

19

50

(2

38

0)

Knotter

(Rasp

e)

Num

ber

of K

notters

46

46

Po

we

r R

eq

uire

me

nt

65

kW

(8

5 P

S)

69

kW

(9

0 P

S)

88

kW

(11

5 P

S)

92

kW

(1

20

PS

)

Cuttin

g m

echanis

m (

Nu. of bla

des)

15

25

sa

fte

y co

up

ling

:-

Knotter

shaft

(sin

gle

knotter)

Do

we

l scre

ws

6kt. M

8x4

0 D

IN 6

10

-8.8

Scre

w 6

kt. M

10

x55

DIN

93

1 8

.8 D

ow

el scre

w 6

kt. M

8x4

0 D

IN 6

10

-8.8

Scre

w 6

kt. M

10

x55

DIN

93

1 8

.8

- D

rive P

TO

shaft

Slip

clu

tch

Md

= 1

35

0 N

mS

lip c

lutc

h M

d =

15

50

Nm

- P

ick-u

pO

ve

r-ru

n c

lutc

h M

d =

30

0 N

mO

ver-

run c

lutc

h M

d =

30

0 N

m

- C

uttin

g s

yste

m5

50

0 N

m

- F

ly w

he

el

ca

m-t

yp

e c

ut-

ou

t M

d =

45

00

Nm

- N

ee

dle

yo

ke

Hex. shear

bolt 6

kt. M

10

x55

DIN

93

1-1

0.9

- F

eed r

ake

auto

m. ra

tchet clu

tch (

settin

gs c

an o

nly

be a

dju

ste

d b

y the facto

ry!)

I - 4

General Information

PTO Shaft Speed 1000 rpm

PTO Shaft Tractor-wide angle with free wheelMachine-free wheel slip clutch

Hitching Trailer coupling;Swinging drawbar(permitted load min. 1200 kg; MultiCut = 1500 kg)(height of swinging drawbar variable)Caution! When making an adjustment the hexagonalscrews must be tightened up to:see page 59 for torque moments

Support Support foot, retractable – variable height.

Pick up Drum Hydraulic liftingHeight adjustment via bar with holes on support wheel.

Tine carrier 5 pieceNo. of tine 13 (16) double tines/tine carrier

Lateral Feed Right and left augers

Crop Feed Forced entry via feed packer drumFeed packer drum with 5 conveyor feed packers, 1 feederpackerA cutting drum is connected in series with MultiCut.

Plunger Stroke length 750 mm50 / 38,5 ram strokes per minuteThe baling ram moves on 4 guide rollers5 / 7 blades on the ram2 blades in the bale channel

Adjusting the baling pressure electronic-hydraulic regulation via an adjustablepressure relief valve, adjustable from the tractor

Twine box both sides, 12 rolls of twine for each

Twine Synthetic fibre, 130–150 m/kg

In case of reaching end of roll and of broken twine Electric twine control with acousticyand optical signal.

Ejecting residual packs Standard Mechanism via a twin action control valve,operated from the tractor.

Roller chute Double-acting control valve of the tractor operating valvefor chute and remaining bale ejector at the rear right ofthe machine

Depositing packs Two part pack chute (must be folded up duringtransport).

Holding brake Operation by crank located on the left hand rear side ofthe baler

Brake Connections on the Tractor

Balers with compressed air actuated brake Dual line brake system required

Balers with hydraulically actuated brake Connection for hydraulic brake system required

Max. operating pressure 120 bar

I - 5

General Information

When using bio-oils, always change the oil at the specified intervals due to aging of the oils.

Quantity lit Designation/Brand Designation/Brand

up to the top Standard engine oil SAE 20dipstick marking or 20 W 40

0,2 l

Oil Quantities and Designations for the compressor

on request

on request

Oil Quantities and Designations for the On-Board Hydraulics


Oil container on baler 10 Fuchs Renolin MR 46 MCBP Energol SHF 46Shell Tellus 46Esso Univis N 46Aral Vitan VS 46

Lubricant Quantities and Designations for the Gearboxes


Main gearbox 15

Packer gearbox 2,5

Transfer gearbox Knotter/Packer 0,8

Anglular gearbox up to the pick-up 0,8

Anglular gearbox down to the pick-up 0,15

Cutting system gearboxfor MultiCut top 2,75

Cutting system gearboxfor MultiCut bottom 3,85

Bio-Lubricants

SAE 90 or

Esso-Spartan EP 150

Shell Omala Öl 150

Fuchs - EP 85 W90

Castrol EPX 90

on request

Hydraulic Connections on the Tractor

Pick up lifting (yellow protective caps Single action control valveResidual pack ejection Double action control valveBlade controle MultiCut (blue protective caps) Single action control valveSwath Distributor (red protective caps) Double action control valve

Electrical Connections on the Tractor

Baler lighting 7-pole socket

Constant current supply for the baler electrical control 3-pole socketsystem (direct battery connection required)

I - 6

General Information

II - 1

Safety

2 Safety

2.1 Identifying Safety Instructionsin the Operating Manual

The safety instructions contained in this manual, whichcould result in personal injury if not followed, areidentified by the general danger sign:

safety sign in accordance with DIN 4844 - W9

General function instructions are indicated as follows:

2.2 Safety Instructions andAccident Prevention Regulati-ons

2.2.1 Personnel Qualification and Trai-ning

The big baler must only be used, maintained andrepaired by personnel who are acquainted with themachine and have been informed of the dangersinvolved. The operator must precisely define the areasof responsibility and competence and monitor thepersonnel. Should personnel lack the required know-ledge they must receive the required training andinstruction. The operator must also ensure that thecontents of this operating manual have been fullyunderstood by the personnel.

Repair work not described in this operating manualshould be completed by authorized service centersonly.

2.2.2 Failure to Follow the SafetyInstructions

Failure to follow the safety instructions could result inpersonal injury and environmental hazards as well asdamage to the machine. Failure to follow the safetyinstructions could result in the forfeiture of any claimsfor damages.

Failure to follow the safety instructions could, forexample, result in the following hazards:

– risk to persons by failure to secure the workingarea

– breakdown of important machine functions– failure of prescribed methods for repair and

maintenance– risk to persons due to mechanical and chemical

effects– damage to the environment due to leaking

hydraulic oil

2.2.3 Working in a Safety ConsciousManner

Follow the safety instructions included in this operatingmanual, existing accident prevention rules and anyinternal work, operating and safety rules set out by theoperator.

The safety and accident prevention regulations of theresponsible professional associations are binding.

Observe the safety instructions provided by the vehiclemanufacturer.

Instructions which are attached to the machine need tobe followed and kept fully legible.

II - 2

Safety

Observe the applicable traffic laws when using publicroads (for example, in Germany, the Road Traffic TypeApproval Law and Road Traffic Law).

2.2.4 Safety Instructions and AccidentPrevention Regulations

1. Please follow all generally applicable safety andaccident prevention regulations in addition to thesafety instructions contained in this manual!

2. The attached warning and safety signs provideimportant information for safe operation. Payattention to these for your own safety!

3. When using public roads, make sure to observethe applicable traffic regulations!

4. Make sure that you are familiar with all equipmentand controls as well as their functions before youbegin working with the machine. It is too late tolearn this when you are operating the machine!

5. The user should wear tight fitting clothes. Avoidwearing loose or baggy clothing.

6. Keep the machine clean to prevent danger of fire!

7. Before starting or moving the machine, makecertain that nobody is in the vicinity of themachine! (Watch for children!) Make sure that youhave a clear view!

8. Carrying passengers during operation andtransport on the working implement is notpermitted.

9. Attach implements correctly! Attach and secureimplements to specified devices only!

10. When attaching or removing implements, placethe supporting devices in the correct positions!

11. Use extreme caution when attaching or detachingimplements onto or from the tractor!

12. Always attach ballast weights properly to the fixingpoints provided!

13. Observe permitted axle loads, gross weight andtransport dimensions!

14. Check and attach transport equipment such aslighting, warning devices and any protectiveequipment!

15. Actuating mechanisms (cables, chains, linkagesetc.) for remote controlled devices must bepositioned in such a way that no movements are

unintentionally triggered at any transport orworking positions.

16. Ensure that implements are in the prescribedcondition for on-road travel and lock them in placeaccording to the manufacturer's instructions!

17. Never leave the driver's seat when the vehicle ismoving!

18. Always drive at the correct speed for the pre-vailing driving conditions! Avoid sudden changesin direction when travelling uphill or downhill oracross a gradient!

19. Attached implements and ballast weights affectthe driving, steering and braking response of themachine. Make sure that you are able to brakeand steer the machine as required!

20. Take into account the extension radius and/orinertia of an implement when turning corners!

21. Start up implements only when all protectivedevices have been attached and set in therequired position!

22. Keep clear of the working range of the machine atall times!

23. Do not stand within the turning and slewing rangeof the implement!

24. Never operate the hydraulic folding frames ifanyone is inside the slewing range!

25. Parts operated by external power (e.g. hydraulics)can cause crushing and shearing injuries!

26. Before leaving the tractor, lower the implementonto the ground, switch off the engine and removethe ignition key!

27. No one should stand between the tractor and theimplement unless the vehicle has been securedagainst rolling with the handbrake and/or wheelchocks!

II - 3

Safety

2.2.5 Trailer Implements

1. Secure implements against rolling.

2. Observe the maximum supported load on thetrailer coupling, swing drawbar or hitch!

3. If a drawbar coupling is used, make certain thatthere is enough play at the coupling point.

2.2.6 Power Take-Off Operation

1. Use only PTO shafts specified by themanufacturer!

2. The guard tube and guard cone of the PTO andthe PTO guard must be attached and in goodworking condition (on the implement side, too)!

3. Make sure that the required tube covers are inplace for PTO shafts in transport and workingposition!

4. Before installing or removing PTO shafts,disengage the PTO, switch off the engine andremove the ignition key!

5. When using PTO shafts with an overload safety orfree-running coupling which are not shielded bythe guard on the tractor, mount the overloadsafety or free-running coupling on the implementside!

6. Always make sure that the PTO shaft is properlyinstalled and secured!

7. Attach chains to prevent the PTO shaft guardfrom rotating with the shaft!

8. Before engaging the PTO shaft, make sure thatthe selected PTO shaft speed of the tractormatches the permissible implement speed!

9. Before engaging the PTO shaft, make sure thatno one is in the hazard area around theimplement!

10. Never engage the PTO shaft if the engine isswitched off!

11. No one should be in the vicinity of the rotatingPTO shaft when it is in use.

12. Always switch off PTO shaft when the angle is toolarge or the PTO shaft is not required!

13. Caution! The flywheel will continue to rotate forsome time even after the PTO shaft has beendisengaged! Keep clear of the implement duringthis time. Do not do any work on the implementuntil the machine has come to a complete stand-still and the flywheel has been secured using thehand brake.

14. Disengage the PTO shaft, stop the engine andremove the ignition key before cleaning,lubricating and adjusting the PTO shaft drivenimplements or the PTO shaft! Secure the flywheelwith the hand brake.

15. Place the disconnected PTO shaft onto thebracket provided!

16. After removing the PTO shaft, attach theprotective cover to the PTO shaft end!

17. If damage occurs, correct this immediately beforeusing the implement!

2.2.7 Hydraulic System

1. The hydraulic system is pressurized!

2. When connecting hydraulic cylinders andengines, make sure that the hydraulic hoses areconnected correctly!

3. When connecting the hydraulic hoses to thetractor hydraulics, make sure that the hydraulicsof both the tractor and the implement have beendepressurized!

4. In the case of hydraulic connections betweentractor and implement the coupling sleeves andplugs should be marked to ensure a properconnection! If the connections are switched, thefunction will be reversed (e.g. raising/lowering) -danger of accidents!

5. Check the hydraulic hose lines at regular intervalsand replace them if damaged or worn! The newhoses must fulfill the technical requirements setby the manufacturer of the implement!

6. When searching for leaks, use suitable aids toavoid the risk of injuries!

II - 4

Safety

7. Liquids escaping under high pressure (hydraulicoil) can penetrate the skin and cause seriousinjury! Seek medical help immediately shouldinjuries occur! Risk of infection!

8. Before working on the hydraulic system, lower theimplement, depressurize the system and switchoff the engine!

2.2.8 Tyres

1. When working on the tyres, make sure that theimplement has been safely lowered and securedagainst rolling (wheel chocks).

2. Installing wheels and tyres requires adequateknowledge and suitable tools!

3. Repair work on the tyres and wheels should bedone by specially trained personnel usingappropriate installation tools only!

4. Check tyre pressure regularly! Inflate the tyres tothe recommended pressures!

2.2.9 Maintenance

1. Repair, maintenance and cleaning work as well asthe rectification of malfunctions may only ever becarried out when the drive is switched off and theengine is at a standstill!- Remove the ignition key! Pull the parking brakefor the balancing weight.

2. Regularly check that nuts and bolts are properlyseated and tighten if necessary!

3. When doing maintenance work to a raisedimplement, always use suitable means to secureit against falling.

4. When replacing working tools with cutting edges,use suitable tools and gloves!

5. Dispose of oils, greases and filters accordingto regulations!

6. Always disconnect the power supply beforeworking on the electrical system!

7. If protective devices and guards are subject towear, check them regularly and replace them ingood time!

8. When doing electrical welding on the tractor andattached implements, disconnect the alternatorand battery cables!

9. Replacement parts must at least comply with thetechnical requirements set by the manufacturer ofthe implements!This is guaranteed when using genuine KRONEreplacement parts!

10. Only use nitrogen for filling pneumaticaccumulators - Risk of explosion!

2.2.10 Unauthorized Modification andManufacture of Replacement Parts

Modifications to the machine are permitted only withthe prior approval of the manufacturer. Genuinereplacement parts and accessories authorized by themanufacturer help ensure safety. Use of other partsmay void liability for damage which results.

2.2.11 Prohibited Modes of Operation

The operational safety of the machine is guaranteedonly if it is used for its intended purpose in accordancewith the General Information chapter of the operatingmanual. The limit values listed in the data chartsshould not be exceeded under any circumstances.

II - 5

Safety

II - 6

Safety

2.3.1 Location of Safety Decals on the Machine

The KRONE big baler is equipped with all required safety devices (protective equipment). Not all potentiallydangerous positions on this implement can be fully secured, as this would be incompatible with full functionalcapability. Corresponding danger notices attached to the machine warn against any dangers.The safety instructions are provided in the form of so-called warning pictograms. Important information on thelocation of these safety signs and what they mean is given below!

Familiarize yourself with the meaning of the warning signs. The text printed next to the dangersign and its location on the machine indicate where specific hazards are located on themachine.

2.3 Introduction

6 1

4

5

7

RE/LI RE/LIRE/LI

RE/LI

RE/LI

6 3 2 8

II - 7

Safety

Do not mount the machinewhile the PTO shaft isconnected and the engineis running.There are stickers located onboth the right and left handstep to the working platform.

Order No.: 939 408-2 (2x)

Never reach into the pick upworking area while the machineis running.There are stickers located onboth the left and right sidesof the machine.

Order No.: 939 407-1 (2x)

3

Danger from rotatingaugers.

Order No.: 939 520-1 (2x)

4

5 6

Close the guardbefore putting intooperation!

Order No.: 942 002-4 (7x)

1

The PTO shaft speed may not exceed 1000 rpm!The hydraulics system operating pressure maynot exceed 200 bar!

Order No.: 939 101-4 (1x)

Before putting the machineinto operation read andobserve the operatinginstructions.

Order No.: 939 471-1 (1x)

939 101-4

MAX.1000/ min

MAX. 200 bar

2

Never put your hand into thedanger area as long as partsmay be moving.

(only for pack chutewith guide rollers)

Order No.: 942 196-1 (2x)

7

Keep clear of hot surfaces.

(only for Compressor)

Order No.: 942 210-0 (1x)

8

II - 8

Safety

8. Jack Stand9. Adjustable Swinging Drawbar

10. Wide Angle PTO Shaft with Overload ProtectionMechanism and Free-Wheel Facility

11. Twine Box12. Manual Actuation of Knotter and Knotter Shaft Lock13. Fire Extinguisher14. Wheel Chocks

1. Mechanical Flywheel Holding Brake2. Bracket for Quick-Release Coupling and Plug3. Longitudinal Adjustment of Packs4. Crank for Parking Brake5. Twine Controller and Tensioning Mechanism6. Pick Up with Feeler Wheel7. Baffle Plate

2.4 Overview of the Big Pack Baler with Tandem Axle (Left Side)

BP

-VF

S-0

02

11

II - 9

Safety

1. Electronic Control Valves with Pressure Gauges 2. Knotter Shaft 3. Hydraulic Oil Reservoir Tank 4. PTO Shaft Jack Stand for Bottom Attachment

5. Adjustable Swinging Drawbar6. On-Board Computer

7. PTO Shaft for MultiCut8. Shut-Off Tap for Pick Up Hydraulics9. Slewable Mudguard

10. Twine Brake beneath the Twine Box (single knotter)11. Maintenance Platform12. Folding Pack Chute

2.5 Overview of Big Pack Baler with Tandem Axle (Right Side)

BP

-VF

S-0

03

11

12

5

3

109

68

21

j

7

4

II - 10

Safety

2.6 The BIG PACK Baler Working MethodMulti Cut - VFS Feeding System

21 3 4 51514

14 15

16

1211

13 16

109876

BP-VFS-004

1211

10987621 3 4 5

16

16

13

II - 11

Safety

The conveyor feed packers (4) fill the conveyor channel.The crop is pre-compressed by the action of thepackers. The sensor rake (16) detects the pressure inthe conveyor channel. The sensor rake swings backonce a preset pressure is obtained.

The plunger thrust is controlled automatically by thehydraulic cylinder (9) at the bale channel shutters. Whenthe set pack length has been reached, the knotter me-chanism star wheel projecting into the bale channel isactuated. The Big Pack 88 is equipped with 4 knotters(7) and the Big Pack 127 and 128 with 6 knotters (7).The packs are deposited by a two-part pack chute (10).

In the bale channel the pre-compressed crop is pressedto a highly compressed big pack by the plunger (6). Thelength and of course the density of the pack are infinitelyvariable.Big packs can therefore be produced for the most variedof requirements.

The BIG PACK Baler must be driven by a tractor with atleast a 65 kW (85 bhp) power output.

The BIG PACK Baler is hitched to the trailer coupling orthe swinging drawbar.The swinging drawbar is fitted with a height adjustmentfeature so that the big pack baler can operate in ahorizontal position.

The drive to the BIG PACK is via a PTO shaft whichtransmits the torque from the tractor via a flywheel mass(11) to a straight bevel gear pair (12). The maximuminput speed of 1000 rpm may not be exceeded, as thereis a risk of the machine being damaged.

The PTO shaft is equipped with a wide angle joint on thetractor side. The operating instructions for the PTO shaftare located at the PTO shaft. Before putting the big packbaler into operation, the operating instructions for thePTO shaft should also be read. These detail in particularthe shortening of the PTO shaft as well as any repairand maintenance work.

The 2 m (2,4 m) wide pick up (2) collects the cropcleanly.A height-adjustable baffle plate (1) ensures error-freecollection and helps prevent blockages. The balingmaterial is carried via 2 filling augers (3), which are onthe left and right side of the pick-up, to the packer drum(13) or the cutting rotor (14) and blades (15).

The pick up can be raised and lowered with the tractorhydraulics. The feeler wheels on the pick up are height-adjustable so that the optimum pick up collection heightis always reached.

II - 12

Safety

Roll-type crop guard:A roll-type crop guard can be used to pre-compress thewindrow during the pick-up and to guarantee evenloading of the machine.

Swath distributor:A swath distributor is available as an extra to ensure aneven feed of the bale channel with narrow swathers.

Hydraulic folding bale chute with rollers:Especially when using the big baler for baling grasssilage, the rollers in the bale chute make it easier todeposit the bales.

Compressor:If hydraulic brakes are used on the big baler, acompressor can be installed as an extra for knottingdevice cleaning.

MultiCut:The MultiCut cutting system is available particularly forsilage recovery or when short bailing material is needed.A size reduction to as little as 45 mm is possible usingthis.

Wide pick-up:To better deal with wide harvester-thresher swaths, thebig baler can optionally be delivered with a wide pick-up(2.4 m).

Hitching export versions:Depending on the requirements of the respective countryeither a pivoting drawbar eye or a hitch coupling isavailable.

Double knotterWhen harvesting silage, the double knotter has someadvantages over the single knotter. The twine is notplaced in the knotter during baling. This reduces thewear on the knotter and the twine during baling. Thetying mechanism with the double knotter is howevermore time-consuming during set-up, maintenance andwhen resetting.

Automatic centralised lubrication system:The centralised lubrication system provides the mostimportant greasing points with lubricant (knotters,plunger with connecting rod, bogie axle, gauge wheelsand pick-up).

Electric bale length adjustment:Bale length can be varied continuously during the balingprocess using the display of the control unit.

Special Equipment

III - 1

Preparing the Big Pack Baler

Before starting adjustment work, place the big baler on the parking leg and uncouplethe tractor.

The drawbar can be set for either top or bottomattachment. The tractor attachment height can beadjusted in both the “top attachment” and the “bottomattachment” positions (three-point linkage or pendingattachment).The big baler must be attached horizontally to ensure anoptimum working method. The top of the twine box isused as a match edge here.

