OPERATOR’S MANUAL
Bale Command Plus
for BR7060, BR7070
TM
Round Balers
Auto
Manual
Part number 84267638
3rd edition English
July 2010
Replaces part number 87604750
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
INSTALLATION OF TRACTOR-MOUNTED COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 2-1
OPERATOR’S PANEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIELD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
0-1
PRECAUTIONARY
STATEMENTS
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual and on machine decals, you will find signal words DANGER, WARNING, and CAUTION
followed by special instructions. These precautions are intended for the personal safety of you and those working
with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
color associated with DANGER is RED.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The
color associated with WARNING is ORANGE.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury. The color associated with CAUTION is YELLOW.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color
associated with Notice is BLUE.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other
information in the manual. The word Note is not intended to address personal safety or property damage.
0-2
SECTION 1
GENERAL INFORMATION
This manual covers the electronic/electrical portion
of the Bale Command Plus™ system. Refer to the
baler operator’s manual for the mechanical portion of
the Bale Command Plus system.
Bale Command Plus is a computerized control
system that allows the operator to visually and
audibly know when to shift the baler from one side of
the windrow to the other for proper feeding of the
round baler. The control box also provides the
operator with the ability to select the desired number
of twine or net wraps on the bale and wraps the bale
automatically. The system retains the selected wrap
program as long as desired but can be easily
reprogrammed. The Bale Command Plus system
can also energize a hydraulic splitter valve solenoid,
if equipped, for the rotor reverse feature on balers
with the CropCutter® option.
NOTE: The Bale Command Plus system is designed
for use with a 12-volt negative ground system only.
BALE COMMAND PLUS SYSTEM
COMPONENTS
The Bale Command Plus system includes the
components that are shown in Figures 1 through 14.
The components are connected together by wiring
harnesses.
TRACTOR-MOUNTED COMPONENTS
Operator’s Panel
Figure 1 is a front view of the Bale Command Plus
operator’s panel. The main display window, 1,
contains various segments that are activated during
operation. The bale shape display window, 2,
contains bar graphs that are activated by signals from
the bale shape left-hand and right-hand sensors.
An audible alarm is located at 3, and an alarm light is
at 4. The alarm volume can be increased or
decreased by opening or closing the gate over the
horn.
Touch-sensitive keys are located beside and below
the display panels to allow the operator to control the
system. Each key is marked to indicate its function.
Anytime a key is depressed, an audible signal (beep)
will sound to alert the operator that the signal was
recognized by the control box.
1-1
1
2
4
3
50022664
1
SECTION 1 - GENERAL INFORMATION
Wire Harness Connector Bracket
The wire harness connector bracket, 1, is mounted
on the rear of the tractor to connect the baler wiring
harness, 2, to the tractor harness. The tractor
harness is divided to connect to the operator’s panel
and also to the power source.
2
1
20021693
2
Remote Override Rocker Switch
The remote override rocker switch,1, is installed on
the wire harness near the operator’s panel. The
electrical lead is normally disconnected and is stored
in the vicinity of the operator’s panel.
1
20022010
3
The rocker switch is labeled with an extend icon, 1,
and retract icon, 2.
In the event the Bale Command Plus operator’s panel
becomes inoperable, the remote override rocker
switch lead is connected to the respective baler net
or twine actuator and will allow override control of
actuator extend or retract functions in order to
complete the wrapping and ejection of the current
bale.
1
2
76093642
4
1-2
SECTION 1 - GENERAL INFORMATION
BALER-MOUNTED COMPONENTS
Control Box
The control box, 1, processes the information from
the various sensors and the operator’s panel to
control the operation of the Bale Command Plus
system based on the information it receives. It must
be set for the model of the baler it is installed on for
it to function properly. It processes signals from the
actuator position, bale size, bale shape, tailgate
position and net counter roll sensors. It sends signals
to the operator’s panel to display information for the
operator. It also contains solid-state relays that
supply power to the wrap actuators and net/twine
actuator selector relay.
1
76093643
5
Remote Override Lead
An electrical lead is used to connect the switch to one
of the actuators. This lead is normally disconnected
and stored in the vicinity of the control box.
Bale Size Sensor
The bale size sensor, 1, is a rotary potentiometer that
changes the level of its return signal to the control box
based on the amount of rotation of the sensor rotor
section that is connected through linkage to the
bale-forming belt take-up arm. The control box
converts the signal to a bale size and displays the
size on the operator’s panel.