3. Preparing the Big Pack Baler3.1 Special Notes on Safety

• Particular care is required when attaching the big pack baler to or detaching it from thetractor. There must be nobody between the tractor and the big pack baler. After coupling,switch off the engine and remove the ignition key. Apply the flywheel brake.

• When carrying out care, maintenance, adjustment and repair work, always switch off the PTOshaft, switch off the engine and remove the ignition key.

• Only put the big pack baler into operation when all protective devices have been attached andare in the correct positions.

• The big pack baler may be operated with a maximum PTO shaft speed of 1000 rpm.• Only PTO shafts specified by the manufacturer with the correct overload coupling and free

wheel facility may be used.• The PTO shaft may only be attached and detached when the tractor PTO shaft is switched off,

the engine is switched off and the ignition key is removed.• Lay hoses and connection cables in such a way that they are not under tension and do not

come into contact with the tractor wheels when going round corners.• Check hydraulic hose lines regularly and replace if damaged or aged.• When connecting hydraulic hoses to and disconnecting them from the tractor hydraulics

make sure that the hydraulics both in the tractor and in the machine are not pressurised.

3.2 Adjusting the Height of the Swinging Drawbar

• Secure the big pack baler from rolling away by using wheel chocks and putting on theparking brake.

• Use suitable parking stands to support the big pack baler.• Risk of crushing feet when winding down the jack stands.

III - 2


Adjusting the attachment height

To adjust the drawbar height unscrew the screws (2) onboth sides. Screw in two screws M12 x 60 (included) onboth sides in the thread bore (3) until the drawbar can beturned. Insert the screws (2) in the selected position.Remove screws from thread bore (3) and tighten allscrews (2). After loosening the nut (1) move the ringhitch into a position parallel to the ground. Tighten nut(1).

Torque moments see Kap. 7.2

3

2

2

1

BP380-7-006

BP380-7-007

1 3

2

2

Removal of the flywheel brake

For any adaptation of the drawbar height, the flywheelbrake must be removed from the drawbar.

For this proceed as follows:

1. With the flywheel brake pulled, withdraw pin (1) fromthe brake lever and remove the brake lever.

2. Release bolts (2) and remove the guard.3. Release bolts (4) and (5). The complete brake can

now be removed from the drawbar. To prevent thebrake embarrassing the adjusting procedure, thebrake housing should be stowed on the prop standcrank or kept in raised position using a crane.

BP380-7-165

1

2

BP380-7-167

90˚

6

3

4 57

III - 3


3.3 Adapting the Main PTO Shaft

• Before sliding the PTO shaft on to that on the tractor, switch off the tractor PTO shaft, switchoff the engine and remove the ignition key. Apply the flywheel brake.

• Secure the big pack baler and the tractor from unintentional rolling away.• Nobody may be between the tractor and the big pack baler when carrying out the cornering

required for the adaption of the PTO shaft length.

To adapt the length of the PTO shaft attach the big packbaler to the tractor. The shortest PTO shaft position isreached when going round tight corners.

To measure, take the PTO shaft apart and slide eachhalf (1) and (2) on to the baler and the tractorrespectively. The exact procedure for the length adaptioncan be found in the PTO shaft manufacturer's operatinginstructions.

2

1

BP380-7-171

On the machine side, remove first guard (1) and thebolts (2). Then connect the PTO shaft and secure usingthe bolt supplied. Re-install guard (1) making sure that itis positioned inside the first fold of the PTO shaftbellows. Use the chain to secure the bellows againstrotation.

Installation of the flywheel brake

Place the brake housing onto the drawbar and tighten thesecuring bolts. Check that the brake disc runs freelythrough the brake saddle. For any correction of the brakeadjustment see section 6.13 “Basic adjustment of theflywheel brake”.

BP380-7-008

12

III - 4


3.4 Putting the Big Pack Baler into Operation3.4.1 General

Main Drive

A straight bevel gear pair provides the main drive. Thenecessary torque is transmitted by the PTO shaft and alarge flywheel mass. The maximum PTO shaft speed of1000 rpm may not be exceeded. The PTO shaft on themachine is fitted with a slip clutch facility (1) as a safetymeasure.

There is a cam-type cut-out clutch locatedon the rear side of the flywheel mass. Assoon as the clutch engages, stop themachine, turn off the PTO shaftimmediately and stop the flywheel. Thecam-type cut-out clutch switches onagain automatically once the fault hasbeen eliminated.

Feed packer drum drive

The drive for the feed packer drum is located on the lefthand side of the machine. The gearbox is fitted with aspring-loaded ratchet clutch as a safety measure.

As soon as the ratched clutchengages, stop the machine, turn offthe PTO shaft immediately. Theratchet clutch starts working againautomatically once the fault has beeneliminated.

Knotter Shaft Drive

The drive for the knotter shaft is provided by an angulargear arrangement. A PTO shaft transmits the torque tothe knotter shaft.

BP380-7-009

1

BP380-7-010

BP380-7-011

III - 5


Pick Up Drive

The drive for the pick up is located on the right hand sideof the machine. The torque is transmitted by a bevelgear arrangement (1) downwards through a PTO shaft (2)with an overload protection mechanism (over-run clutch)to an angular gear (3).

3.4.2 Attaching the Big Pack Baler to the Tractor

Hitching

Attach and secure the big pack baler to the tractorhitching mechanism as specified.Depending on the requirements of the respectivecountry either a pivoting drawbar eye or a hitch couplingis available. (see ch. 12.6).

Spacer Bush for the Swinging Drawbar with Bottom Attachment

Swinging drawbars often have a retaining bolt with adiameter smaller than for the hitch. For this reason aspacer bush (2) is supplied along with big pack balerswith bottom attachment, which can be used with thetractor hitch (1) when required.

• Nobody may be between the tractor and the baler when reversing the tractor up to the bigpack baler.

• Observe the maximum supported and towed loads for the hitching mechanism on thetractor.

BP380-7-012

1

2

3

BP380-7-013

BP380-7-014

2

1

III - 6


Crank on the Jack Stand

The crank (2) can be fitted on the head of the jack standin two positions, (a) and (b).Position a) direct 1:1 translation to wind the jack stand

up and down quickly.Position b) gear reduction for winding up and downwhen the big pack baler is resting on thesupport foot.

Jack Stands

As soon as the big pack baler is hitched up, take theload off the support foot (3) by turning the crank (1).Pull out the retaining bolt (5) on the lower part of the jackstand (2), slide in the jack stand and secure in position(4) with the bolt. Wind up the jack stand completely.

BP380-7-015

5

43

2 1

BP380-7-016

b

2

a

1

III - 7


Compressed Air Connections for Air Brakes

Insert the coloured service line hose couplers on thecompressed air hoses (1) into the fittings with the samecolours on the tractor and let them lock into position.

First let the yellow and then the redconnector head lock into position.When uncoupling proceed in thereverse order.

Hydraulic Connections

The big pack baler requires one double and two singleaction hydraulic control valves on the tractor. The pro-tective caps on the hydraulic (1) hoses in the chute (2)are colour-coded. This means perfect identification of thenecessary control valves is guaranteed:

yellow = single-action control valve (pick up)blue = double-action control valve (pack ejector)red = single-action control valve (Blade controle

MultiCut)

Hydraulic Brake

A hydraulic brake is provided for certain export models.This version requires a hydraulic brake valve on thetractor.

BP380-7-017

BP380-7-018

1

III - 8


Before sliding the PTO shaft on to the tractor PTO shaft, always secure with the mechanical orhydraulic holding brake.

PTO Shaft

To fix the flywheel turn the brake lever (1) on the lefthand side of the swinging drawbar from position (b) toposition (a). The flywheel is now braked.

• After mounting, ensure that the PTOshaft has locked into place.

• Only use the PTO shaft suppliedfrom the factory.

Installing the PTO shaft

On the machine

• see ch. 3.3

On the tractor

• Remove the PTO shaft from the retaining chain (1) orsupport (fold in!)

• Slide the PTO shaft on the tractor PTO shaft withthe engine shut off and the ignition key removed andthen secure.

• Secure PTO shaft guard against turning as well byhanging up the safety chain (3).

ba

1

BP380-7-019

13 2 BP380-7-020

Release the flywheel brake beforethe PTO is turned on.

III - 9


The big pack baler is equipped with its own on-boardhydraulic pump. It is flanged on to the upper rear area ofthe main gearbox. The reservoir tank (2) is located onthe right hand side of the machine. Check the oil level onthe dip stick (1) every time before putting into operation.

3.4.3 On-Board Hydraulics

• Repairs to the hydraulics system may only be carried out by trained specialists.• High-pressure fluids from the hydraulics system can penetrate the skin and cause severe

injuries! Seek immediate medical attention in case of injury! Risk of infection!

Parking Brake

The crank (1) for the parking brake is located on theleft hand side of the big pack baler beneath the balechannel. Before unhitching the machine, it must besecured from unintentional rolling away using the parkingbrake.

Electrical Connection Cables

The big pack baler requires an electrical supply for theon-board computer. A socket to be mounted on thetractor is part of the scope of supply. Plug the connect-ion cables into the corresponding sockets on the balerand secure them from coming loose.

Socket 1: Connection cable between the on-boardcomputer and the control and indicator

box on the tractor. Remove the protectivecap before plugging in.

Socket 2: Power supply for the on-board computer.Socket 3: Standard 7-pole socket for the lighting

system.

As soon as the constant currentsupply plug has been plugged in andthe control and indicator box isswitched on, and there is no twine inthe needles, the acoustic signal fortwine control sounds.

2

1

3

BP380-7-021

BP380-7-022

1

BP380-7-023

1

2

III - 10


1

BP-VFS-300

When the pack chute (2) is folded up, it should besecured in the brackets (3) with the retaining chains (1).

Pack Chute

The pack chute is divided into front (3) and rear (1) parts.To put the pack chute in the transport position, the lock(2) on the rear part must be actuated. Fold in the rearpart and lift it together with the front part to just in frontof the bale channel and secure with the retaining chains(4).

Pick Up

Raise the pick up and secure it from lowering with theshut-off tap (1). The lever located on the front right handside of the machine must be turned from position (a) toposition (b).

3.4.4 Road Journeys

• Driving on public highways is only permitted with the bale channel empty and the packchute folded in.

• The maximum speed is 40 km/h (62 km/h).• Carrying passengers on the big pack baler is not permitted.• The big pack baler's roadworthiness must be checked and guaranteed, especially the

lighting, the protective plates and twine box flaps must be locked, and the pick up must beraised and secured.

• Before setting off, ensure that you have perfect visibility on and around the tractor and thebig pack baler.

On machines with wide pick-up(optional equipment) the gaugewheels must be moved to transportposition and secured (see section11.5)

BP380-7-025

4

32

1

BP380-7-026

1

3

2

III - 11


3.4.5 Detaching the Big Pack Baler

• Only park the big pack baler on firm level ground. When parking on less firm ground,increase the area of the pads on the jack stands.

• Secure the big pack baler from rolling away by applying the parking brake and placing wheelchocks under the wheels.

• Caution when winding down the jack stands. Risk of crushing feet!• Depressurise the hydraulics systems on the tractor and on the machine.• Only remove the PTO shaft when the tractor PTO shaft is switched off, the engine is switched

off and the ignition key has been removed. Apply the flywheel brake.

Wheel Chocks and Parking Brake

Apply the big pack baler parking brake using thecrank (1).

Lights

Connect the lighting unit to the tractor electrical system.Check and clean the tail lights (2) and the rear reflector(1). The same applies for the yellow reflectors on thesides of the big baler and the front white clearancelamps.

2

11

BP380-7-027

BP380-7-022

1

III - 12


Jack Stand and PTO Shaft for Top Attachment

The wheel chocks (1) are located on the rear left andright hand sides beside the bale channel. Place thewheel chocks in front of and behind the wheels. Themachine is thereby secured from rolling away.

Gently wind down the raised jack stand (4) using crank(1). Pull out the bolt (2) and extend the lower part of thejack stand. Secure with the bolt. Increase the area ofthe pad on the support foot (3) where the ground is softand place a wooden plank underneath.

1

BP380-7-028

BP380-7-029

23

5

4 1

6

Top Attachment

Remove the PTO shaft (5) and rest in the retaining chain(6).

Bottom Attachment

Fold up the support (1), remove the PTO shaft and placeit on the support (1).

BP-VFS-013

1

III - 13


3.4.6 Maintenance Platform

• Only mount the maintenance platform when the PTO shaft is switched off, the engine isswitched off and the ignition key has been removed.

• Carrying passengers on the maintenance platform is prohibited.

There is a maintenance platform (1) located on each ofthe left and right hand sides of the machine behind thebale channel, from which, amongst other things, workcan be carried out on the knotter mechanism.

Hydraulic brake

Plug the hose for the hydraulic brake into the adapter.

Compressed Air and Hydraulic Hoses

Fit the compressed air hoses (1) and (2) in the corres-ponding brackets on the top side of the swingingdrawbar. Lay the hydraulic hoses (3) in the bracket (4).

BP380-7-030

4

21

3

BP380-7-017

BP-VFS-200

III - 14


BP380-7-0343

2

ab 1

1

3.4.7 Fire Extinguisher

There is a fire extinguisher (1) mounted on the left handside of the machine beside the bale channel.

Please have the fire extinguisherregistered. This is the only way ofguaranteeing that the necessaryinspections are carried out.

3.4.8 Shunting Without an Air Brake Connected

If the hoses for the air brake are not connected to abrake system, the big pack baler cannot be operated.

If a minimum pressure of 4 bar is present in the reservoirtank (2) for the big pack baler's brake system, the bra-kes can be freed by pressing the push button (1) to posi-tion (a). As soon as the hoses are connected up to an airbrake system again the push button returns to its originalposition (b).

If the air pressure in the reservoir tank (2) falls below4 bar, the remaining pressure must be released at thewater evacuation valve (3). Only then can the big packbaler be operated again.

Before operating the valve or beforedepressurizing the reservoir tank, securethe machine to prevent it moving on itsown.

BP-VFS-007

1

IV - 1

Comfort Controls

4. Comfort Controls4.1 Special Notes on Safety

• Switch off the engine when carrying out assembly work on the tractor or the big pack baler.Remove the ignition key. Apply the flywheel brake.

• Secure the tractor and the big pack baler from rolling away.• When mounting the control and indicator box on the tractor make sure that the connection

cable to the big pack baler is not under tension and does not come into contact with thetractor wheels.

4.2 General Description

The electronic unit for the Big Pack essentially consistsof the on-board computer, the control box and thecontrol and function elements. The control box (2)provides the driver with information and makesadjustments for the operation of the big pack balerusing information gathered and processed by the on-board computer.

The On-Board Computer

The on-board computer (1) is located on the right handside of the big pack baler behind the protective plate.

Disconnect the power supply to the electronic comfort controls when carrying out assembly andrepair work, especially when welding on the big pack baler. Over-voltage can damage the com-fort controls electronics.

The following functions are monitored, regulated andcarried out by the on-board computer:

• Regulation of the baling thrust• Bale counter• Control of knotter cleaning• Transmission of alarm messages• Provision of requested information

Protect the on-board computer against moisture.Do not use HP cleaning device, especially when cleaning the housing and the connectors.

BP-VFS-008

1

2

5 6 87 9

#

0

43

1 2

IO

_Prog

+

Quit

Pmax

BP-VFS-009

IV - 2

Comfort Controls

4.3 MountingAttach the control box on the tractor in a place where it isclearly visible to the driver.

Connect the comfort controls to the on-board computer:

• Plug the control cable (1) into the control box (3) socket (2).

• Secure the connection using the union nut (4).

• Connect the power supply cable (12 V) for the comfortcontrols to the 3-pin power outlet on the tractor (DIN9680). See Chapter 3.4.2 Electric Supply.

Place and secure the connecting cablesbetween the tractor and the roundbaler in such a way that they do nottense during turning or come intocontact with the tractor wheels.

BP-VFS-010

IV - 3

Comfort Controls

4.4 The Control Box

Reduce density force (–)

Increase density force (+)

“alarm off” button

"Bale counter" button

Manual density limitation

Blade check *

Reduce bale length*

Increase bale length*

ON/OFF

Programme button

Quit button

"+" button

"-" button

1

2

4

7

Pmax

8

9

0

#

1 2 9 0

3 4

13

9

11

0

12

1

3

2

4

15 1416

QuitProg

87

BP-VFS-011

5 6 87

Pmax

* Option

8 blade check indicator light *

9 Indicator light: lights up if balelength is reduced*

0 Indicator light: lights up if balelength is increased*

11 "Open bale chamber"indicator light

12 "Display Information"indicator light

13 display

14 main switch

15 horn

16 control cable socket

1 density force indicator light (-)

2 density force indicator light (+)

3 "horn" indicator light

4 "bale counter" indicator light

5 free

6 free

7 Indicator light for manualdensity limitation

IV - 4

Comfort Controls

All buttons located below the display have an indicatorlight in the top right hand corner. The indicator lightindicates the operating status of the button (this is not

the case for button 8

, where the operating status

of the cutter mechanism is indicated):

indicator light illuminated: operatingindicator not illuminated: not operating

4.5 Ready Status

• Switch on control box at the main switch (14).

• Actuate key

A brief self-test follows if the power supply is properlyconnected.

– The control box indicator lights light up briefly.

– Horn sounds briefly.

– The display (13) indicates the terminal versionnumber.

then

The display (13) indicates the machine version –number.

If the self-test is not performed, checkthe power supply.

If the self-test (duration 10 sec.) has been performedsuccessfully, the comfort controls are operative andchange into the operating mode.

Operating mode:

- In the display (13) the preselected density forceappears.

#

1 2 9 0

3 4

BP-VFS-070

---- K R O N E ----- Komfortelektronik -- T E R M I N A L --Version Nr..: x.x --

13

Prog Quit

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-071

---- K R O N E ----- Komfortelektronik -- B I G - P A C K --Version Nr..: x.x --

13

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-072

a

90 90

5 6 87

Pmax

IV - 5

Comfort Controls

4.6 Basic setting

Two sensors on the front part of the frame detect andamplify the density force and transmit it to the on-boardcomputer. The on-board computer interprets the signalsand then controls the pressure in the hydraulic cylindersof the bale channel shutters. At the same time, thesignals are transmitted to the control panel. They appearas a bar graph on the display to the left (b) and right (c)of the indicator for the baling pressure (Pmax-Mode) (a)or desired density force (Automatic-Mode) (a).The two bars (b and c) display the density forcedistribution on the left and right of the bale channel.Therefore the two bars (b and c) may have a differentlength.

When larger deviations occur between the currentdensity force (b) and (c), 4 arrows (e) appear on the leftor right of the display. They indicate which way the drivermust go when travelling over the windrow, in order toachieve even feeding of the bale chamber.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-206

cb a

90 90

5 6 87

Pmax

d

e

Prog Quit

#

1 2 9 0

3 4

BP-VFS-202

cb a

90 90

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-203

cb

80 80

5 6 87

Pmax

e

4.6.1 Pmax mode

After the in-cab control unit has been switched on, it’salways the Pmax mode that is activated (the LED of thePmax mode key (e) lights up). The central bar graph (a)visualises the density force (expressed as percentage)which builds up in the density control system with themachine running at nominal speed (33 percent = abt. 50- 60 bar).

Using the keys 1

and 2 it’s possible to adjust

the Pmax density force at any time between 0 and 100per cent (0 - 180 bar). The actual density force can beseen from the pressure gauge. The central bar graph (a)and the lateral bar graphs (b = LH) and (c = RH)(pressure exerted on the bale) are independent fromeach other. That means that the lateral bar graphs canshow higher or lower values than the central bar graph(Pmax target value). If the lateral bar graphs reach theirmaximum height, that means that the machine isoperated at the limit of capacity and pressure cannot befurther increased up to the target value (overloadprotection feature).

IV - 6

Comfort Controls

Prog Quit

#

1 2 9 0

3 4

BP-VFS-206

cb a

90 90

5 6 87

Pmax

d

e

4.6.2 Automatic modeAfter the in-cab control unit has been switched on, it’salways the Pmax mode (e) that is activated. Increasingthe speed to the nominal value will cause an initialpressure of abt. 50 to 60 bar to be shown on thepressure gauge. Pressing the Pmax key (e) activatesthe automatic mode (the LED of Pmax key (e) goes out).

Contrary to the Pmax mode, the keys 1

and

2 are not used to determine a fixed density value,

but a target value between 0 and 100 per cent. Themachine is trying to control the density force byincreasing or reducing the value until the densitymeasured inside the bale (bar graph (b) = LH side andbar graph (c) = RH side) complies with the target value(central bar graph (a) (average value of the RH and LHbar graph identical to the target value).

While the bale chamber is being filled,you should never increase the densityvalue or switch to automatic mode. Thisrule must be strictly observed to preventthe deformation of the bale chambershutters.

The control only operates when the feedpacker drum supplies crop to the ram.If no crop is supplied (at the headlandor when idling for example) the currentpressure will be maintained.

During operation the on-board computer controls thecontact pressure of the bale chamber shuttersindependently so that the density force pre-selected bythe comfort controls is obtained. In the process, thepressure on the manometer may fluctuateconsiderably!

IV - 7

Comfort Controls

The valve which opens the bale channel is actuated

by pressing button . The indicator light (11) is

illuminated. The bale channel is open. After pressing

button , the valve the bale channel is switched off

again. The indicator light (11) on the button isextinguished.

Switch back to the bale display using button 1

or

2.

The bale channel can only be openedwhen the machine is at a standstill.

4.6.3 Open Bale Channel

The display switches to another mode when button

7

Pmax is pressed. The following message appears:

Release bl. chamber?You really want to ?

no-- release ----yes

Correction measures for deviations

Prog Quit

#

1 2 9 0

3 4

BP-VFS-074

b ca

90 90

5 6 87

Pmax

7

Prog Quit

#

1 2 9 0

3 4

BP-VFS-077

Ballenkammer loesen?Wollen Sie wirklich?

nein-- loesen ----ja

115 6 87

Pmax

Observation:The indicators (b) and (c) of the current density force areconsiderably smaller than the one of the desired densityforce (a) and the pressure on the manometer displaysthe maximum pressure of approx. 180 bar.

Cause:The preset desired density force (a) cannot be obtainedwith the oil pressure provided by the on-board hydraulicsand the existing conditions (crop parameters andoutput).

Remedial action:Adjust desired density force (a) down to the level of themeasured current density force (b and c) using the

1 key. The machine’s hydraulic pressure is

reduced and the control can react faster if high forcessuddenly occur.

When larger deviations occur between the currentdensity force (b) and (c), 4 arrows (e) appear on the leftor right of the display. They indicate which way the drivermust go when travelling over the windrow, in order toachieve even feeding of the bale chamber.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-203

cb

80 80

5 6 87

Pmax

e

IV - 8

Comfort Controls

4.6.5 Information

Information relating to the ram strokes per pack and per

minute can be called up by pressing button .

The following message appears in the display:

Lifts/Bale:.....0040Lifts/min:......0042

4.6.4 Bale Counter

The on-board computer on the big pack baler is equipped with

an integral bale counter. When button 4 is pressed the

following message appears in the display:

Bales pie.:.....1723Bales tot.:.....2693

pie.-- clear- --tot.

The current number of big packs is shown in the upperline. The lower line indicates the total number of packsproduced up to that point. Both counters are indepen-dent of each other and each can be reset witoutinfluencing the other.

BALES CURRENT-reset press button

BALES TOTAL-reset press button

Switch back to the bale display using button 1

or

2.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-075

Ballen Stueck: 1723Ballen G-Stueck:2693

St--- loeschen --Gst

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-078

Huebe/Ballen:...0040Huebe/Min:......0042

5 6 87

Pmax

IV - 9

Comfort Controls

4.6.7 Blade Check on the Cutting Mechanism (Special Equipment)

off-.blade contr. on....... off !.......

or

off-.blade contr. on....... on !........

You can switch from "ON" to "OFF" by pressing button

or by switching button from "OFF" to "ON".

You can return to the programme by pressing button

1.

A flashing indicator light on button (8) indicates that thetension bolt in the blade safety mechanism is faulty.

- Alarm-No.:....0000Tensioner faulty!!..

4.6.6 Alarm Messages

Alarm messages appear in the display when irregularitiesare picked up by the on-board computer. Alarm messa-ges always take preference. They interrupt the currentdisplay immediately.

A horn sounds in the control box at the same time asthe alarm message appears. The horn can be switched

off using button 3. If button

3 is pressed

again, the alarm message in the display disappears andthe previously shown message reappears. Some faults,e.g. "BALING THRUST EXCEEDED", correct themsel-ves.

For an overview of the alarm messages please refer toAppendix A 1.4 Alarm and Error Messages Big Pack88/127/128.

Depending on the operating status, the following messages

appear in the display when button 8

is pressed:

Prog Quit

#

1 2 9 0

3 4

BP-VFS-079

- Alarm-Nr.:....0000Fadenspanner defekt!

13

5 6 87

Pmax

Prog Quit

#

1 2 8 9 0

3 4

BP-VFS-080

aus Messerkontr. ein....... aus !.......

5 6 87

Pmax

8

IV - 10

Comfort Controls

4.7 Miscellaneous

For information regarding trouble-shooting, tests and special settings referto Appendix A 1!

Prog Quit

#

1 2 9 0

3 4

BP-VFS-207

el. Ballenlaenge

Sollwert 160

5 6 87

Pmax

4.6.8 Electric bale length indication(optional)

If the keys 9

or 0

are pressed, on the display

appears:

electr. bale lengthtarget value 160

Bale length can be reduced or increased using the keys

9

or 0

.

Press key 1

or 2

to return to the program.

Bale length is variable within a rangebetween 100 and 270 (1 - 2.7 m).

V - 1

Working with the Big Pack Baler

5. Working with the Big Pack Baler5.1 Special Notes on Safety

• The following always applies for all maintenance, repair and adjustment work: switch off thePTO shaft, switch off the engine and remove the ignition key. Apply the flywheel brake.

• Keep a safe distance from all moving parts on the big pack baler during operation. Thisapplies in particular to the crop collection mechanism.

• Only put the big pack baler into operation once all protective devices have been fitted and arein a proper operating condition.

• Only free blockages when the machine is at a standstill. Switch off the engine and remove theignition key. Apply the flywheel brake.

• In dangerous situations switch off the PTO shaft and bring the big pack baler to a standstillimmediately.

• Never run the big pack baler without an operator on the tractor.

5.2 Basic Setup for the Big Pack Baler

5.2.1 Pick Up

Raise the pick up when driving into a curve and when driving backwards!

Adjusting the Working Height

To adjust the height of the pick up, raise it and lock with the shut-off tap on the right handside of the machine to secure it from unintentional rolling away.

The adjustment of the working height is made at thefeeler wheels (3) on both sides of the pick up. To makethe adjustment raise the pick up and secure. Pull out thespring pin (2) and set the feeler wheels in the desiredposition on the bar with holes (1). Secure the feelerwheels again using the spring pin.

Make sure that the feeler wheels onboth sides of the pick up are in thesame po-sition on the bar with holes.

BP380-7-035

21

3

V - 2


Make sure that the low limiter is inthe same position on both sides ofthe pick up.

Adjusting the Low Limiter

To prevent the pick up from becoming buried in theground, when for example driving over deep ruts, it isfitted on each side with a low limiter (1). To adjust, undothe screws (2) and set the low limiter to the desiredposition in the slot (3). Tighen up the screws again.

Adjusting the Height of the Baffle Plate

The height of the baffle plate is dependent on thefollowing factors:

Crop Length of Crop Swath Size Which Setting? long short large small

Straw / hay X X Baffle plate high

Straw / hay X X Baffle plate low

Straw / hay X X Baffle plate high

Straw / hay X X Baffle plate low

Silage X Baffle plate high

Silage X Baffle plate low

The adjustment of the height of the baffle plate (2) ismade using the retaining chains (2) suspended fromthe brackets (1) on both sides of the machine.

Make sure that the same length ofchain is in the bracket on each side.

BP380-7-036

3

2

1

BP380-7-037

2

1

3

V - 3


5.2.2 Pack Chute

When folded out the pack chute is an extension of thebale channel. The pack chute must be at the same levelas the bale channel so that the packs can be depositedproperly.An adjustment can be made using the nuts (1) and (4) oneach side of the bale channel. This adjusts the length ofthe retaining chain (3) for the front section of the packchute and the retaining chain (2) for the rear section.

5.2.3 Regulation of the Baling Thrust

The baling thrust in the bale channel is regulated by anelectronic-hydraulic system. The baling thrust is adju-sted on the comfort control. The current pressure in thebaling hydraulics can be read off the pressure gauge (1)on the front right hand side at any time.

There is another pressure gauge (2) located on the righthand side of the machine near the knotter board besidethe hydraulic control block (1).

BP380-7-0383

2

1

4

BP380-7-040

21

BP-VFS-012

1

V - 4


5.3 Adjusting the Length of the BigPacks

The length of the big packs is adjusted on the left handside. The length of the big pack can be pre-selected byturning the crank (1). The indicator (2) on the scale (3)provides an aid for the adjustment.

5.4 Twine

To ensure secure tying, only synthetic twine with arunning length of 130 – 150 m/kg should be used.

The big pack baler is equipped with twine boxes on bothsides of the machine, each of which can hold 12 rolls oftwine.

When placing the twine in the twinebox make sure that the lettering onthe rolls can be read. Observe theside identified with "top".

Tie the rolls of twine together with the reef knots shownhere. Reduce the ends by the knot down to x = 15-20 mm.

BP380-7-041

3 2

1

X

X

BP 380-7-043

TypeNo.

KnottersNo. Rolls of twine

per Knotters

Big Pack 88 4 6

Big Pack 127 6 4

Big Pack 128 6 4

Take the following steps before inserting new balertwine:

• Disengage the tractor PTO• Turn off the tractor motor• Stop the flywheel either mechanically

or hydraulically• Secure the knotter shaft by moving the

safety lever

BP 127/128

BP 88

BP-VFS-302

BP 127/128

BP-VFS-303

5.4.1 General

V - 5


5.4.2 Inserting the Twine

The knotter shaft must be secured every time new twineis inserted, so that the needle yoke cannot move. To dothis move the safety lever (1) from position (a) to posit-ion (b) and rest on shaft (2).

BP380-7-044

1

2

2

1

a

b

a

b

The mudguard must be swung out of the way to be ableto feed the twine into the twine brake. To do this turn thelock (1) upwards and swing the mudguard (2) out of theway.

BP-VFS-015

V - 6


Feeding the Twine into the Twine Brake(Single knotter)

Insert the baling twine (1) running through the bottomeyes of the twine box into the twine brake (2) and threadit into the eyes (4) via the outer twine guide (3). Fromhere, thread the twine into the tying needles (7) via thetwine tension springs (5) and the eyes (6) and attach it tothe appropriate eyes (8).

Big Pack 127/128 right hand side

Big Pack 127/128 left hand side

Big Pack 88 right hand side

Big Pack 88 left hand side

BP-VFS-304

87

1

2

3

5

4

BP-VFS-305

BP-VFS-306

87

1

2

3

5

4

BP-VFS-307

V - 7


5.4.3 Electric Twine Fault Display

If the end of the twine has been reached or the twine isbroken, place the sprung twine tensioners (1) on theswing angle (2). An acoustic warning signal is activatedon the control panel. An error message appears on thedisplay.

To switch off the acoustic warningsignal while threading the twine, seeChapter "Alarm Messages".

The twine brakes are adjusted by turning the adjustingscrews (1) (see Chapter 6.4).

5.4.4 Initiating the Binding Process Manually

For the twine to enter the bale channel and to be takenby the knotter, the binding process must be initiated ma-nually. To do this, first swing the safety lever (2) down-wards. Move lever (1) upwards to initiate the binding pro-cess. Move the needles upwards to the knotters manual-ly at the flywheel (in the working direction) or by swit-ching on the PTO shaft. The binding twine is now in thebale channel.

BP380-7-051

2

1

BP-VFS-205

BP-VFS-016

x

3

V - 8


5.5 Emptying the Bale Channel

The maintenance platform may only be mounted when the machine is at a standstill. Switchoff the engine and remove the ignition key. Apply the flywheel brake.

The packs in the bale channel should be bound beforeemptying the bale channel. To do this initiate the bindingprocess manually (see chapter 5.4.4 "Initiating theBinding Process Manually").Open the bale channel from the control and indicatorbox. The procedure is thoroughly described in chapter4.6.2 "Opening the Bale Channel".Actuate the pack ejector (1) with the double actioncontrol boxes and transport the big pack out of the balechannel.

Always return the bale ejector to thefront position after ejecting the bigpack.

BP380-7-052

11

VI - 1

Settings

6. Settings

• The following always applies for all maintenance, mounting, repair and adjustment work:switch off the PTO shaft. Switch off the engine and remove the ignition key. Apply theflywheel brake.

• Only put the big pack baler into operation when all protective devices have been attachedand are in a proper operating condition.

• In dangerous situations stop the PTO shaft and bring the big pack baler to a standstillimmediately.

• Never run the big pack baler without an operator on the tractor.• When working under the machine or on the needles in the baling channel, the needle carrier

must be secured against falling down. Danger of injury!

6.2 Adjusting the Needles

Carry out all adjustments to the needles without any twine threaded!

6.2.1 Lateral Adjustment of the Needles

Insert the needles (1) centrally between the clampingbrackets and the needle yoke, turn them towards theneedle slits and screw tight with screws (2). To be ableto carry out the adjustment, the binding process isinitiated manually and the needle yoke manually turnedup in the working direction at the flywheel mass. Whenraised, the needles must just laterally touch the left andright hand sides of the knotter frames. To correct thelateral distance, the screws (2) are undone and theneedles laterally positioned with the adjusting screws (3).Always make sure that the screws are all tightened upfirmly again after making the adjustment.

BP380-7-053

1

23

2

6.1 Special Notes on Safety

VI - 2

Settings

6.2.2 Height of the Needles on the Knotter

To adjust the height of the needles (4) when these areentering the knotting system, start a binding process andthen turn the flywheel manually in the normal sense ofoperation until the lower roller of the needle point islocated above the cleaning disc of driver (2). Distance„a“ from the lower edge of the needle roller to the topedge of the cleaning disc should be equal to 1 - 3 mm iftwine is installed. If this dimension should not be availble,an adjustment can be made by using the set screws (7).When entering the knotter, the needles should slightlytouch the knotter on the RH side. Any required sideadjustment of the needles can be performed using the setscrews (6) (see section 6.2.1). After adjustment it isessential to check that the screws (6) and (7) are properlylocked.

6.2.3 Needles' Upper Dead Centre

If a binding process starts, the needle yoke is set inmotion by connecting rod (3). To adjust the upper deadpoint of the needles, the needle yoke must be moved toits highest position (dead point). The needles (4) projectfrom the knotter. Distance „b“ from the top edge of thedriver disc (2) to the center of the lower roller should beequal to x mm if twine is installed. If the adjustmentshould not be correct, shorten or lengthen needleconnecting rod (3) until the required value is available.The needles should not touch the driver disc when in thehighest position.

BP380-7-054

12

3

456

7

a

b

BP-VFS-018

12

3

456

7

a

b

Single Knotter

Double Knotter

Single knotter:

BP 88 / 128 b = 110 - 120 mmBP 127 b = 120 - 130 mm

Double knotter:

BP 88 / 127 / 128 b = 90 - 100 mm

During their up-and-down stroke, theneedles and the needle yoke shouldnot come into contact with chassis,plunger or other machinecomponents.

VI - 3

Settings

6.2.4 Needles in Idle PositionIf the needle yoke is in the idle position, i.e. the crankarm (1) and the needle drive connecting rod (2) areextended, there must be a distance „c“ = 0 - 20 mmbetween the cross tube of needle yoke (4) and brake (3).

BP-VFS-308

42

1

3

c

A

3

3

If an adjustment is required to reach dimension c, movebrake (3) relative to the set of holes (A).

If dimension c cannot be reached by moving the brake,check the position of the needles relative to the knotters(see section 6.2.3).

VI - 4

Settings

6.2.5 Needles Relative to the plunger

To set the needles relative to the plunger, the drive PTOshaft for the knotter shaft must first of all be dismoun-ted. The plunger is turned manually in the working direc-tion at the flywheel mass until the crank arms and thepiston rods are overlapping each other (i.e. the balingram is at the front dead centre).

The knotter gear is then turned until the coloured mar-king on the knotter shaft crown wheel is aligned withthe upper rear edge of the knotter gearbox. After the ad-justment has been made place the PTO shaft for the kn-otter shaft back in position and secure. Check the set-tings as described in the following chapter.

Checking the Setting of the Needles Relative to the plunger

To be able to check the setting of the needles relative tothe plunger, the binding process is initiated. Beforechecking the dimensions it is necessary to releaseneedle yoke brake (3).

To do this:

• Release nut (4) on the RH and LH machine side.

1

a

BP380-7-057

2

6 5

BP-VFS-019

The plunger (2) is manually turned in the workingdirection at the flywheel mass until the tips (1) of thebinding needles are at the same height as the ram blade.In this position the needle tip must be covered by theplunger, with the dimension a = 40–70 mm. If this is notthe case the setting must be corrected by altering theposition of the knotter drive PTO shaft.

• Adjust the length of spring (5) to 110 mm bytightening nut (4).

BP-VFS-310

3

45

VI - 5

Settings

The adjustment is made by undoing the screws (3) and(4) on the twine bar (1). Shift the twine bar in the slotuntil the dimension "b" = 2–5 mm.

The setting for the distance at the side "a" is adjusted atthe control rod assembly (5) for the twine bar (1). Tomake the adjustment undo self-locking nuts (6) and takeoff the ball head (7). Twist the control rod until thedimension a is set at a = 0 – 5 mm. When the twine baris pressed in the direction of the slot, the „a“ dimensionmust still be maintained. Tighten up the self-locking nutsagain.

If the twine bars (1) are in the middle of the openings,the distance from the tip of the twine bar and the innerside of the needle (2) must be "b" = 2–5 mm.

6.3.1 Adjusting the Twine Bar

Initiate the binding process manually (see chapter 5.4.4"Initiating the Binding Process Manually"). Turn theflywheel in the working direction. The needles moveupwards. At the same time move the twine bars over theopenings through which the needles transport the twineto the knotter.

6.3 Twine Bar (Single knotter)

The twine bar (1) draws the twine down from the needleand presses it against the knotter hook. If the twine isnot taken by the twine bars, the knotter hook cannot takeup the twine.

BP-VFS-020

1

1

2 BP-VFS-021

3 4

1

BP-VFS-022

4

3

1

BP-VFS-023

5 6

7

VI - 6

Settings

The twine brakes (2) are located below the twine boxes.The adjusting screws (3) keep the baling twine (1) undertension.

The various types of baling twine may have differentfrictional properties. The tensile stress of the skein mustbe checked when the type of baling twine is changed.The level of the tensile stress on the twine should beselected so that the twine tension springs do not touchthe swing angle. The X dimension depends on theselected baling twine and must be establishedindividually by checking the skein. Exceeding feedtension of the skein may cause knotter faults and putsexcessive stress on the components involved.

Checking the Tension:1. Thread the twine as specified.2. Initiate the knotting process manually.3. Turn the big pack baler's flywheel manually in the

working direction until the binding needle hasreached its upper dead centre.

4. Draw out approx. 200 mm of twine and cut.5. Pull the skein slowly and evenly until the twine

tension springs reach their highest position underthe channel.

6. While holding the twine, the twine tension springsmust remain in this position without the twine beingable to be tightened by the brake.

7. With slight increase of the tensile force the brakemust allow the twine to slip through.

6.4 Adjusting the twine brake(Single knotter)

BP-VFS-024

12

1

1

BP-VFS-016

x

3

VI - 7

Settings

6.5 Plunger Setting

The bale chamber is equipped with two blades (6).• The plunger (3) on the Big Pack 127/128 is equipped

with seven blades (5).• The plunger (3) on the Big Pack 88 on the other hand

is only fitted with five blades (5) due to the smallerwidth of the bale chamber.

Adjusting the plunger blades

The plunger blades must be set precisely to obtain asmooth surface on the underside of the pack. To adjustthe distance to "a" = 2 mm the height of the plunger canbe adjusted with the eccentric sleeves (2) on the guiderollers. After separating the two halves of the clampbedding (1), the eccentric sleeves are turned to raise andlower the plunger. After making the adjustment, thetighten the two halves of the clamp bedding again. Makesure that the guide rails (4) and the guide rollers do notbecome dirty. This can lead to increased wear and animprecise height setting of the plunger.

• The guide rollers for the plunger must carry uniformly.• The gap between the plunger blade and the blades in the bale channel must be uniform over

the whole width of the ram.

1 2 3 4 5 6

2

1

a

BP 380-7-062

BP380-7-063

a

1

22

1

3

Guide Rail Cleaning

There are cleaning rails attached to the four plungerrollers (3), which clear the plunger guide rails of depositsof dirt.To make the adjustment undo screws (1) and set thecleaning rails to the dimension a = 1–2 mm. Tightenup the screws again.

The cleaning rails (2) must tilt easilyaround the roller axle!

VI - 8

Settings

Dismount the protective plate from the bracket (6) on theleft hand side of the machine. Remove the roller chain(5) from the packer gearbox (7) drive shaft. Move the pi-ston rods into the exrended position (rear dead centre).The packer (fixed into position with the mounting lever)and the ram are now in position for the adjustment. Pla-ce the chain coupling roller chain (5) in position and se-cure. Attach protective plate and remove the mountinglever.Turn the machine manually through one entire revolutionat the flywheel.

6.6 Setting the packer Relative to theBaling Ram

The packer must be adjusted whenpacker gearbox or the chain couplingconnection chains are replaced.

Turn the packer manually in the working direction untilthe small guide roller (3) of the packer (1) is visible inwindow (2) on the left hand side of the machine. Lift upthe guide roller with a mounting lever (4) so far that itmeets resistance. This ensures that the packer drive isengaged.The packer is then turned forwards until the packer edge(8) which advances the feeder edge (9) lines up with thesetting mark (10). Lock the packer in this position with amounting lever.

BP380-7-064

1

2

3

4

BP380-7-065

3

2

1

BP-VFS-095

The central point of the packerfingers (8) should not project beyondsetting mark (10).

VI - 9

Settings

6.7 Setting the clutch

1. Adjust the adjusting screw (14) so that the clutchswitch ratchet (18) sits B = 6 - 8 mm on the middleof the roller (19) when the clutch is switched off.

2. If the anvil (15) sits on the adjusting screw (14), therear of the back holder rake (12) has to stand parallelto the back wall of the feed packer channel. You canset it at the threaded rod (13) (arrange measure of A= 438 mm).

3. After rotation the roller (16) will drop down the outsidemargin of the pulley (17). When the back holder rakepulls back the anvil will apply to the adjusting screw.In this position the top of the back holder rake (12)still has to reach 5 - 10 mm into the feed packerchannel. You can set it with the adjusting screw (11).

6.8.2 Setting the damper equipment

The damper equipment prevents the anvil from switchingon the VFS-clutch through its own movements. Theadjustable tension of the pressure spring (20) dependson e.g. the condition of the brake (wear grade, paint,rust).To check the spring's tension you have to actuate theback holder rake (12). For that reason put some feeder inthe big baler. If the back holder rake swings back again(at full number of revolution), the anvil (15) is allowedto bounce back from the adjust screw (14) max. 1 - 3mm. If the anvil bounces back further you will have toincrease the tension of the pressure spring (20).If the back holder rake swings out, the anvil has to arriveat the adjust screw (11). If not, reduce the springtension.

6.8.1 Lateral setting of the damperequipment

To compensate tolerances because of welding andadaptation the damper equipment is adjustable.

Checking the settings:Press the anvil (15) against the adjust screw (14). In thisposition there should be a gap of 35 - 37 mm to the backfrom the strech screw for the pressure spring (20) in theslot (22) of the anvil. To correct the adjustment undo thescrews (21) and correspondingly displace the damperequipment.

6.8 Damper equipment

A

B

12 11

14

15

16

18

19

17

13

BP-VFS-091

BP-VFS-089

VI - 10

Settings

6.10 Adjusting the FlywheelCleaning Mechanism (only BigPack 88)

Even small deposits of dirt in the interior of the flywheel(1) can lead to imbalances. The setting of the plastic bar(2) should therefore be checked regularly. If the gapbetween the flywheel and the plastic bar is too large,undo the nuts (3) on the bracket (4) and slide the plasticbar in the slots up towards the flywheel mass. Tightenup the nuts again.

BP380-7-069

2

13 4

The spring (23) is responsible for bringing the backholder rake into its swing position again after the feederinsertion (over the anvil (15) and the threaded rod (13)).The anvil (15) therefore has to arrive at the adjust screw(24).

The arrange measure is swing length “C” = 130 mm.

• The tension of the swing should be increased, if- the end position of the back holder rake and the

anvil cannot be reached (see chapter 6.8.)- the filling of the press channel's height is not

sufficient.-> Badly filled baler corners mostly result due to

bad forms of swathe or onesided drivingconditions

• Excessive spring tension can cause a blockage ofthe packer and therefore reduce the output.

6.9 Setting the sensibility of theactuator

C

24

15 23

13

BP-VFS-093

Setting of the spring of the zeroizing device

• When the zeroizing device is in its unlatched state,the spring should be tensioned to a dimension of a =185 mm

Adjusting the VFS brake setting:

• The spring in the brake of the VFS circuit should betensioned to a dimension of b = 65 mm.

A

BPVFS322

A

BPVFS323

VI - 11

Settings

6.11 Location of the sensors

BP

-VFS

-028

1

34

For information regarding sensor settings please refer to Appendix A 1.2.2!

1 Blade sensor "Multi Cut"

Location of the sensors on BP 88 / 127 / 128(Left hand side)

3 Needle connecting rod sensor4 Flywheel brake sensor

VI - 12

Settings

1 Pack shute sensor2 Packer controle sensor3 Feeder packer sensor4 Knotter sensor

5 Calibration sensor6 Measurement sensor7 Twine tightener sensor

Location of the sensors on BP 88 / 127 / 128(Right hand side)

BP

-VFS

-312

7

VI - 13

Settings

6.12 Adjusting the Sensors

The distance between the transmitter (2) and the sensor(1) must be a = 3 mm.

Adjustment:

• Unscrew nuts on both sides of the sensor.• Turn the nuts until the distance "a" = 3 mm has been

reached.• Tighten up the nuts again. a

BP-VFS-0882

1

Adjusting sensors 3, 5, 6 (right machineside)

The distance between the transmitter (2) and the sensor(1) must be a = 5 mm.

Adjustment:

• Unscrew nuts on both sides of the sensor.• Turn the nuts until the distance "a" = 5 mm has been

reached.• Tighten up the nuts again.

aBPVFS3212

1

VI - 14

Settings

6.13 Basic adjustment of theflywheel brake

The flywheel brake must be re-adjusted if the brakepower is no longer satisfactory (worn brake block) or ifthe flywheel brake has been removed (e.g. afterreplacement of the friction clutch).

For this proceed as follows:

1. Remove pin (1) from the brake lever and remove thebrake lever (this step is best with the flywheel brakepulled).

2. Release bolts (2) and remove the protective cover.3. Install the brake lever.4. Release the brake.5. Check dimension „A“: this should be equal to 200

mm. Adjust as necessary using nut (3).6. Pull the brake.7. Check dimension „B“: this should be equal to 28

mm. To correct dimension „B“ release the brake againand adjust the grub screws (4) at either side of thebrake saddle. This will move the brake blocks closerto the brake disc. Pull the brake again and checkdimension „B“.

The distance between brake saddle (5) androds (6) must be equal at either side of thebrake saddle. Correct by adjusting thebolts (4) as required.

BP380-7-165

1

2

4

BP380-7-166

3

BA

B

BP380-7-168

5

6

VI - 15

Settings

6.14 Installing the flywheel brake

The flywheel brake must be removed for anyreplacement of the friction clutch.

Utmost care is essential during the subsequentinstallation of the brake.

Installation procedure:1. Install the intermediate PTO shaft onto the friction

clutch.2. Install the guard of the intermediate PTO shaft.3. Slide cross bracket (1) with bearing housing, grooved

ball bearing and eccentric ring onto the intermediatePTO shaft. The bearing must face the rear side.

4. Slide brake disc (2) with the profiled hub onto theintermediate PTO shaft. The profiled hub must facethe rear side.

5. Install housing (3) onto the drawbar. Note that thefront coach bolts (4) must be inserted from outsideto prevent damage to the tractor tyre. The rear coachbolts (5) must be inserted from inside. Do not yettighten the bolts.

6. Install the cross member hand tight onto the housing.The bolts (6) must be inserted from outside.

7. Align housing (3) at a right angle to the intermediateshaft. The inner dimension of the housing is A = 300mm. The distance between drawbar and housing canbe corrected using shims. Tighten the bolts (4) and(5) firmly.

8. The distance between the brake discs and the crossmember must be B = 26 mm over the entire length.Only when this distance is set to the correctdimension, the bolts of the cross member can betightened. Attention: This dimension must beadjusteed as accurately as possible. Work withutmost care!

9. Tighten the bolts inside the profiled hub.10.Bolt on the brake saddle.11.Install the brake rods.12.Adjust the brake rods in accordance with the

description of section 6.13.13.Check once more that the brake disc does not come

into contact with the brake saddle.

BP380-7-169

1 2

B

BP380-7-170

A

BP380-7-167

90˚

6

3

4 57

VI - 16

Settings

VII - 1

Care and Maintenance

7. Care and Maintenance

• Repair, care, maintenance and cleaning work may only be carried out with the machine at astandstill. Switch off the engine and remove the ignition key. Apply the flywheel brake.

• Secure the big pack baler and the tractor from rolling away.• After completion of care and maintenance work replace all protective plates and protective

devices properly.• Avoid skin contact with oils and greases.• High pressure hydraulic fluids can cause severe injuries. In case of injury seek immediate

medical attention. Risk of infection.• Follow all other notes on safety to prevent injury and accidents.

To guarantee perfect operation of the big pack baler and to reduce wear, maintenance and carework must be carried out at certain intervals. This includes amongst other things cleaning,greasing, lubricating and oiling of parts and components.

7.2 General

Torque moment MA (if not otherwise specified).A = thread size(Screw class visible on screw head.)

Check regularly (approx. every 50 hours) that nuts and screws are firmly tightened and tightenup if necessary!

8 . 8

1 0 . 9A

BP380-7-073

A 5.6

2942

2,24,57,6183764

100

160

4,48,7153672

125200215310

1050

330

350

M 4M 5M 6M 8M 10M 12M 14M 14x1,5M 16M 16x1,5M 20M 24

6.8M (Nm)

8.8 10.9

AO/12.9

M 24x1,5M 24x2M 27M 27x2M 30

5,110184384

145235255365

2450

390

3,05,910254985

135145210225

730

710

1220

135018001950

2100

115015501650

1450

80011001150

610425


VII - 2


7.3 Cleaning

The big pack baler, in particular the knotter, must becleaned of chaff and dust every time it is used. Undervery dry working conditions clean several times a day.Also remove chaff and dust off the rake control andflywheel daily.

• Repair work on the tyres may only be carried out by specialists with suitable mounting tools.• Park the big pack baler on firm level ground. Secure from unintentional rolling away using

wheel chocks and by applying the parking brake.• Check regularly that the wheel nuts are fastened tightly and tighten up if necessary.• Do not stand in front of the tyre when inflating with compressed air. The tyre can burst if the

pressure becomes too high. Risk of injury!• Check the tyre pressure regularly.

7.4 Tyres

Observe the order of tightening and loosening wheelnuts shown in the adjacent diagram. Check the wheelnuts 10 operating hours after mounting and tighten up ifnecessary. Subsequently check every 50 operatinghours that they are fastened tightly.

7.5 Opening the Front Guard Plate

The front guard plate (2) is unlocked using a Schrauben-dreher (1). Engage the flywheel brake. Insert screwdriverin the opening and move the catch back. As soon asthe front guard plate is unlocked it can be swungupwards.

When opening the front guard platemake sure that it does not hit any partof the machine.Move the lever of the flywheel brake tothe stop position.

Thread

M18 x 1,5

M20 x 1,5

Spannersize

24

27

Max. torqueblack

265

343

MA (Nm)zinc-plat.

245

294

Check the tyre pressure at regular intervals and inflate ifnecessary. The tyre pressure is dependent on the tyresize. The values are listed in the section "TechnicalData".

BP 380-7-074

8

1

3

5

7

2

4

6

BP-VFS-030

12

VII - 3


7.6 Hydraulics

• Before carrying out works on the big pack baler's hydraulics system, release the pressure inthe hydraulic cylinders for the bale channel flaps.

• Check hydraulic hoses and lines regularly and replace any damaged ones.• The replacement parts employed must comply with the technical requirements of the

machine manufacturer. Only use genuine KRONE replacement parts.• Repair work to the hydraulics system may only be carried out by qualified specialists.

• Ensure perfect cleanliness when working on the hydraulics system.• Check the hydraulic oil level every time before putting into operation.• Observe the intervals specified for changing the hydraulic oil and the hydraulic oil filters.• Dispose of used oil properly.

7.6.2 On-Board Hydraulics

The big pack baler's on-board hydraulics system ispressurised by its own hydraulic pump. It is flanged onto the lower part of the main gearbox and requires nomaintenance.

The on-board hydraulic oil and hydraulic oil filter must bechanged annually before the start of the season. Have asuitable collection container ready when making the oilchange. Take out the drain screw (4) in the reservoirtank (3). Once all the oil has emptied, screw the drainscrew back in. Unscrew screw plug (5) and fill in therequired amount of hydraulic oil. Check oil level withusing dipstick (2). The hydraulic oil specifications arelisted in the section "Technical Data".

The hydraulic cylinders for the balechannel flaps must be retracted whenchanging the hydraulic oil.

BP380-7-076

2

3

1

4

5

5

BP-VFS-313

Hydraulic filter (5) is located behind the twine box on theright-hand machine side.

Replace the filter:• at the start of each season (at least once a year).• Relieve all pressures from the hydraulic on-board

system.• Unscrew the filter housing.• Renew the filter element.• Screw on the filter housing.• Check the circuit for leakages.

7.6.1 Special Notes on Safety

VII - 4


7.6.3 On-Board Hydraulic Circuit Diagram

190+20 bar

30-200 bar

30-200 bar

P

T

AM2

DV1 M1

S1

DV2

M3

MS

aa

b

c

d

e f

II

III

IV

V

I

VI

VII

VIII

IX

0

2

1

2

0

1

0

2

1

2

0

1

L12

P

105

T

ABAB

L12

L12

L12

L6

L6

P

T

VII - 5


7.7 Changing and Checking the Oil in the Gearboxes

• When checking the oil level in the gearboxes, make sure that the big pack baler is in a hori-zontal position. Use the upperside of the twine box as a reference.

• The respective oils and quantities can be found in "Technical Data".• Check all oil levels before using the machine every day during the season and fill up with

oil if necessary.

Designations:

a) Circuit diagram for the on-board hydraulicsb) Circuit diagram for the pick up liftingc) Circuit diagram for bale ejectord) Circuit diagram for roller chute and bale ejectore) Circuit diagram for blade zero position (Single

blade safety device)f) Circuit diagram for blade zero position (Block-

blade safety device)

Abbreviations:

A = ConnectionM = Pressure gaugeP = PumpS = AccumulatorT = Tank

Designations:

I =Electro-hydraulic valve blockII =Baling shutters cylinderIII =Pick-up hydraulic cylinderIV =hydraulic cylinder bale ejectorV =hydraulic cylinder roller chuteVI =hydraulic cylinder BallenschieberVII =Control block manual operationVIII =blade zero position hydraulic cylinder

(Single blade safety device)IX =blade zero position hydraulic cylinder

(Block blade safety devie)

7.7.1 General

VII - 6


Checking the Oil

7.7.2 Main Gearbox

The oil check (3) and oil drain (2) screws are located onthe left hand side of the main gearbox (1).

Changing the Oil

7.7.3 Feed packer Gearbox

The feed packer gearbox (3) is located on the left handside of the machine.

Checking the Oil

7.7.4 Transfer Gearbox

The transfer gearbox (2) is located on the left hand sideof the machine.

Checking the Oil

Check the oil level in the main gearbox every timebefore using the machine. To do this unscrew the oilcheck screw (3). The oil must come up to the oil checkhole. Top up with oil if necessary. Screw the checkscrew in again after checking the level.

Change the oil after every season. To do this unscrewthe oil check screw (3) and the oil drain screw (2).Collect oil discharged in a suitable collection container.Screw in the drain screw again and fill with new oil up tothe checking hole. Screw the oil check screw back inagain.

Check the oil level in the feed packer gearbox (3) everytime before using the machine. To do this unscrew theoil check screw (1). The oil must come up to the oilcheck hole. Top up with oil if necessary. Screw thecheck screw in again after checking the level.

Check the oil level in the transfer gearbox (2) every timebefore using the machine. To do this unscrew the oilcheck screw (1). The oil must come up to the oil checkhole. Top up with oil if necessary. Screw the checkscrew in again after checking the level.

Changing the OilChange the oil after every season. To do this unscrewthe oil check screw (1) and the oil drain screw (3).Collect oil discharged in a suitable collection container.Screw in the drain screw again and fill with new oil up tothe checking hole. Screw the oil check screw back inagain.

Changing the OilChange the oil after every season. To do this unscrewthe oil check screw (1) and the oil drain screw (2).Collect oil discharged in a suitable collection container.Screw in the drain screw again and fill with new oil up tothe checking hole. Screw the oil check screw back inagain.

BP380-7-078

3

2

1

BP380-7-079

2

1

3

BP380-7-080

12

3

VII - 7


7.7.5 Pick Up Gearbox

The upper and lower pick up gearboxes (3) are locatedon the right hand side of the machine.

Checking the Oil

Check the oil level in the upper pick up gearboxes (3)every time before using the machine.To do this unscrew the oil check screw (1). The oilmust come up to the oil check hole. Top up with oilif necessary. Screw the check screw in again afterchecking the level.

Changing the Oil

Change the oil after every season. To do this unscrewand remove the check screw (1) on the upper gearboxand the ventilation screw (4) and the drain screw (2)from the gearbox. Collect oil discharged in a suitablecollection container. Screw the drain screw in again.

Screw in the check and air evacuation screws again.

Oil check

Check the oil level in the angular gearbox (1) before eachoperation.To do this remove the check screw (2). The oil levelmust reach the lower edge of the check hole, ifnecessary top up the oil.

Oil change

The oil should be changed after every season.To change the oil, remove the discharging screw (3) andthe check screw (2). Collect the draining oil in a suitablecontainer and dispose of it in an environmentally friendlymanner. Fit the discharging screw (3) and fill in oil up tothe check hole. Fit the check screw (2).

7.7.6 Cutting system gearbox for Big Pack MultiCut

On the right-hand side of the machine there is an angulargearbox at the top and a pick-up/cutting system transfergearbox at the bottom.

BP380-7-081

4

23

3

4

1

2

BP380-7-082

1

2

3

VII - 8


7.8 Compressed Air Unit7.8.1 General

Before draining condensed water from the compressed air reservoir tank, make sure that themachine is secured from rolling away. Apply the parking brake and place wheel chocks underthe wheels.

Big pack balers equipped with an air brake have twocompressed air reservoir tanks and pneumatic brakecylinders. For hydraulically actuated brakes, only onecompressed air reservoir tank is fitted for the knottercleaning mechanism. Condensed water collects in thecompressed air reservoir tanks. This condensation canlead to malfunctions. It must therefore be drained everyweek.

7.8.2 Compressed Air Reservoir Tank

On big pack balers with air brakes, the compressed airreservoir tank (2) is located on the left hand side of themachine. It is connected to the compressed air reser-voir tank for the knotter cleaning mechanism by a pres-sure line (1). Condensed water can be drained at thewater evacuation valve (3).

The compressed air reservoir tank for the knotter me-chanism is located on the left hand side of the machineat the top beside the bale channel. Condensed watermust also be drained here at the water evacuationvalve.

Oil check

Check the oil level in the angular gearbox (1) before eachoperation.

To do this remove the check screw (2). The oil levelmust reach the lower edge of the check hole, ifnecessary top up the oil through the breather hole (3).

The oil should be changed after every season.To change the oil, remove the breather screw (3) thedischarging screw (4) and the check screw (2). Collectthe draining oil in a suitable container and dispose of it inan environmentally friendly manner. Fit the dischargingscrew (4) and fill in oil up to the check hole. Fit thecheck screw (2) and breather screw (3).

Oil change

BP380-7-083

13

42

BP380-7-0843

2

1

VII - 9


7.8.3 Brake Cylinders

Excess pressure should be released from the compressed air system before disassembling themembrane brake cylinder.There is a danger of injury!

Special maintenance for the brake cylinders (1) is notnecessary. The membrane cylinders should beremoved, disassembled, cleaned, parts subject to wearreplaced and reassembled at least every two years.

The guide rollers (1) on the feed packer drum (2) aresubject to heavy use. Undo the nuts (3) to replace theguide rollers. Pull the guide rollers out of the hole in theside wall of the packer housing.Insert new guide rollers and secure with the nuts.

Torque moment:Large guide rollers: NukR 72 (M24 x 1,5) = 250 NmSmall guide rollers: NukR 40 (M18 x 1,5) = 120 Nm

7.9 Replacing the Guide Rollers on the Packers

BP380-7-085

1

BP380-7-086

2

31

VII - 10


VIII - 1

Lubrication

8.3 LubricationThe lubrication points on the big baler should belubricated regularly. The lubrication point positions andlubrication intervals can be be found in the lubricationschedules in the operating manual or on the stickers onthe front of the twine boxes. Remove the grease whichescapes from the bearings after lubrication.

Lubrication intervals:10 h corresponds with approx. daily50 h corresponds with approx. weekly

8. Lubrication


• Secure the big pack baler and the tractor from rolling away.• After completing care and maintenance work replace all protective plates and protective

devices again properly.• Avoid skin contact with oils and greases.• In case of injury caused by discharged oil, seek immediate medical attention.

8.2 GeneralAs a standard feature the big pack baler is fitted with acentral lubrication system for the knotter area. The grea-se press for this system is located on the rear right handbale channel at the same height as the maintenanceplatform.Soft, smooth lithium NLGI grade 2 soap grease with E.P.additives in accordance with DIN 51825 are to be usedas lubricating greases. We advise against using lubrica-ting greases taking something else as a basis.

Main PTO ShaftThe lubricating periods for the main PTO shaft are givenin the adjacent diagram. Further information can befound in the PTO shaft manufacturer's operatinginstructions.

BP 380-7-088

939 450-1939 212-1

1050

BP380-7-089

40h 8h40h

8h8h 8h 20h


Bio-degradable lubricants

ARAL Langzeitfett H

BP Energrease LS-EP2

DEA Glissando EP2

FINA Marson EPL 2A

Shell Alvania Ep2

ESSO EGL 3144

On request only

• Do not use any greases containing graphite• Problems may occur if different greases are mixed

together

VIII - 2

Lubrication

Knotter shaft support bearings central lubrication

Knotter gear lever shaft left central lubrication

Needle yoke right and left central lubrication

Knotter central lubrication

Toothing of the knotter apply grease or viscous oil

Toothing inside the knotter drive gear apply grease or viscous oil

Multi Cut drive diagonal shaft 5

Gearbox cutting rotor dumb-bell shaft 2

Star-shaped ratchet 1

Bearings for the brake lever adjustment onindividual axle right and left 2

Brake shaft right and left 2

Tandem axle: Brake lever bearings (right / left) 4Brake shaft bearings (right / left) 4Axle rocker arm (right / left) 2-> Relieve the bearing when lubricatingBowden cable (right / left) 2

PTO shaft: Main drive 6Pick up drive (low maintenance, 1/ year) 5Knotter drive (low maintenance, 1/ year) 3

Lubrication Points No. of Lubricating Nipples

Crank pin for plunger drive right and left 2

Piston piin for plunger drive right and left 2

Bearing rollers on ram right and left 4

Guide rollers on conveyor and feeder packers 12

Cam track pick up right 1

Feeler wheels 2

Jack stand 1

Parking brake 1

Lubrication PointsIn the following table lists the most lubrication points on the big pack baler, as well as the number of lubricatingnipples.

VIII - 3

Lubrication

Lubricating points of the big square baler (left hand side)

50h

10h

10h

10h

10h

50h

50h

10h

50h

50h

50h

10h

5 x

200h

VIII - 4

Lubrication

Lubricating points of the big square baler (right hand side)10

h

10h

10h

10h

50h

10h

10h

BP 1

28 =

8 x

BP 1

27 =

8 x

BP 8

8 =

6 x

10h

50

100

150

bar

50h

50h

50h

200h

10h

VIII - 5

Lubrication

Lubricating points of the big square baler with MultiCut (left hand side)

50h

10h

10h

10h

50h

50h

10h

50h

50h

50h

10h

5 x

200h

VIII - 6

Lubrication

Lubricating points of the big square baler with MultiCut (right hand side)10

h

10h

10h

10h

50

100

150

bar

50h

50h

50h

50h

10h

50h

50h

10h

50h

BP 1

28 =

8 x

BP 1

27 =

8 x

BP 8

8 =

6 x

10h

VIII - 7

Lubrication

8.4.1 Method of operation of the BEKA-MAX central grease lubrication system:

The BEKA-MAX central grease lubrication system operates on a progressive basis and is capable of using grease toNLGI Class 2. „Progressive“ signifies that the bearings are lubricated in a progressive sequence, i.e. one after theother. This design principle permits easy monitoring of the system by means of an in-built pressure relief valve in thepump element. If any lubrication point cannot be lubricated from the distributor, a back pressure of up to 280 bar willbe built up in system and at that point, a controlled discharge will be effected by the pressure relief valve. A microswitch on the relief valve of the pump element send a warning signal, this means, the terminal shows a warningsymbol, if a fault occurs. Normally, progressive systems are operated using commercially available standardgreases to NLGI Class 2.

8.4.2 Design of the BEKA-MAX central grease lubrication system:

An electrically actuated piston pump, with up to three pump elements, supplies lubricant to the main progressivedistributor (if installed) which, in turn, distributes grease to the secondary distributors in the correct ratio. Thesesecondary distributors then supply the lubricant to the various bearings on the vehicle. If there are less than twentylubrication points on the vehicle, only one distributor will be required. An electronic control modulewill trigger lubricating and „off“ times of the pump and hence the total quantity of lubricant supplied.

1 electronic control unit S-EP 42 transparent lubricant reservoir3 filling nipple4 relief valve with micro switch5 main progressive distributor6 auxiliary progressive distributor7 main pipe8 lubricant pipes9 lubrication points

8.4 Central grease lubrication system

2

1 3

7

4

5

8

6

9

Schmierzeit (min.) Pausenzeit (h)

Kontroll LED

16

24

32

8 12

28 20

2 4

EA/PA Controller Typ S-EP 4

0,5

1 2

3

5

4

67

8

VIII - 8

Lubrication

8.4.3 Function description, centrallubricating pump EP-1:

Method of Operation:The DC motor (10) provides a continuos drive to theeccentric (5) with thrust ring (6). This cam arrangementproduces the suction and pressure stroke of the primarypiston (7) and the integrated check value (8) preventsreturn of lubricant.The rotating charging arm (2) forces lubricant from thereservoir (1) via the perforated base plate (4) into thepump housing at the bottom end of the pump body.The combination of charging arm and perforated plateserves to reduce air bubbles to insignificant dimensions.A rubber wiper blade on the charging arm (2) permitsvisual check of grease level in the transparent reservoir(1). Filling of the reservoir is effected via the hydraulicgrease nipple.The pressure relief valve (9), is preset to 280 baroperating pressure, to provide protection for the pumpand piping system.

148

238

175

Ø151

Variante mit1,9 kg Behälter

"X”


Kontroll LED

16

24

32

8 12

28 20

2 4


0,5

1 2

3

5

4

67

8

152

130

177 138

320

107

197,5

"X”

107

197,5

1

2

8

5

3

6

4

9

7


Kontroll LED

16

24

32

8 12

28 20

2 4


0,5

1 2

3

5

4

67

8

"X”

Version with1,9 kg container

VIII - 9

Lubrication

45

25

10

5

10

5

105

45

105

75

45

105

75

45

45

75

75

75

75

25

25

25

25

25

25

25

25

25

45

75

25

Ce

ntr

al lu

brica

tio

n B

P 8

8

1:2

.5

Allg

em

ein

tole

ran

ze

n

02

86

-71

0-0

(NE

U M

IT 6

000 )

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Ne

ed

le r

ocke

r a

rm,

left

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

op

era

tin

g le

ve

r sh

aft

(d

rive

)

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

Kn

ott

er

sh

aft

su

pp

ort

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Ne

ed

le r

ocke

r a

rm,

rig

ht

Co

nn

ectin

g r

od

at

the

pis

ton

pin

, le

ft

Co

nn

ectin

g r

od

at

the

cra

nk p

in,

left

Co

nn

ectin

g r

od

at

the

pis

ton

pin

, rig

ht

Co

nn

ectin

g r

od

at

the

cra

nk p

in,

rig

ht

Pis

ton

ro

ll, r

ea

r le

ft

Pis

ton

ro

ll, f

ron

t le

ft

Pis

ton

ro

ll, r

ea

r rig

ht

Pis

ton

ro

ll, f

ron

t rig

ht

Oscill

atin

g a

xle

, rig

ht

Fe

ele

r w

he

el, r

igh

t

Ch

ain

lu

brica

tio

n p

ick-u

p,

rig

ht

Cu

rve

tra

ck p

ick-u

p,

rig

ht

Oscill

atin

g a

xle

, le

ft

Fe

ele

r w

he

el, le

ft

Ch

ain

lu

brica

tio

n p

ick-u

p,

left

Cu

rve

tra

ck p

ick-u

p,

rig

ht

Ch

ain

lu

brica

tio

n p

ick-u

p,

left

Fe

ele

r w

he

el, le

ftF

ee

ler

wh

ee

l, r

igh

t

Ch

ain

lu

brica

tio

n p

ick-u

p,

rig

ht

Ele

ctr

ic p

um

p E

P-1

Ce

ntr

al lu

brica

tio

n f

or

pre

ss p

isto

n/c

on

ne

ctin

g r

od

Ce

ntr

al lu

brica

tio

n fo

r

oscill

atin

g a

xle

/pic

k-u

p

Ce

ntr

al lu

brica

tio

n fo

r

pic

k-u

p (

sin

gle

axle

)

Centr

al lu

brication c

om

ple

te (

w/o

lubrication o

f th

e c

olle

cto

r) B

ig P

ack 8

8

Dis

trib

uto

r w

ith

pip

es

for

Kn

ott

er

12

/24

Dis

trib

uto

r w

ith

pip

es

for

pre

ss p

isto

n/c

on

ne

ctin

g r

od

4

/8

Dis

trib

uto

r w

ith

pip

es

for

oscill

atin

g a

xle

/pic

k-u

p

4/7

Dis

trib

uto

r w

ith

pip

es

for

pic

k-u

p (

sin

gle

axle

) 3

/5

Lubrication p

oin

ts:

Sin

gle

axle

: 3

7

Do

ub

le a

xle

: 3

9

Ma

in d

istr

ibu

tor

with

pip

es

for

sin

gle

axle

3/3

Ma

in d

istr

ibu

tor

with

pip

es

for

do

ub

le a

xle

3/3

to dis

trib

uto

r

"d"

to dis

trib

uto

r

"b"

to dis

trib

uto

r

"a"

"a"

"b"

"c"

"d"

Ad

justin

g:

Ino

pe

rative

pe

rio

d: 0

,5 h

Tim

e o

f lu

brication: 10 m

in.

8.4.4 Lubrication scheme Big Pack 88

VIII - 10

Lubrication

75

75

75

75

25

25

25

25

25

25

25

25

25

25

25

25

25

45

25

10

5

45

25

10

5

10

5

10

5

45

10

5

75

45

10

5

75

25

45

10

5

Ce

ntr

al lu

brica

tio

n B

P 1

27

/12

81:2

.5

Allg

em

ein

tole

ran

ze

n

02

86

-711

-0

(NE

U M

IT 6

00

0 )

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Needle

rocker

arm

, le

ft

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

op

era

tin

g le

ve

r sh

aft

(d

rive

)

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

Knotter

shaft s

upport

Knotter

Knotter

Knotter

Knotter

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Kn

ott

er

be

arin

g o

n t

he

sh

aft

Ne

ed

le r

ocke

r a

rm,

rig

ht

Connecting r

oad a

t th

e p

isto

n p

in, le

ft

Co

nn

ectin

g r

oa

d a

t th

e c

ran

k p

in,

left

Co

nn

ectin

g r

oa

d a

t th

e p

isto

n p

in,

rig

ht

Co

nn

ectin

g r

oa

d a

t th

e c

ran

k p

in,

rig

ht

Pis

ton r

oll,

rear

left

Pis

ton r

oll,

fro

nt le

ft

Pis

ton

ro

ll, r

ea

r rig

ht

Pis

ton r

oll,

fro

nt right

Oscill

atin

g a

xle

, rig

ht

Feele

r w

heel, r

ight

Chain

lubrication p

ick-u

p,

right

Curv

e tra

ck p

ick-u

p, right

Oscill

ating a

xle

, le

ft

Fe

ele

r w

he

el, le

ft

Chain

lubrication p

ick-u

p,

left

Curv

e tra

ck p

ick-u

p, right

Chain

lubrication p

ick-u

p,

left

Feele

r w

heel, left

Feele

r w

heel, r

ight

Chain

lubrication p

ick-u

p,

right

Dis

trib

uto

r w

ith

pip

es

for

knotter

8/1

6

Ele

ctr

ic p

um

p E

P-1

Ce

ntr

al lu

brica

tio

n f

or

pre

ss p

isto

n/c

on

ne

ctin

g r

od

Ce

ntr

al lu

brica

tio

n fo

r

oscill

atin

g a

xle

/pic

k-u

p

Ce

ntr

al lu

brica

tio

n fo

r

pic

k-u

p (

sin

gle

axle

)

Ce

ntr

al lu

brica

tio

n c

om

ple

te (

w/o

lu

brica

tio

n o

f th

e c

olle

cto

r) f

or

Big

Pa

ck 1

27

/12

8

Dis

trib

uto

r w

ith

pip

es

for

knotter

9/1

8

Dis

trib

uto

r w

ith

pip

es

for

pre

ss p

isto

n/c

on

ne

ctin

g r

od

4/8

Dis

trib

uto

r w

ith

pip

es

for

oscill

ating a

xle

/pic

k-u

p 4/7

Dis

trib

uto

r w

ith

pip

es

for

pic

k-u

p (

sin

gle

axle

) 3

/5

Main

dis

trib

uto

r

with

pip

es

for

do

ub

le a

xle

3/4

Lu

brica

tio

n p

oin

ts:

Sin

gle

axle

: 4

7

Do

ub

le a

xle

: 4

9

Main

dis

trib

uto

r

with

pip

es

for

sin

gle

axle

3/4

to dis

trib

uto

r

"e"

to dis

trib

uto

r

"c"

to dis

trib

uto

r

"b"

to dis

trib

uto

r

"a"

"a"

"b"

"c"

"d"

"e"

Ad

justin

g:

Ino

pe

rative

pe

rio

d:

0,5

h

Tim

e o

f lu

brica

tio

n: 1

0 m

in.

8.4.5 Lubrication scheme Big Pack 127 / 128

VIII - 11

Lubrication

Integrated electronic control unit S-EP 4 with data memory for pump type EP-1The electronic control unit S-EP 4 is used for control of a central lubrication system, governed according to operatingtimes, both for progressive systems (EP-1 pumps) and for multi-line systems (OC-1 pumps).

Sequence of steps of operation:

(Time of lubrication; inoperative periods): After ignition has been turned ON, the yellow LED will be lighted for approx.2,5 sec., this signalling that the system is ready for operation. If a function test is to be performed, an intermediatelubrication cycle has to be started by means of a push button at the engine housing or in the dashboard.

When that push button in the dashboard or at the engine housing is actuated, the time of lubrication is started and thepump is turned ON. After the time lubrication is completed, the pump motor will be turned OFF and the inoperativetime begins. All subsequent steps of lubrication will be started automatically in accordance to the rhythm of the pre-selected inoperative times.

If the ignition is turned off while an inoperative time or a lubrication cycle is going on, the time will be interrupted andstored in the memory. When the ignition is turned on again, the dates stored in the memory will be re-activated andthe sequence of operations will be continued at that point where it was interrupted before.

When the ignition is turned ON, an intermediate lubrication cycle can be started at any time by means of the pushbutton at the engine housing or in the dashboard.

Whenever the control unit is connected for the first time, a lubrication cycle will be started.Each control unit is equipped with a yellow LED, indicating the following functions:

8.4.6 Description of control

Ignition ON: Diode is lighted for approx 2,5 secLubrication cycle: Diode is flashing


Schmierzeit (min.)Pausenzeit (h)

KontrollLED

8

12

160,5

416

14 10

12

23

5

4

67

8

Drucktaster

Anschlußkabelca. 10 m

gelbeLeuchdiode

Push button

Connection cableapprox. 10 m

LED, yellow

VIII - 12

Lubrication

To enable setting of the time, remove the red frame, using a flat screwdriver, and detach the 4 crosshead screws.After that, the transparent cover can be removed, if the cover should not be closed in the correct way, water maypenetrate the system which then may be destroyed. In any such case, warranty claims cannot be accepted.

23

4

56

7

8

10,5

46

8

1012

14

16

21

812

16

2024

28

32

41

Inoperative period:0,5 h - 8 h

Adjusting KroneBig Pack 88 / 127 / 128 0,5 h

Time of lubrication:Time range I: 1 min. - 16 min.

Time range II: 2 min. bis 32 min.Adjusting KroneBig Pack 88 / 127 / 128 10 min

VIII - 13

Lubrication

8.4.7 Signals of control

Signals of the LED and the external signal lamp:

1,5 sec.

0,5 sec.

1 sec.

0,5 sec.

2 sec.

4 sec.

2 sec.

Signal of operating readiness:

Signals lubricating procedure:

MalfunctionOperation of electric grease level indicator

MalfunctionOperation of pressure relief valve

MalfunctionOverloading of the electric Motor

VIII - 14

Lubrication

50h

50h

10h

50h

50h

50h

5 x

200h

Lubricating points of the big square baler with centralised lubrication system (left-handmachine side)

Additional lubricating points which must be supplied with lubricant

VIII - 15

Lubrication

Lubricating points of the big square baler with centralised lubrication system (riht-handmachine side)


50

100

150

bar

50h

50h

50h

200h 10

h

VIII - 16

Lubrication

Lubricating points of the big square baler with Multi Cut pre-chopping mechanism andcentralised lubrication system (left-hand machine side)

50h

50h

10h

50h

50h

50h

5 x

200h


VIII - 17

Lubrication

Lubricating points of the big square baler with Multi Cut pre-chopping mechanism andcentralised lubrication system (right-hand machine side)

50

100

150

bar

50h

50h

50h

50h

50h

50h

10h


VIII - 18

Lubrication

IX - 1

Knotter

9. Knotter9.1 Special Notes on Safety

• All maintenance, adjustment and repair work on the knotter may only be carried out with themachine at a standstill. Switch off the engine and remove the ignition key.

• Lock the flywheel brake.• Lock the knotting initiating mechanism by locking the safety catch to prevent unintentional

initiation.

The closer (4) on the knotter hook (3) is tensioned withthe spring (2). The spring pressure can be adjusted witha hexagonal nut (1). If the clamping action in the knottermouth is too strong, the knot gets stuck in the mouth.The twine breaks. If the clamping action is too weak,either no knot or a loose knot is formed. These faultscan be avoided by correcting the spring tension on thespring (2).

9.2 The Knotter Hook

9.1.2 Start up

The knotter is set and checked by the manufacturer. Itshould operate correctly without any furtheradjustments. Should any problems with the bindingoccur during commissioning, the systems should notimmediately be reset as these are often faults causedby varnish, rust and rough spots.It is recommended to remove the antirust grease fromthe twine mount and knotter prior to commissioning.

BP 380-7-090

1

2

34

IX - 2

Knotter

9.4 The Blade LeverThe blade lever (2) must be positioned such that thetying hook (1) can rotate freely without touching any partof the blade lever (2).

9.3 The Twine Retainer

The adjustment of twine driver (5) depends on theposition of the notch relative to twine disc cleaner (7).The notch of twine driver (5) must be positioned asshown in the figure alongside (a = 2-3 mm), otherwisethe two twines fed by the needle cannot pass throughthe space between twine disc cleaner (7) and twineretainer (6). If the notch of twine driver (5) is positionedtoo far at the front (i.e. displaced in clockwise direction),the twine fed by the needle cannot be caught by thetwine driver. On the other hand, if the notch of twinedriver (5) is positioned too far at the rear (i.e. displacedin counterclockwise direction), the twines can becomeentangled around the knotter bill hook or be caught bythe knotter tongue.To adjust the carrier (5) the auger clamped on to onecone on the auger shaft must be loosened. To do thisthe hexagonal nut (4) is loosened to the point where oneof its faces projects approx. 1 mm over the end of theshaft. The auger comes loose when tapped lightlyagainst the hexagonal nut (4). The optimum position canbe found by making a corresponding rotation. The augercan only be turned when there is no twine in the twinemount.

The clamping strength is adjusted at the hexagonal nut(3) which tensions the helical spring (2) on the twineretainer. The twine retainer should clamp the twine justtightly enough for it not to be pulled out of the twineretainer during the tying process. If the clamping actionis too strong the twine is frayed. The clamping strengthshould be set proportionally to the increasing packdensity. The type and moisture content of the crop aswell as the choice of twine require different settings,which can be tried out under working conditions ifnecessary. The spring (2) must never be tensioned tothe length of the block.

It is necessary to perform at least twobinding processes before checkingthe position of the notch.

GERMANY

GGG 60

1

3

2

5

7

6

4

BP-VFS-314

a

BP 380-7-092

2

1

IX - 3

Knotter

The stripping comb on the blade lever (2) must touch therear of the knotter hook (3) lightly but uniformly. Thedistance between the stripping comb on the blade lever(2) and the tip of the knotter hook (1) should be"a" = 15 to 18 mm in the blade lever dead centre.The blade lever has reached the dead centre when theblade lever roller (1) (Fig. BP 380-7-093) is on thehighest point on the cam (1) (Fig. BP 380-7-094) in theknotter disc (2) (Fig. BP 380-7-094).

BP 380-7-094

2

1

BP 380-7-093

3 1

a

2

IX - 4

Knotter

The parts of the blade lever (highlighted area) whichguide the strands of twine must be smoothed androunded off to prevent the twine from being cut. Theblade lever should be replaced when there is any wear(grooves) on the highlighted area.

To adjust the blade lever (1), loosen the Knottingdevice's fixing device (3) on the bale channel and swingthe frame around the knotting device drive shaft. Forbending the blade lever (1) it is useful to make anapproximately 400 mm long straightening lever (2) like infig. BP 380-7-095.With heavy blade levers the lever must be removed andadjusted with a special tool in a specialist workshop.

9.5 Adjusting the blade Lever

The cutting edge of the twine blade must always besharpened as soon as the twine ends are cut unevenlyor become frayed. The blade must be replaced if brokenor excessively worn.

BP 380-7-095

3

2

1

BP 380-7-096

BP 380-7-097

X - 1

10. Over the Winter


• Secure the big pack baler and the tractor from rolling away.• After completing care and maintenance work, replace all protective plates and protective

devices again properly.• Avoid skin contact with oils, greases, cleaning agents and solvents.• In case of injuries or burns caused by oils, cleaning agents or solvents, seek immediate

medical attention.• Follow all other notes on safety to prevent injuries and accidents.

10.2 GeneralBefore putting the big pack baler away for the winter, clean inside and outside thoroughly. If using a high-pressurecleaner, do not direct the water jet at the bearings. Lubricate all lubrication points after cleaning. Do not wipe awayany grease coming out of the bearings. The grease ring provides additional protection against moisture.

Remove drive chains and chains for the chain coupling (then check packer setting) and wash in petroleum (do notuse any other solvent). At the same time check for wear on the chains and chain wheels. Oil the chains oncecleaned and then mount and tighten up again.Check that all moving parts such as deflection rollers, joints, tensioning rollers etc. can be moved easily. Ifnecessary dismount, clean, grease and remount. Replace with new parts if required. Only use genuine KRONEreplacement parts.

Take the PTO shafts apart. Lubricate the inner tubes and the guard tubes. Grease the lubricating nipple on theuniversal joint as well as the bearing rings on the guard tubes.

Park the big pack baler in a dry place away from artificial fertilisers and animal stalls.

Touch up the paintwork where required. Protect bare spots, especially the twine lugs, the knotter (knotter clamp andthe twine retaining disk) and the bale channel thoroughly with plant-based oils.

Only jack up the big pack baler with a suitable vehicle jack. Make sure that the machine is in astable position when jacked up.

Jack up the round baler to prevent damage to the tyres (damage to the tyres can occur when the round baler standsin the same position for a long time). Protect the tyres from the effects of oil, direct sunshine etc.

Release the parking brake and the flywheel brake. Drain condensation from the compressed air reservoir tanks.

Have the necessary repair work carried out in the time directly after the harvest season. Prepare a list of all spareparts required. By doing this it is easier for your KRONE dealer to process your orders and you can be sure that yourmachine will be in top condition for the start of the next season.


XI - 1

Putting into Operation Again

11. Putting into Operation Again

• The following always applies for all maintenance, assembly, repair and adjustment work:bring the machine to a standstill. Switch off the engine. Remove the ignition key. Apply theflywheel brake.

• Secure the tractor and the big pack baler from rolling away.• Avoid skin contact with oils greases, cleaning agents and solvents.• In case of injuries or burns caused by oils, cleaning agents or solvents, seek immediate

medical attention.• After completing care and maintenance work replace all protective plates and protective

devices properly.• Observe all other specific notes on safety.

11.2 General

• Before putting into operation again initiate the knotting process manually and turn the big pack baler round byhand. Check knotter and needle functions while doing this.

• Clean the knotter of protective materials (plant-based oils).• Grease all lubrication points and oil chains. Wipe away all excess grease from lubrication points.• Change the oil in all gearboxes.• Check for leaks in all hydraulic hoses and lines and replace if necessary.• Check the air pressure in the tyres and pump up if necessary.• Check all screws are fastened tight and tighten up if necessary.• Check all electrical connection cables and repair or replace if necessary.• Check all settings on the big pack baler and correct if necessary.• Check the comfort control functions.• Check the operation of the knotter shaft brake (to the right of the knotter shaft).

11.3 The Overload Coupling on the Flywheel

After long idle periods the surfaces inthe overload coupling (1) can becomestuck to the contacting surfaces. Freethe overload coupling before use.

The overload coupling is located on the flywheel (3). Toventilate, tighten the nuts (2) on the overload coupling (1)diagonally. Turn the PTO shaft manually. Then loosenthe nuts again diagonally.

BP380-7-099

1

3

2

2


XI - 2

Putting into Operation Again

XII - 1

Special Equipment

12.1 MultiCut cutting system

The following always applies for all maintenance, assembly, repair and adjustment work:• Bring the machine to a standstill.• Switch off the engine and remove the ignition key.• Secure the tractor and the Big Pack baler from rolling away.• Secure the pick-up against intentional lowering.• There is a high risk of injury when fitting and removing the blades. Only touch blades

with suitable gloves.• Engage the flywheel brake.

12.1.1 Special notes on safety

12.1.2 General

The Big Pack MultiCut has a cutting system with a cuttingroller and fixed blades.Cutting allows better bale processing and increased baledensity. The blades can be swung out of the conveyorchannel hydraulically from the tractor if there are blockages.The machine can also be used without blades. The cuttingroller then takes over the conveying function between thepick-up and pre-baling channel.

The Big Pack MultiCut 88 cutting system can be equippedwith a max. of 15 blades. The Big Pack MultiCut 128 andBig Pack MultiCut 127 cutting system can be equipped witha max. of 25 blades. Theoretically cutting length is 45 mm(Adjustment "45" on the selector disc). A cutting length of"90 mm" can be achieved with two of the blade sets. Thecutting length can be read off the selector disc (1).

The cutting length is determined by the number of bladesused:

• Big Pack MultiCut:

Cutting length Number of blades SettingBP 88 BP 127/128

– 0 0 "0"45 mm 15 25 "45"90 mm 8 13 "90"90 mm 7 12 "90"

12.1.3 Setting the cutting length

1

"0"

BP380-7-103

BP380-7-104

The setting is made on the left-hand side of the machineusing a special spanner (1). The spanner is on the left-hand side of the machine in the twine box (2).Blades have to be removed for a greater cutting length.

12. Special Equipment

XII - 2

Special Equipment

BP-VFS-031

The blade control shaft must besecured using the locking leveronce the setting has been made.

Setting the cutting length

Turn the locking lever (3) to the right.(selector disc unlocked.)Fit the special spanner (1) onto the blade controlshaft (2) and turn it in the direction of the arrow.

Turn the blade control shaft (2) to the desired positionusing the special spanner (1). (Here 45 mm cuttinglength)The locking lever (3) must be turned to the left until itclicks in.

The outer blades must be removed theouter edges of the bales becomeunstable.

BP380-7-105

XII - 3

Special Equipment

BP-VFS-031

1

BBP-VFS-032

A

The cutter system blades can be reached fromunderneath the machine.

12.1.4 Changing blades

Clean the conveyor channel beforechanging the blade.

Put the blade control shaft into an inter-mediate position

An intermediate position is a settingbetween 2 control settings.

Turn the locking lever (3) to the right (selector discunlocked).Turn the blade control shaft (2) to an intermediateposition using the special spanner (1).

Unlocking the blade shaft

Pull out the retaining pin (1).Swing the safety lever(2) to position "B" until theretaining pin (1) clicks in.

Position "A": knife shaft lockedPosition "B": knife shaft unlockedIf the knife shaft should be difficult to turn use open-ended wrench "24".

Changing bladesLift knife (1) at the rear (I) and pull it to the top (II) untilit comes clear of its mounting. Then swing knife to thebottom and to the front (III) and take it out ot the rear(IV).Install the new knife and secure the knife shaft again(Position "A").

KB802177

KB802178

XII - 4

Special Equipment

Switching blade control shaft offmechanically

12.1.5 Blade stop

The blade control shaft (2) can be brought into the zeroposition using a hydraulic cylinder (1).

Switching blade control shaft offhydraulically

The hydraulic cylinder is operated from the tractor. Thezero position is indicated on the comfort control.

The hydraulic blade stop is used,amongst other things, to eliminate anyblockages.

After a prolonged operation of thehydraulic zero blade setting it mayhappen that the blades slowly returninto the channel (this can be causedby an oil leakage of the tractor). It istherefore recommended to switch offthe blade control shaft mechanically.

Do not activate the hydraulic zeroblade setting if the blade controlshaft is switched off mechanically.

Unlock the locking lever (3).Turn the blade control shaft (2) to an intermediateposition using a special spanner.

If the Big Pack MultiCut is to beoperated for a long time without acutting system, we recommendremoving the blades. (see Chapter12.1.4)

12

3

BP380-7-111

BP380-7-112

XII - 5

Special Equipment

12.1.6 Setting the blade control shaftsensors

12.1.7 Setting the blade protection system

The sensor (2) is only used to send a signal to thecomfort control. Blade operation is indicated on thecomfort control.The sensor (2) is on the left-hand side of the machine onthe blade control shaft. Distance (x) should be3 mm.

Loosen the lock nuts (1).

Set the sensor (2) so measurement (x) = 3 mm andtighten lock nuts (1).

The blade protection system should prevent the bladesbecoming damaged. To cut tough crop the bladeprotection system should be set harder. Set the bladeprotection system softer when there are a lot of stonesin the crop.The projection of the blade (1) over the blade controlshaft cam (2) should be (a) = 15 to 18 mm.

The pretensioning of the blade protection system is setusing the screw (3).

Loosen the lock nut (4).Set the blade control shaft (5) so measurement(a) = 15 to 18 mm using the screw (3).Tighten the lock nut (4).

Softer blade protection (a) = 18 mm.Harder blade protection (a) = 15 mm.

12.1.8 Locking the free-wheel

If the cutting rotor should become blocked with feed, thisblockage can be removed by turning back the cuttingrotor. Here the free-wheel must be locked in the cuttingrotor gearbox.

Procedure:• Move all cutting blades to 0 position• Shut down the engine - remove the ignition key• The free-wheel of the cutting rotor becomes locked

by pulling the handle (1) and simultaneously movingthe control lever (2) from position A to position B onthe cutting system gearbox.

BP380-7-113

BP380-7-114

45

3

BP380-7-115

BP380-7-1161

2

XII - 6

Special Equipment

BP-VFS-034

21

3 42

If the big pack baler is fitted with hydraulic brakes, thecompressed air for cleaning the knotter is supplied via acompressor (1) mounted between the hitch supports. Itis driven by a V-belt disk (3) and V-belt (2) mounted onthe flywheel. The tension of the V-belt can be adjustedby shifting the compressor in the slots (5).The oil level must be checked at the dipstick (4) everyday before use. Top up with oil (engine oil SAE 20) ifnecessary. The specifications for the oil required arelisted in the section "Technical Data".

12.2 Compressor

The air inlet filter (6) should becleaned at least once a day and incase of heavy dust loads several timesa day.

• Move the retaining clip (2) on the air filter (1) up/down• Remove cover (4)• Dismount filter cartridge (3), tap it and with blow

through from the inside outwards with air jet• Dismount cover (4) again and tap it• Install filter cartridge• Put cover on filter and secure with retainng clips

Make sure that the filter pot with the airfilter locks tightly. Please follow the„oben (top)“ marking.

Filter cleaning

• Let the control lever (2) engage in position B• Turn back flywheel until the blockage is removed.

When you start up the machine again the free-wheelswitches on automatically. The control lever (2) goesback into basic position A.

BP380-7-117

2

BP-VFS-033

1 4

2

3

6

5

XII - 7

Special Equipment

12.3 Swath Distributor

12.3.1 Assembly Instructions

1) Lateral limiter (left)2) Hydraulic hoses (pressure and reverse-flow hose)3) Lateral limiter (right)4) Hydraulically driven swath distributor

To be able to distribute narrow swaths along the totalwidth of the pick-up, the hydraulically driven swathdistributor is available as an accessory.

Swath distributor is not fitted at the factory.


• Only put the big pack into operation when all protective devices have been attached and arein a proper operating condition.

4

2

1 3

BP380-7-120

XII - 8

Special Equipment

Hydraulic hose connections

Connect the pressure connection to a single-actioncontrol device. Connect the reverse flow to a pressure-free reverse-flow connection.

A hydraulic connection with continuous oil supply andnon-pressurised reverse-flow is required on the tractor.The amount of oil must not exceed 20 litres per minute.

Lubrication points

All repair, maintenance, servicingand adjustment work may only becarred out when the machine is at astand-still. Switch off the engineand remove the ignition key.Engage the flywheel brake.

50h

BP380-7-123

Lateral limitation

• Lift the swath distributor (1) from below to thedrawbar (3)

• Place swath distributor with screws (2) on drawbar(3)

• Line up the swath distributor in the centre in front ofthe pick-up

• Tighten the screws• Install the protective plate above the drive

Installing swath distributor

• Push in the lateral limiter (4) on both sides with thesupport (3) in the rectangular pipe (1)

• Adjust the range of the pick-up width and undo thescrews (2)

• Set the lateral limiter according to the pick-up width• Tighten the screws

1

2

3

2

BP380-7-121

BP380-7-122

4321

XII - 9

Special Equipment

12.4 Hydraulic folding bale chute with rollers

Secure the vehicle and machine against rolling away.Keep people clear of the danger zone when folding the bale chute in and out.Only drive on public roads if the bale chute has been folded in.

A hydraulic folding bale chute (4) with seven rollers (3) isavailable for the Big Pack as an optional extra. Operati-on of the residual bale ejector from the rear right-handside of the machine is also part of this option.The bale chute is held in working position by retainingchains (2). When folded down the front and rear parts ofthe bale chute are interlocked. The bale chute can beset using the adjust-ing screws (1) so that it is at thesame level as the baling channel floor. Otherwise thelock will not work properly.

The hydraulic line control unit on the tractor must be setto lift so the bale chute and the residual bale ejector canbe operated.The control unit (3) for the hydraulic folding bale chuteand the residual bale ejector is between the mainten-ance platform (2) and the wheel chock (1) on the right-hand side of the machine.

BP380-7-124

BP380-7-125

XII - 10

Special Equipment

Folding the bale chute in and out

The residual bale ejector is operated using the right-handoperating lever.Lift the safety collar (1) and move the operatinglever (2) to position (A) or (B).

Position (A): residual bale ejector moves forwardsPosition (B): residual bale ejector moves backwards

4

I

II

BP-VFS-317

BP380-8-126

BP380-8-127

• To unfold bale chute (1) move control lever (3) toposition (B).

• To retract bale chute (1) move locking lever (4) fromposition II to position I

• and move control lever (3) to position (A).• The bale chute is folded into transport position and

the locking lever automatically locks intoengagement.

Release lock (4) to move the roll-type bale chute toworking position.

To do this:

• Slightly press the roll-type bale chute (1) against themachine.

• Move locking lever (4) from position I to position II.

Once unlocked, the roll-type balechute starts lowering as a result of itsdead weight.

XII - 11

Special Equipment

12.5 Wide pick-up

Transporting the Big Pack 127 and 128 with wide pick-up (2.4 m) on public roads is onlypermissible with retracted gauge wheels. Observe the type approval requirements!

Folded in the gauge wheels

• Remove pin (1).

• Release the perforated strip from pick-up (2).• Swing the gauge wheel bracket to the top and the rear

(3).

BP380-7-128

3

2

BP380-7-129

XII - 12

Special Equipment

with cutting mechanism MultiCut

• Place the gauge wheel bracket into its support (4).• Secure the bracket by installing pin (5) in the lower

hole (7).

Standard

• Place the gauge wheel bracket into its support (8).• Secure the bracket by installing pin (5).• Put the perforated strip (6) towards the front in the

direction of travel.

4

5BP380-7-130

8

5

6

BP380-7-1317

The use of this drawbar eye is only permitted in someexport countries. Height adjustment see Chapter 2.2.

Please observe permissible drawbarload.

12.6.2 Hitch Coupling

Height adjustment see Chapter 2.2.

Please observe permissibledrawbar load.

12.6.1 Pivoting drawbar eye

12.6 Further coupling options

XII - 13

Special Equipment

12.7 Double knotter12.7.1 System operation

During the baling process both a top and bottom skeinare fed to the bale. They are knotted together at the start(start knot) and at the end (end knot) of each bale.The bottom skein is fed through the needle via atensioning system. It encloses the bottom and the twoends of the bale, while the top skein is fed directly to thebale via a tensioning system and covers only the top ofthe bale.The twine supply required by the bottom skein isapproximately double the requirement of the top skein.

12.7.2 Tying process

The tying needle is equipped with a moving roller at thepoint and another moving roller immediately below thefirst roller.The second roller guides the skein coming from belowthe bale. The first roller on top at the needle point holdsthe skein coming from the top and feeds it with thebottom skein into the knotter where both are knottedtogether.The double knotter operates in the same way as aconventional twine knotter. The only difference is thatthe knotter discs have two rows of teeth, which allowactivation of the knotter hook, carrier plate and bladelever twice during one complete knotter shaft rotation inorder to tie two knots.

1 Knot at the rear end of the bale (start knot)

2 Bottom skein3 Roll of twine4 Plunger5 Top skein6 First knot in the tying process, located at the end of

the completed bale (end knot)7 Second knot in the tying process, located at the

start of the new bale (start knot)7

4

1

5

6

3

3 BP-VFS-035

2

XII - 14

Special Equipment

12.7.3 Inserting the twine (Double knotter)

Inserting the twine see Chapter 5.4.2.All differences are listed here.

During the bale tying cycle, two skeins are fed to each ofthe six (4) knotters. One skein is fed through the needlesfrom the bottom and the second one directly to the balefrom the top.

Tying the rolls of twine together (see alsoChapter 5.4.1)

The rolls of twine are connected innumerical order. Please note theinformation in Chapter 5.4.1!

Big Pack 88 (left hand side)

Big Pack 127/128 (left hand side)

The rolls of twine, which are in front, in the direction oftravel, supply the top thread and lead to the knotters (1).The rolls of twine, which are in the back, in the directionof travel, supply the bottom thread and run to theneedles (2).

Machine type Number of Number of rolls of Number of rolls of Spareknotters twine per knotter twine per knotter

(bottom twine) (top twine)

Big Pack 88 4 4 2 -

Big Pack 127 / 128 6 2 1 6

1

BP-VFS-3152

BP-VFS-316

1

2

XII - 15

Special Equipment

Bottom skein (left side)

The twine (1) is inserted into the brake (4) through theeyes (2) of the twine box via the twine guide (3). Fromhere, it runs to the bottom of the bale via the eye of thetension spring (5) through the rollers of the knotterneedles (6).

If the baler is empty, the top and bottom skein can beknotted together in the center of the bale chamber.

If there is a bale in the channel, the bottom skein is tiedto the hook (7).

BP-VFS-040

Top skein

The twine (1) is inserted into the brake (4) through theeyes (2) of the twine box via the twine guide (3). Fromhere, it runs to the top of the bale via the eye of thetension spring (5) through the rollers of the insertion arm(6).

If the baler is empty, the top and bottom skein can beknotted together in the center of the bale chamber.

The top skein is guided underneath the rear crossbar (7)of the knotter mechanism and attached to the frame atan appropriate position. This could be the hinged bolt (8)of the top tension flap for example. The thread must besecured so that the tension arm (5) is under tension. Cutoff thread at the hinged bolt after completion of the nexttying process. Alternatively, the loose end of the topthread may be pressed into the bale. To do this, guidethe twine through the rollers of the insertion arm (6) andlower approx. 50 cm of twine into the baling channel.When continuing the baling process, the thread getscaught in the bale pulling the tension arm down. It isimportant that the tension arm is under tensionimmediately prior to the start of the tying process.

BP-VFS-039

BP-VFS-094

XII - 16

Special Equipment

The following faults may be displayed:

The twine flow display remain on the top:- The twine is wrapped around the knotter hook.- The needle did not pick up the top thread (twine will

not be cut)- The knot got caught on the knotter hook (after

completing the tying, one twine flow display remainslonger at the bottom than the others do).

The twine flow display remains at the bottom:- The twine tension is too low.- The top skein snapped.- The knotter hook did not tie a knot.

12.7.4 Twine flow display

The bottom skein is electronically controlled (Chapter5.4.3 Electric twine fault display).The run of the top twine can be monitored by reflectors(twine flow display), which are attached on top of themachine.While baling, the twine flow display should move backand forwards, reciprocating.In general, all indicators raise and drop at the sametime, unless a malfunction occurs. A malfunction isshown if the indicator of the faulty twine flow is not in thesame position as the other indicators.

XII - 17

Special Equipment

12.7.5 Settings

This chapter only describes the settings, which differfrom those of the single knotter. For informationregarding the settings refer to the appropriate chapters.

Twine tension on the top skein

The brakes (2) should retain the top skeins (1) at amaximum tensile force of 60 – 80 N.Before the twine brakes allow the twine slipping through,the twine tension arm (3) should move down against thespring resistance until the twine (1) is guided through theeye of the tension arm (4) without much deflection.Checking the twine tension:Tie the thread (1) to a spring scale. The spring scalemay display 60 – 80 N immediately prior to the slippingthrough of the thread.

The tensile force can be increased by tightening thethumb nut (5). Release the thumbnut to reduce thetension.

BP-VFS-041

Twine tension on the bottom skein

The twine brakes are located at the rear wall of the feedchannel. The adjustment of the braking effect is identicalto the settings on the top twine brakes.

Checking the tensile stress:

1. Thread the twine according to the instructions.2. Initiate the knotting process manually.3. Turn the flywheel manually in working direction until

the tying needles have reach their top dead center4. Pull approx. 200 mm of twine out of the needle and

cut it.5. Pull the skein slowly and evenly until the twine

tension springs reach their highest position under thechannel.

6. While holding the twine, the twine tension springsmust remain in this position without the twine beingable to be tightened by the brake.

7. With slight increase of the tensile force the brakemust allow the twine to slip through.

BP-VFS-042

XII - 18

Special Equipment

Adjusting the twine bar

Initiate the tying process manually (see Chapter 5.4.4Initiating the binding process manually). Turn theflywheel in working direction. The needles moveupwards. At the same time the twine bars move over theopenings through which the needles thread the twine tothe knotter.

If the twine bars (1) are in the center of the openings, thedistance between the tip of the twine bar and the insideof the needle (2) must be b = 10 – 15 mm.Continue tying by turning the flywheel. Once the firstknot (end knot) is completed, the needle moves downagain and the insertion arms are inserted in the channelslots at their lowest point. Then the twine bars moveover the openings again.When the twine bars pick up the twine, they must have aminimum overlap of 10 mm (the twine must be picked upat least 10 mm from the twine bar tip).

The adjustment is made by releasing the screws (4) and(3) on the twine bar (1). Shift the twine bar in the slotuntil both requirements are met.

The setting for the side clearance „a“ is adjusted at thecontrol rod assembly (5) of the twine bar (1). To makethe adjustment release the self-locking nuts (6) and takeoff the ball head (7). Twist the control rod until the „a“dimension is set at 5 – 10 mm. When the twine bar ispressed in the direction of the slot, the „a“ dimensionmust still be maintained. Then tighten the self-lockingnuts again.

1

2 BP-VFS-044

3 4

1

BP-VFS-045

5 6

7

Tying needle - insertion arm alignment

The centerlines of the insertion arm rollers should run atan offset of a = approx. 3 mm to the left of the needlecenter, so that the insertion arms are set with a safetymargin of b = 1-2 mm to the left side of the channel slot.This can be achieved by using shims at the ends of theinsertion arm shaft.If this offset cannot be obtained at individual insertionarms, these must be readjusted.

BP-VFS-043

XII - 19

Special Equipment

12.8 Trouble-shooting for the double knotterWe know from experience that a large percentage of binding problems are caused by insufficient twine tension.Check the twine flow and twine tension prior to commencing work.

The most common faults including their causes are listed below and some information regarding remedial actions isprovided. Otherwise, the chapter in which the relevant subject is explained is mentioned.

Disengage the PTO shaft, turn off the tractor motor, apply the flywheel brake and lock the safety lever for the bindingrelease prior to completing maintenance work or adjustments.

Nr.

1

2

Fault

Frequent breaking ofthe knotter latch

Knot gets caught onthe knotter hook.

Possible cause

Second knot getting caught onthe knotter hook

Twine tension on the bottomskein too low

Twine tension on the top skeintoo low

Blade lever has axial play

Excessive tension on theknotter latch

Twine carrier plate too faradvanced

Blunt stripping blade

Stripping arm too far from theknotter hook

Worn or rough spots on theknotter hook

Remedy

See no. 2

Check and correct the bottom twine flow.Readjust the twine brake below the twineboxes.Remove the dirt accumulated between theplates and the twine brake. Replacebroken springs and worn plates.Checktwine tension spring and twine flow.

Check and correct the top twineflow.Tighten the spring of the twine brake.Remove dirt accumulated in the top twinebrakeReplace broken wheels or worn brakewheels

Tighten nut of the blade lever axis,otherwise replace blade lever

Slightly release tension on knotter latchspring

Check setting, reset as required

Adjust or sharpen cutting blade or replaceit if required

Bend the stripping arm so that the armswings 15 – 18 mm above the knotterhook in its dead center position

Remove rough spots, otherwise replacefaulty parts

Kap.

6.4

12.7.5

9.3

9.4

9.2

9.3

9.4

9.4

9.2

XII - 20

Special Equipment

Nr.

3

4

5

6

7

Fault

First knot: (end knot)only on the top skeinavailable

Second knot: (startknot) knot only on thebottom skein available(no knot in the topskein)

Second knot: (startknot) knot only on thetop skein available (noknot in the bottomskein)

Second knot: (startknot) twine wrapsaround the knotter

First knot: (end knot)twine wraps aroundthe knotter

Possible cause

The twine bar did not grip thebottom skein.

The distance between the twinebar and the insertion arm is toolarge, so that the twine bar couldnot grip the top skein.

Spring of the top tension armbroken or unhooked

Control of the insertion armfaulty. Roller does not follow thecam disc.

The bottom twine tensionsprings do not operate properly.

Overrun of the needle in topdead center position too small.

Twine bar does not workproperly or is wrongly adjusted.

Top twine tensioning devices donot operate properly.- Tensioner is jammed- Insufficient tension

Bottom twine tension springbroken or detached.

Insufficient twine tension on thebottom skein.

Twine carrier plate starts toolate.

Incorrect adjustment of thetwine bar in relation to theinsertion arm.

Twine carrier plate starts toolate.

Needle does not grip top skeinproperly.

Remedy

Readjust the twine bar.Check the needleadjustment.

Adjust the twine bar towards the insertionarm.CAUTION: When adjusting the twinebar, check that both the insertion arm andthe needle have the correct distance to thetwine bar. If correct adjustment is notpossible, please check needle deviation.

Replace or reattach spring.

Replace roller or ensure smooth running ofthe insertion arms. Check spring.

Check clearance of the bottom twinetension springs. Increase bottom twinetension.Check needle setting

Check the adjustment in relation to theinsertion arm (see above).

Check that top twine tensioning device runssmoothly.- Clear tensioner- Increase tension

Replace or reattached spring.

See fault no. 2

Advance the twine carrier plate by turningclock-wise.

Check the twine bar setting, adjust insertionarm if required.

Advance the twine carrier plate by turningclock-wise.

Check needle setting. Adjust the insertionarm in relation to the needle

Cha.

12.7.5

12.7.5

12.7.5

6.11

6.2.3

12.7.5

12.7.5

6.11

9.3

12.7.5

9.3

12.7.5

XII - 21

Special Equipment

Nr.

8

9

Fault

No knot availableneither in the top norbottom skein

Knot ends too short.Sometimes the knotcomes undone (ingeneral the secondknot)

Possible cause

The twine bar is not activated.

Damaged knotter latch.

Insufficient tension at knotterlatch.

Twine retaining spring too tight.

Skeins are cut in the twineretainer.

Knotter hook does not turn.

Twine retaining spring too tight.

Twine retaining spring too loose,so that the knots are tied tooloose and slip through.

Twine tension not correct

Insufficient tension at knotterlatch.

Remedy

Check the twine bar mechanism and itssetting.Replace knotter latch.

Increase tension at the knotter latch

Check the setting for the twine retainingspring.

Remove accumulated dirt and chaff belowthe twine retaining springs.

Replace the pin of the knotter hook drivingwheel.

Tighten the twine retaining spring nut

Release the twine retaining spring slightly

Check twine flow.In general, the twinetension should be increased to obtainlonger knot ends.

Increase tension at the knotter latch bytightening the spring nut slightly.

Cha.

12.7.5

12.7.5

12.7.5

9.2

9.2

9.3

9.2

9.2

9.3

9.2

XII - 22

Special Equipment

XIII - 1

Faults, their Causes and Elimination

13. Faults, their Causes and Elimination

• The following always applies for all maintenance, assembly, repair and adjustment work:bring the machine to a standstill. Switch off the engine. Remove the ignition key. Apply theflywheel brake.

• Secure the tractor and the big pack baler from rolling away.• Use the knotter safety mechanism to secure the knotter from being activated

unintentionally.• Lock the brake on the flywheel hydraulically or mechanically.• Avoid skin contact with oils, greases, cleaning agents and solvents.• In case of injuries or burns caused by oils, cleaning agents or solvents, seek immediate

medical attention.• After completing care and maintenance work replace all protective plates and protective

devices properly.• Observe all other specific notes on safety.


13.2 Needle Yoke Does Not Go Up

The connecting rod (1) for the needle yoke is securedwith a shear bolt (2). Check whether the shear bolt isbroken. If necessary replace with a M10 x 60,DIN 931-10.9 bolt.

Only use genuine KRONE replacementparts.

An error message on the controlpanel and a horn alert indicate theerror.

BP380-7-133

1

2

XIII - 2


13.4 Failure of Regulation of the Baling Thrust

• In emergencies, the pressure adjustment for the bale channel flaps is made while themachine is running. Particular care is required when making the adjustment. High risk ofinjury! Make sure that the machine can be switched off immediately in case of danger.

• The big pack baler can be operated temporarily in emergency mode if the regulation of thebaling thrust should fail.

• Without the regulation of the baling thrust, the maximum baling pressure may be exceeded.This can lead to serious damage. Never work for long periods without the electronic control.

To adjust:

The baling pressure of the bale channel flaps is adjustedat the hydraulic control block (1) on the right hand side ofthe machine underneath the knotter shaft.

• Unplug the on-board electronics!• Loosen the self-locking nut (2) on the knurled

screw (3).• Take out the knurled screw (3) completely.• Screw in screw (4) completely.• Set the desired pressure by slowly screwing in the

knurled screw (3).• Read the pressure above the control block.• Tighten up the self-locking nut (2) again.

13.3 Packer Drum

The packer drive is protected from overloading with aspring-loaded ratchet clutch inside the gearbox. If theclutch is activated, switch off the PTO shaft imme-diately. Stop the tractor and the machine. Allow the bigpack baler to come to a standstill. Do not brake theflywheel.If the blockage has not cleared itself with the machinerunning on, turn the flywheel back by hand and removethe blockage or foreign body.

Work can be resumed once the blockage has beencleared completely. The ratchet clutch switches on againautomatically.

BP380-7-136

3

2

1 4

An error message on the controlpanel and a horn alert indicate theerror.

XIII - 3


Fault

Horn and indicator lamp for the twine error display notactivated at end of twine or when twine broken.

Horn and indicator lamp for twine activated.

Plunger / binding mechanism jams.

Needles fall back.

Packs too loose.

Packs too firm.

Rake jams.

Pick up jams.

Cutting rotor and pick up stop.

Knotter jams.

Needle yoke jams. The needle yoke alarm is activated.

The most frequent knotter faults have trivial causes andyou can correct them yourself in many cases.The errors can often be found in the twine quality,twine guiding, twine tension, positions of the bindingneedles or twine bar.

The following fault diagrams are intended to identifythe cause of the fault.

Too loose a knot with two cleanly cut ends.

Cause / Remedy

1. Cable connection, 3-pole plug to tractordefective.

1. Twine broken, twine tensioner in contact with theangular rail.

2. Twine used up. Thread new twine.

1. Stop the tractor immediately.2. The cam-type cut-out clutch in the flywheel disc

locks into place at low speeds.3. Reduce the baling pressure.4. Check the tractor PTO shaft speed.5. Pull the needles out of the bale channel, replace

the shear bolt in the knotter and needle drive ifnecessary.

1. Tighten up the knotter shaft brake more firmly.

1. Increase the baling pressure.

1. Reduce the baling pressure.

1. Ratchet clutch is slipping - reduce engine speed.2. Stop the tractor and the machine and clear

blockage.3. Reduce forward driving speed.

1. Ratchet clutch in the drive PTO shaft disengages -switch off the PTO shaft drive and clear blockage.

2. Reduce forward driving speed.3. Drive centrally over the swath.

1. Blockage in the area of the rotor. Cam clutch in therotor drive train disengages.

2. Reduce engine speed. Clutch engages againwith reduced speed.

3. If the rotor can be released on its own, stop thetractor and machine and clear blockage.

4. Reduce driving speed.

1. Shear bolt in the knotter drive has sheared off -eliminate the cause - replace the shear bolt.

1. Shear bolt in the needle drive connecting rod hassheared off - eliminate the cause - replace theshear bolt.

1. Tighten the spring on the knotter hook or replace.

13.5 Further Faults

XIII - 4


Fault

Knot tying mechanism (twine has snagged on theknotter hook and is broken.)

Knot tied: one knot end longer than the other or thelonger of the two ends tied into the knot.

Cause / Remedy

1. Readjust the twine brake, clean or replace ifnecessary.

2. Readjust the knotter shaft brake.3. Remove tangled twine.4. Straighten the pack initiating mechanism.5. Check the twine bar – readjust.

1. Sharpen or replace blunt or jagged twine blades.2. Too little tension on the closer – tighten up spring

with hexagonal screw (do not tighten up on block).3. Too little tension on the twine retainer – tighten the

springs by tightening up the hexagonal screw (donot tighten up on the block).

4. Worn twine carrier or twine retainer – replace parts.5. For too great a pack density – reduce baling

pressure.6. For too great a twine tension – loosen the twine

brake on the twine box.

BP 380-7-137

BP 380-7-138

XIII - 5


Knot ends frayed.

Knot only in the strand of twine guided upwards by theneedle.

Knot only in the strand of twine running into the upperside of the pack.

No knot or a knot with very short ends which mostlyslips through the knot loop.

1. Blunt twine blade – sharpen the cutting edge of thetwine blade or replace blade.

2. Too little tension on the twine retainer – tighten thesprings by tightening up the hexagonal screw (donot tighten up on the block).

3. For too great a pack density – reduce balingpressure.

4. Worn twine carrier or twine retainer – replace parts.

1. Binding needle in wrong position – change theposition of the binding needle on the yoke.

2. Twine bar in wrong position – adjust the position ofthe twine bar on the bale channel.

3. Wrong path of swinging twine bar – adjust the strutsto the twine bar.

4. Broken or deformed retaining springs in the upperchannel cover – replace springs.

5. Twine tension too low – tighten the springs on thetwine brake.

1. Tension on the closer for the knotter hook toolow – tighten up the closer for the knotter hook.

2. Worn knotter hook – replace knotter hook.3. Tension on the twine retainer too high – loosen

the springs with the hexagonal screws.

1. Tension on the closer for the knotter hook toohigh – loosen the closer for the knotter hook.

2. Too great a distance between the stripping comb onthe blade lever and the back of the knotterhook – position the blade lever by hitting lightly witha hammer.

3. Rough surface on the knotter hook – replace theknotter hook.

4. Twine bar setting not correct – correct it.

Fault Cause / Remedy

Knots hanging on the knotter hook.

BP 380-7-139

BP 380-7-140

XIII - 6


5. Blade lever scraping distance too low (the bladelever can be deformed if the twine blade is blunt) –remove the blade lever and position, replace ifnecessary; check the cams on the knotter disc forwear, replace disc if necessary.

6. Twine tension too low – increase pack density.Tighten up the twine brake on the twine box(1–2 revolutions), increase the pack length.

Twine guide edges on the blade level rough –smoothe edges.

Twine guide edges rough.

Eye of binding needle rough or worn – smootheedges.

Rough twine guide edges in the lower section of thebaler needle – smoothen edges.

Cause / Remedy

1. The twine was not inserted in the twine retaineras the distance between the needle and the twinecarrier is too great – correct the position of thebinding needle.

2. Twine carrier and twine retainer form no openingfor the twine collection – correct the position of thetwine carrier, replace worn carrier pin.

1. Too large a gap between the strripping comb onthe blade lever and the back of the knotter hook –position the blade lever by hitting lightly with ahammer.

2. Tension on the twine retainer too great – loosenthe springs with the hexagonal screw.

3. Density force too high.

Knots hanging on the knotter hook.

Twine breaks or shows signs of chaffing:

1. directly beside the knot.

2. 40 - 50 mm from the knot.



Fault

Twine round a wrongly tied pack knotted to the twineof the previous pack.

Twine breaks inside the knot.

XIII - 7


Fault

Blockage in the system or in any connectedbearings.

Hand-actuated systems.Hand lever cannot be moved or is hard to move.

Blockages in the Distributor

If no lubricant comes out of the outlets after allthe outlets on the main distributor and/or the sub-distributor have been taken off, the distributor isblocked.

13.6 Finding Errors in the Central Lubrication System

Eliminating the Fault

Establishing the Causes of Blockages and EliminatingThem.

PROCEDUREFirst check whether the transport pump is working and isproviding the distributor with lubricant. To do this take off thepump outlet and switch on the pump. If the pump is workingproperly connect the pump outlet again. (Conclusion: the pumpis in perfect condition.)

Let pump run until the next blockage occurs or the nextunacceptable pressure increase occurs. Let the pressureremain.Loosen the inlet screw fittings on the sub-distributor or the maindistributor one after the other. For single-stage systems loosenthe inlet screw fittings one after the other.The distributor which suddenly leaks lubricant when the screwfitting is loosened unter pressure leads to the source of thefault.The screw fittings should then be tightened up again. Thepertinent bearing inlet screw fittings should then be loosened oneafter the other. The bearing whose inlet screw fitting leakslubricant when loosened under presure is the bearing which isblocked. Clear the blockage.

Replace the blocked distributor.If necessary the distributor can be cleaned under the followingconditions.A clean working area must be available.Remove all pipe connection screw fittings.Remove the piston screw plug with a strong screw driver. Ifloosen by striking the screw with a hammer.Die piston should be removed with a soft mandril (with less than6 mm Ø, if possible plastic).Very important: A record should be kept of which piston belongsto which drilling so that the pistons cannot be mixed up.Clean the distributor body several times with grease-solublecleaning agent and blow dry with compressed air.There are inclined channels with a diameter of 1.5 mm locatedat the ends of the thread on the piston screw openings, whichshould be cleared with a piece of wire or a pin.Clean and blow dry the distributor again.Congealed grease may have formed in the piston screw plugs,which should be removed.Re-assemble the distributor, at the same time replacing allcopper strips.Before screwing in the pipe oputlet fittings, oil (if possible) shouldbe pumped through the distributor several times with a handpump or similar.The pressure in the distributor should not exceed 25 bar. Apressure higher than this means that the distributor was notcleaned properly or that the piston openings are damaged. If thedistributor operating pressure does not fall below 25 bar in spiteof remedial action, the distributor should be replaced.

XIII - 8


A - 1

Appendix

A1 Integrated Diagnostic Program – Comfort Controls

The integrated diagnostic program is an integral part ofthe comfort controls.The diagnostic program enables you to check the electri-cally and electronically operated components on the bigbaler and their power supply. You can also modify thefactory-preset basic settings.

This technical documentation describes the technicaldata of the time when it was drawn up. Subject to tech-nical alterations. When allocating the plug and cabledesignations please always observe the currentindication in the comfort control display.

If errors should occur in theprocessing sequence, always checkwhether there have been anyoperating errors first. Observe theoperating manual!

If it is possible to localize an error onthe machine and if according to visualexami-nation the error correctiondoes not seem easy, please contactyour service partner!

Do not carry out any technicalmodifica-tions on the machine. Thismay cause damage to the machine orsafety equip-ment!

A1.1 General Information

A - 2

Appendix

A1.2 Sensor TestChecking and adjusting the sensors and valves usingthe diagnostic program:

• Actuate the key and hold it down.

• Actuate key.

• Release the key once „Sensortest (sensor

test)“ appears on the display.

• Use the key to browse in the diagnostic

program.

A1.2.1Auto Sensor Test

• Actuate key.

No check of the mechanical setting (no functional test).All machine sensors are checked electronically.

This message is displayed on the control panel if noerror is detected during the auto sensor test.

If the program detects an error the program stops.The following message appears on the control boxdisplay:

Example:1. line: Sensor Adjustment2. line: Error typez. B.: ground fault

cable breakshort circuitshort circuit of the power supply

3. line: Fault locationz. B.: X2 plug on onboard computer

31/19 Kontakte am Stecker X2-> connection toS1 sensor plug2/ 1 contacts on S1 plug

Example: cable break (line break) in theconnection between X2:31 and S1:2

or X2:19 and S1:1.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-046

Hand Auto Sensortest weiter...ok?......

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-047

---- Sensortest --------- beendet! -----weiter...ok? ......

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-048

Messer EinstellenType: KabelbruchX2: 31/19->S1: 2/ 1weiter zurück

5 6 87

Pmax

A - 3

Appendix

A1.2.2 Manual Sensor Test

Each sensor is checked individually and the result isdisplayed.

• Actuate key.

Example:1. line: Sensor blade Adjustment2. line: Error type or switching statefor example error types

ground faultcable breakshort circuitshort circuit of the power supply

switching stateon !off !defect !

3. line: Plug and cable designation

If an error message appears, the fault location (plug andcable designation) is identical to the auto sensor test.The switching state indicates the state of the sensor.

Adjusting the sensor:

• Actuate key.

The following message appears on the display:1. line: Sensor.2. line: The desired electronic value for the sensor.3. line: The actual electronic value.

If the actual value differs from the desired value, thedistance between the sensor and target must becorrected.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-049

Messer EichenType: aus!X2: 31/19->S1: 2/ 1weiter zurück

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-046


5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-050

Messer Sollwert: 145 + -5Istwert: 145 zurück

5 6 87

Pmax

A - 4

Appendix

Once all sensors have been checked, the display returnsto the sensor test.

Scroll to the valve test using the key.

A1.3 Valves TestA1.3.1Auto Valves Test

• Actuate key.

No check of the valves’ mechanical/hydraulic function.All machine valves are checked electronically.

The message on the right is displayed on the controlpanel if no error is detected during the auto valves test.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-046


5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-062

Hand Auto Ventiltest weiter... ok? ......

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-063

--- Test Ventile ------- beendet! ---- weiter... ok? ......

5 6 87

Pmax

A - 5

Appendix

If the program detects an error during the check theprogram stops.The following message appears on the control paneldisplay:

1. line: Valve coil designation2. line: Error typez. B.: ground fault

cable breakshort circuitshort circuit of the power supply

3. line: Fault locationfor example X6 plug on on-board computer

34/5 contacts on X5 plug-> connection toY2 sensor plug2/1 contacts on S1 plug

Example: If cable break appears as an error message,a line break exists in the connection between X6:34and Y2:2 or X6:5 and Y2:1

A1.3.2 Manual Valves Test

• Actutate key.

No check of the valves’ mechanical function.All machine valves are checked electronically.

All valves can be activated using the key and

deactivated using the key. With control valves, the

key must be held down.

All valve connectors are provided with LED to check ifthe correct valve is triggered.The LED lights up when the valve is switched

electronically.

Each valve is checked and the result displayed.

• Actuate key.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-064

zu .. Regelung ..auf Kabelbruch X6: 34/5 -> Y2: 2/1weiter zurück

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-062

Hand Auto Ventiltest weiter... ok? ......

5 6 87

Pmax

.

A - 6

Appendix

Example:1. line: open … control … closed2. line: Error type or switching statefor example error types

ground faultcable breakshort circuitshort circuit of the power supply

switching stateon !off !defect !

3. line: Plug and cable designation

If an error message appears, the plug and cabledesignation (fault location) is identical to the auto sensortest. The switching state indicates the state of thesensor.

Density force control valves

The electro-hydraulic control block is located below theknotter mechanism on the right side of the machine. Itconsists of three valves:„1“ valve to release/unlock the baling channel„2“ valve to lock the baling channel„3“ pressure control valve for the baling channel

Prog Quit

#

1 2 9 0

3 4

BP-VFS-064

zu .. Regelung ..auf Kabelbruch X6: 34/5 -> Y2: 2/1weiter zurück

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-065

zu .. Regelung ..auf ausweiter zurück

5 6 87

Pmax

BP380-7-161

31 2

A - 7

Appendix

Setting the Language

•Select the language using the key and key.

The language selected appears after Desired:

Save language using the . key.

The saved language appears after Actual:The saved language will not be activated until the

comfort controls are switched on.

Voltages Display

Display of the input voltage. Should be between 11.5and 14 Volts.

Knotter cleaning valve

The compressed-air valve of the knotter cleaner islocated on the left front of the knotter mechanism. The

valve is opened by actuating the key.

Compressed air in the knotter cleaner’s supply tank will

be released. The valve closes by actuating the

key.

Prog Quit

#

1 2 9 0

3 4

BP-VFS-066

Spracheinstellung Ist:....deutsch.... Soll:...deutsch.... weiter..ok? ja quit

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-067

Spannung 12V weiter..ok? ja quit

5 6 87

Pmax

Prog Quit

#

1 2 9 0

3 4

BP-VFS-069

aus einVentil Knoterreinig......... aus !......weiter zurück

5 6 87

Pmax

A - 8

Appendix

A 1.4 Electrical Circuit Diagram Big Pack 88/127/128

gngnbrge wsgnsw

X 7X 11X 1

rt

1

0

Dis

play

EP

RO

M

Pla

tine

X2

X4

X9

Relais

CPU

S1

Tas

tatu

r

Hup

e

brws

gegn

rtsw

br (

CA

N_L

)w

s (C

AN

_H)

ge gn (

SW

_ON

)rt

(+12

V)

sw (

Mas

se)

KR

ON

E-K

om

fort

Bed

ien

un

gO

NO

FF

1 2 3 4 5 6 7

1 2 3 4 5 6 7 -XKDb 1 2 -X12V

1 2 3 4 5 6 7 -XDISa 1 2 -X12Va

1 2 3 4 5 6 7 -XDISb 1 2 -X12Vb

CA

N_

L (X

2_32

)/2

.6C

AN

_H

(X

2_18

)/2

.6

SW

_ON

(X

2_41

)/2

.6+

12V

FU

(X

2_42

)/2

.60V

(X

2_15

)/2

.6

+12V

(X

2_28

)/2

.60V

(X

2_29

)/2

.612

V V

erso

rgun

g

Sch

lep

per

Dei

chse

l

+12

VM

asse

12V

Ste

cker

Ter

min

al S

teck

er

Gep

r.

04.0

4.20

02

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

03.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

1/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

KR

ON

E V

erso

rgun

g/D

ispl

ay1

302

474-

2K

ron

e-N

r.:

A - 9

Appendix

9 8 6 4 2 +KB1X5-XLBS

G B J H K N D E P M +KB1X5-XCBb 1 2 +KB1X5-X12Va 1 2 3 4 5 6 7 +KB1X5-XDISa

G B J H K N D E P M +KB2X1-XCBa 1 2 +KBX2-X12Vb 1 2 3 4 5 6 7 +KBX2-XDISb

CA

N_

L LB

S (

X34

)C

AN

_H L

BS

(X

35)

+12

V_S

W (

X10

)+

12V

(X

28)

Mas

se (

X29

)

CA

N_H

Kro

ne

(X39

)C

AN

_L K

ron

e (X

25)

+12V

(X

2_28

)/1

.7,/3

.20V

(X

2_29

)/1

.7,/3

.3

CA

N_L

(X

2_32

)/1

.7,/3

.7C

AN

_H

(X

2_18

)/1

.7,/3

.6

SW

_ON

(X

2_41

)/1

.7,/3

.2+

12V

FU

(X

2_42

)/1

.7,/3

.30V

(X

2_15

)/1

.7,/3

.3

LB

S/IS

O B

rid

ge

Sch

lep

per

Dei

chse

l

LBS

-Ste

cker

12V

Ste

cker

Ter

min

al S

teck

er

Gep

r.

04.0

4.20

02

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

03.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

2/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

LBS

/ISO

Ver

sorg

ung/

Brid

ge

230

2 47

4-2

Kro

ne-

Nr.

:

A - 10

Appendix

SW_ON (X2_41)/2.6

+12V (X2_28)/2.6

+12VEF (X2_14)/5.6

+12VFU (X2_42)/2.6

0V (X1_29)/5.6

0V (X2_15)/2.6

0V (X2_29)/2.6

GND (X1_02)/6.4

GND (X1_03)/6.3

GND (X1_42)/6.6

+8V8_AN_3 (X2_05)/7.3

GND_ANA3 (X2_02)/7.3

12

315

2930

31

1617

32

184

519

3334 6

720

35

218

22

3637 9

2310

1124

3839

2512

1326

4041

2714

28

42

12

315

2930

3116

1732

184

519

3334 6

720

3521

822

3637 9

2310

1124

3839

2512

1326

4041

2714

2842

X 2

X 1

EINGÄNGE

AUSGÄNGE

Versorgung

+12VE

+12VE

SW_ON

+12V

+12V

+12VEF

+12VFU

0V

0V

0V

0V

GND

GND

+8V8_AN

GND_ANA1

+8V8_AN

GND_ANA2

GND_N1

GND_N2

GND_N3

GND_N4

CAN_H

CAN_H

CAN_L

CAN_L

TERM

TERM

RXD

TXD

Versorgung Elektronik

Versorgung Elektronik

Schaltspannungseingang

Versorgung Last

Versorgung Last

+12VE über F25 (25A elektr.)

+12V über F18 (25A)

Masse 12V Versorgung




+8V Analogsensoren

GND Analogsensor 1

+8V Analogsensoren

GND Analogsensor 2

Namursensor 1

Namursensor 2

Namursensor 3

Namursensor 4

Versorgung Analogsensoren

Versorgung Namur-/ Digitalsensoren

CAN

RS 232

0V

0V



GND

GND

GND

0V über F19 (25A)

0V über F19 (25A)

0V über F19 (25A)

0V über F19 (25A)

0V über F19 (25A)

+8V8_AN

GND_ANA3

+8V8_AN

GND_ANA4

+8V Analogsensoren

GND Analogsensor 3

+8V Analogsensoren

GND Analogsensor 4

GND_N5

GND_N6

GND_N7

GND_N8

GND_D10

GDN_D11

GND_D12

GND_D13

GND_D14

GND_D15

GND_D16

GND_D17

Namursensor 5

Namursensor 6

Namursensor 7

Namursensor 8

Digitalsensor 10

Digitalsensor 11

Digitalsensor 12

Digitalsensor 13

Digitalsensor 14

Digitalsensor 15

Digitalsensor 16

Digitalsensor 17

IE_2

X2_41

X1_37

X2_37

X1_28

X2_28

X2_14

X2_42

X1_29

X1_38

X2_01

X2_15

X2_29

X2_38

X1_02

X1_03

X1_42

X2_09

X2_20

X1_21

X1_11

X1_23

X1_12

X2_05

X2_02

X2_06

X2_03

X1_22

X1_30

X1_31

X1_32

X1_33

X1_34

X1_35

X1_41

X2_22

X2_23

X2_24

X2_25

X2_26

X2_35

X2_11

X2_13

X2_27

X1_39

X2_18

X1_25

X2_32

X1_40

X2_17

X2_04

X2_19

X1_17 Sensor MesserkontrolleNAM_01 /4.6

X1_18 Sensor KnoterNAM_02 /4.7

X1_19 Sensor MessenNAM_03 /4.1

X1_20 Sensor EichenNAM_04 /4.3

X1_36 Sensor RafferzufuhrNAM_05 /4.5

X1_10 freiNAM_06

X1_24 freiNAM_07

X1_16 Sensor RafferkontrolleNAM_08 /4.4

X2_16 Sensor FadenkontrolleDIG_10 /5.3

X2_31 Sensor SchwungradbremseDIG_11 /4.8

X2_34 Sensor NadelzugstangeDIG_12 /5.1

X2_36 Sensor BallenschurreDIG_13 /5.2

X2_39 freiDIG_14

X2_40 freiDIG_15

X2_10 freiDIG_16

X2_12 freiDIG_17

X2_30 freiIE_1

X1_26 freiPIC_1

X1_27 freiPIC_2

X1_13 Kolbenkraft rechtsANA_1 /5.4

X1_09 Kolbenkraft linksANA_2 /5.5

X2_33 Elektr. BallenlängeANA_3 /7.3

X2_21 freiANA_4

X1_05 Strommessung RegelventilIMST_1 /6.1

X1_07 Strommessung SperrventilIMST_2 /6.2

X1_01 F-Simulator AusgangOUT_1 /6.8

X1_15 ZentralschmierungOUT_2 /6.6

X2_07 Ballenlängenmotor 1OUT_3 /7.2

X2_08 Ballenlängenmotor 2OUT_4 /7.1

X1_06 Ventil RegelungPWM_1 /6.1

X1_08 Ventil SperrenPWM_2 /6.2

X1_14 Ventil KnoterreinigungPWM_3 /6.4

X1_04 Ventil LösenOSW /6.3

-A1

Jobrechner

GND_N1 (X1_22)/4.6

GND_N2 (X1_30)/4.7

GND_N3 (X1_31)/4.1

GND_N4 (X1_32)/4.3

GND_N5 (X1_33)/4.5

GND_N8 (X1_41)/4.4

GND_D10 (X2_22)/5.3

GND_D11 (X2_23)/4.8

GND_D12 (X2_24)/5.1

GND_D13 (X2_25)/5.2

CAN_H (X2_18)/2.6

CAN_L (X2_32)/2.6

Gepr.

08.11.2002

Änderung

Zustand

12

34

56

78

Urspr.

Kloepper

02.04.2002K

loepper

Bl von A

nz

Blatt-N

r.

Norm

Ers. durch

Ers. für

12

34

56

78

Anlage

BIG

PA

CK

VF

S

3/7

Datum

Datum

Nam

e

Ort

Bearb.

Jobrechner3

302 474-2K

ron

e-Nr.:

A - 11

Appendix

GND_N3 (X1_31)/3.5 1

+KB

X1-

XB

1a

1 2

-B1

Sen

sor

Mes

sen

2+K

BX

1-X

B1a

Ans

chl.

I / O

Mod

ul

X1_

19

-A1

/3.4

NA

M_0

3

Sen

sor

Mes

sen

KM

C1

GND_N4 (X1_32)/3.5 1

+KB

X1-

XB

2a

1 2

-B2

Sen

sor

Eic

hen

2+K

BX

1-X

B2

a

Ans

chl.

I / O

Mod

ul

X1_

20

-A1

/3.4

NA

M_0

4

Sen

sor

Eic

hen

KM

C1

GND_N8 (X1_41)/3.5 1

+KB

X1

-XB

3a

1 2

-B3

Sen

sor

Raf

ferk

ontr

olle

2+K

BX

1-X

B3a

Ans

chl.

I / O

Mod

ul

X1_

16

-A1

/3.4

NA

M_0

8

Sen

sor

Raf

ferk

ontr

olle

KM

C1

GND_N5 (X1_33)/3.5 1

+KB

X1-

XB

4a

1 2

-B4

Sen

sor

Raf

ferz

ufuh

r

2+K

BX

1-X

B4a

Ans

chl.

I / O

Mod

ul

X1_

36

-A1

/3.4

NA

M_0

5

Sen

sor

Raf

ferz

ufuh

r

KM

C1

GND_N1 (X1_22)/3.5 1

+KB

X1-

XB

5a

1 2

-B5

Sen

sor

Mes

serk

ontr

olle

2+K

BX

1-X

B5a

Ans

chl.

I / O

Mod

ul

X1_

17

-A1

/3.4

NA

M_0

1

Sen

sor

Mes

serk

ontr

olle

KM

C1

GND_N2 (X1_30)/3.5 1

+KB

X1-

XB

6a

1 2

-B6

Sen

sor

Kno

ter

2+K

BX

1-X

B6

a

Ans

chl.

I / O

Mod

ul

X1_

18

-A1

/3.4

NA

M_0

2

Sen

sor

Kno

ter

KM

C1

GND_D11 (X2_23)/3.5 1

+K

BX

2-X

B7a

1 2

-B7

Sen

sor

Sch

wun

grad

brem

se

2+

KB

X2-

XB

7a

Ans

chl.

I / O

Mod

ul

X2_

31

-A1

/3.4

DIG

_11

Sen

sor

Sch

wun

grad

brem

se

KM

C1

Gep

r.

08.1

1.20

02

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

03.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

4/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

Ein

gän

ge S

enso

ren

430

2 47

4-2

Kro

ne-

Nr.

:

A - 12

Appendix

GND_D12 (X2_24)/3.6 1

+K

BX

2-X

5b

1+

KB

X1-

X5a

1+K

BX

1-X

B8

1 2

-B8

Sen

sor

Nad

elzu

gsta

nge

2+K

BX

1-X

B8

2+

KB

X1-

X5a

2+

KB

X2-

X5b

Ans

chl.

I / O

Mod

ul

X2_

34

-A1

/3.4

DIG

_12

Sen

sor

Nad

elzu

gsta

nge

KM

C1

GND_D13 (X2_25)/3.6 3

+KB

X2-

X5b

3+K

BX

1-X

5a

1+K

BX

1-X

B9

1 2

-B9

Sen

sor

Bal

lens

chur

re

2+K

BX

1-X

B9

4+K

BX

1-X

5a

4+K

BX

2-X

5b

Ans

chl.

I / O

Mod

ul

X2_

36

-A1

/3.4

DIG

_13

Sen

sor

Bal

lens

chur

re

KM

C1

GND_D10 (X2_22)/3.5 5

+K

BX

2-X

5b

5+

KB

X1-

X5a

1+K

BX

1-X

B10

1 2

-B10

Sen

sor

Fad

enk

ontr

olle

2+K

BX

1-X

B10

6+

KB

X1-

X5a

6+

KB

X2-

X5b

Ans

chl.

I / O

Mod

ul

X2_

16

-A1

/3.4

DIG

_10

Sen

sor

Fad

enko

ntro

lle

KM

C1

1

-XN

1b

Ans

chl.

I / O

Mod

ul

X1_

13

-A1

/3.4

AN

A_1

Kol

benk

raft

rech

ts

KM

C1

F

R

ge gn br ws

-4B

5K

raft

sens

or r

echt

s

2

-XN

1b

Ans

chl.

I / O

Mod

ul

X1_

09

-A1

/3.4

AN

A_2

Kol

benk

raft

links

KM

C1

F

R

ge gn br ws

-4B

6K

rafts

enso

r lin

ks

3

-XN

1b

10+

KB

X1-

X5a

10+

KB

X2-

X5b

+12VEF (X2_14)/3.2

4 0V (X1_29)/3.3

F T

315m

A

1 ON

DIP

23

4

1 ON

DIP

23

4

Pot

i

Pot

i

(+12

V)

(+12

V)

+12V

Mas

se

(0V

)

(0V

)

Sig

n 1

Sig

n 2

TR

AC

O

DC

/DC

Con

vert

er

OF

FO

N

1 2 3 4 5 6 7 8 9 10 11 12

-N1

Ver

stär

kerp

latin

e

Gep

r.

08.1

1.20

02

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

03.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

5/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

Ein

gän

ge S

enso

ren

/ Kra

ftmes

sung

530

2 47

4-2

Kro

ne-

Nr.

:

A - 13

Appendix

Ans

chl.

I / O

Mod

ul

X1_

06

-A1

/3.4

PW

M_1

Ven

til R

egel

ung

KM

C1

1

+KB

X1-

XY

1b

-Y1

Ven

til R

egel

ung

2

+KB

X1-

XY

1b

Ans

chl.

I / O

Mod

ul

X1_

05

-A1

/3.4

IMS

T_1

Str

omm

essu

ng R

egel

vent

il

KM

C1

Ans

chl.

I / O

Mod

ul

X1_

08

-A1

/3.4

PW

M_2

Ven

til S

perr

en

KM

C1

1

+K

BX

1-X

Y2b

-Y2

Ven

til S

perr

en

2

+K

BX

1-X

Y2b

Ans

chl.

I / O

Mod

ul

X1_

07

-A1

/3.4

IMS

T_2

Str

omm

essu

ng S

perr

vent

il

KM

C1

Ans

chl.

I / O

Mod

ul

X1_

04

-A1

/3.4

OS

W

Ven

til L

ösen

KM

C1

1

+KB

X1-

XY

3b

-Y3

Ven

til L

ösen

2

+KB

X1-

XY

3b

GND (X1_03)/3.3

Ans

chl.

I / O

Mod

ul

X1_

14

-A1

/3.4

PW

M_3

Ven

til K

note

rrei

nigu

ng

KM

C1

1

+K

BX

1-X

Y4b

-Y4

Ven

til K

note

rrei

nig

ung

2

+K

BX

1-X

Y4b

GND (X1_02)/3.3

Ans

chl.

I / O

Mod

ul

X1_

15

-A1

/3.4

OU

T_2

Zen

tral

schm

ieru

ng

KM

C1

1+

KB

X1

-XZ

1a

1+

KB

XM

1-X

Z1b

5

+KB

XM

1-X

M1b

M-M

1Z

entr

als

chm

ieru

ng

7

+KB

XM

1-X

M1b

2+

KB

XM

1-X

Z1b

2+

KB

X1

-XZ

1a

GND (X1_42)/3.3

1

-XY

5b

-Y5

Ven

til S

chw

ungr

adre

inig

ung

2

-XY

5b

Ans

chl.

I / O

Mod

ul

X1_

01

-A1

/3.4

OU

T_1

F-S

imul

ator

Aus

gang

KM

C1

OD

ER

So

nd

erau

srüs

tun

g

brsw

Gep

r.

06.0

2.20

03

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

03.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

6/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

Aus

gäng

e V

entil

e/Z

entr

alsc

hmie

rung

630

2 47

4-2

Kro

ne-

Nr.

:

A - 14

Appendix

Ans

chl.

I / O

Mod

ul

X2_

08

-A1

/3.4

OU

T_4

Bal

lenl

änge

nmot

or 2

KM

C1

Ans

chl.

I / O

Mod

ul

X2_

07

-A1

/3.4

OU

T_3

Bal

lenl

änge

nmot

or 1

KM

C1

1+K

B1X

4-M

1X1b

2+K

B1X

4-M

1X1b

1+K

B1X

4-M

1X2

b

Ans

chl.

I / O

Mod

ul

X2_

33

-A1

/3.4

AN

A_3

Ele

ktr.

Bal

lenl

änge

KM

C1

+8V8_AN_3 (X2_05)/3.4 2

+K

B1X

4-M

1X2b

M1 21

32

-M2

Bal

lenl

änge

nmot

or

GND_ANA3 (X2_02)/3.4 3

rtbl

ws

swrt

So

nd

erau

srü

stu

ng

Gep

r.

09.0

4.20

02

Änd

erun

gZ

usta

nd

12

34

56

78

Urs

pr.

Klo

eppe

r

02.0

4.20

02K

loep

per

Bl v

on A

nz

Bla

tt-N

r.

Nor

mE

rs. d

urch

Ers

. für

12

34

56

78

Anl

age

BIG

PA

CK

VF

S

7/7

Dat

um

Dat

umN

ame

Ort

Bea

rb.

Ele

ktris

che

Bal

lenl

änge

730

2 47

4-2

Kro

ne-

Nr.

:

A - 15

Appendix

A1.5 Alarm and Error Messages Big Pack 88/127/128

Problem Possibles cause Remedy

ALARM-NO.: 0 • Twine broken • Check twine and twine tensionerTWINE TIGHTENER DEF! • End of twine

ALARM-NO.: 1 • Blockage in the feed area • Stop the machine immediatelyPACKER CARRYING OVER! of the packer • Switch off the drive shaft

Allow the machine to run down

ALARM-NO.: 2 • Too high target density of the bales • Reduce desired density forceBALE POWER EXCEEDEDBALE CH. OPEN!!

ALARM-NO.: 3 • Sensor defect • Carry out Sensor testRIGHT PISTON POWER • Broken cableSENSOR DEFECT! • Reinforcing board faultyCHECK!! • Set value in the electronics too low • Set correct values

•

ALARM-NO.: 4 • Sensor defect • Carry out Sensor testLEFT PISTON POWER • Broken cableSENSOR DEFECT! • Reinforcing board faultyCHECK!! • Set value in the electronics too low • Set correct values

•

ALARM-NO.: 5 • Blade protection has been initiated • Check blade protectionBLADES REMOVE • Foreign object •

• Blunt blade • Sharpen blades

ALARM-NO.: 6 • Knotter is activated with every • Check bale length settingCHECK KNOTTING DEV. ram stroke

ALARM-NO.: 8 • Broken cable • Carry out Sensor testMEASR:-SENSOR CHECK • Sensor not correctly adjusted

ALARM-NO.: 9 • Broken cable • Carry out Sensor testCALIBR:-SENSOR CHECK • Sensor not correctly adjustedALARM-NO.: 10 • Brake not completely released • Release brakeFLYWHEELBRAKE

ALARM-NO.: 11 • shear bolt broken • Replace shear boltNEEDLE CON: ROD • Check needle

• Check twine guide• Check twine break

ALARM-NO.: 12 • Bale chute not completely • Fold bale chute downPACK CHUTE folded down

ALARM-NO.: 13 • Knoter shear bolt broken • Replace knotter shear boltKNOTTER DRIVE (Single knotter)

• Knotter shaft not in stop position • Check knotter shaft

A - 16

Appendix

A - 17

Appendix

MaschinenfabrikBernard Krone GmbHHeinrich-Krone-Straße 10, D-48480 SpellePostfach 11 63, D-48478 Spelle

Phone +049 (0) 59 77/935-0Fax +049 (0) 59 77/935-339Internet: http://www.krone.deeMail: [email protected]

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