1
20021998
6
Bale Shape Sensors (Right-hand Side Only
Shown)
The bale shape sensors, 1, are rotary potentiometers
that change the level of the return signal to the control
box based on the amount of rotation of the sensor
center section that is connected through linkage to
the bale shape spring inside the bale chamber. The
control box converts the signal to display the
appropriate sections of the bar graphs on the
operator’s panel.
1
20021997
7
1-3
SECTION 1 - GENERAL INFORMATION
Twine Wrapper Actuator
The twine wrapper actuator, 1, moves the pivot link to
operate the twine tubes and also opens and closes
the twine knives.
1
Twine Wrapper Sensor
The sensor, 2, mounted on the actuator monitors the
position of the actuator.
2
The twine wrapper sensor is a rotary potentiometer
that changes the level of the return signal to the control
box based on the amount of rotation of the center
section. The sensor transmits the exact position of the
twine tubes to provide various wrapping
configurations to the operator. One programmable
custom wrap configuration is provided.
20021995
8
Net Wrapper Actuator
The net wrapper actuator, 1, moves the linkage to
operate the net wrap duckbill and knife.
2
1
Net Wrapper Actuator Position Sensor
The net wrapper actuator sensor, 2, is a rotary
potentiometer that changes the level of its return
signal to the control box based on the amount of
rotation of the sensor rotor. The control box converts
the signal to determine the position of the duckbill.
50046175
9
Net Counter Roll Sensor and Magnet
As the net counter roll magnet, 1, rotates past the
sensor, 2, the return signal to the control box
changes. The sensor is a magnetically activated
solid-state switch. When a magnet is close to the
sensor, the circuit is closed. When the magnet is
away from the sensor, the circuit is open. The control
box senses the open or closed circuit to count the
revolutions of the counter roll. The control box
monitors the signal changes to determine that the net
has started to wrap on the bale and move the duckbill
to the precut position. The control box continues to
count the number of signal changes to determine the
amount of net to be wrapped on the bale.
2
1
20021996
10
1-4
SECTION 1 - GENERAL INFORMATION
Tailgate Sensor
The tailgate sensor, 1, monitors the position of the
tailgate. The sensor is a ferrous proximity switch.
When the tailgate latchpin is close to the sensor, the
circuit is closed. When the tailgate latchpin is away
from the sensor, the circuit is open. The control box
senses the open or closed circuit to determine
whether the tailgate is closed or open.
If the sensor moves away from the tailgate for 15
seconds, the control box will activate the alarm on the
operator’s panel and display an error message. If the
sensor moves away from the tailgate during the wrap
cycle, the control box will activate the alarm on the
operator’s panel, display an error message, and the
wrap cycle will be stopped.
1
20021994
11
When the tailgate closes, the control box uses the
signal to reset the display for the next bale and add
1 to the bale count if the bale was wrapped in the
automatic mode.
CropCutter Knife Sensor
The CropCutter knife position sensor, 1, monitors the
position of the knives. The sensor is a ferrous
proximity switch. When the knives are fully engaged
in the cut position, the circuit is closed. When the
knives are not fully engaged, the circuit is open. The
control box senses the open or closed circuit to
determine the knife position. Knife full engagement is
indicated on the display by the knife triangle being on.
The knife triangle indicator is turned off when the
knives are not fully engaged.
1
20022009
12
1-5
SECTION 1 - GENERAL INFORMATION
HOW THE BALE COMMAND PLUS
SYSTEM OPERATES
NOTE: The Bale Command Plus system is designed
for use with a 12-volt negative ground system only.
The following describes the automatic operation of
the Bale Command Plus system during the formation
and wrapping of a 150 centimeter bale, maximum
size for which the control box can be set on Model
BR7060.
BALE FORMATION - NET OR TWINE
1
As the bale size increases (after the core is formed),
the linkage from the take-up arm, 1, moves the bale
size sensor arm, 2, and changes the output signal to
the control box.
2
20021998
13
The control box converts the signal to bale size and
changes the display on the operator’s panel. The
bale shape left-hand and right-hand sensors also
send signals to the control box which uses the signals
to change the height of the respective bar graph. This
provides a guide for the operator to produce a
uniform bale.
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14
1-6
SECTION 1 - GENERAL INFORMATION
The Bale Command Plus offers a near full bale
alarm/indicator to alert the operator that the bale is
almost complete. When the bale being made reaches
the near full bale set point, the alarm will sound for 0.5
seconds and the full bale bracket symbol will flash
until the bale reaches full size.
NOTE: The value of 80 centimeters is the minimum
bale size the near full bale alarm/indicator can be
activated. For example: if the near full bale
alarm/indicator size is set at 15 centimeters, and the
full bale size is 90 centimeters, the near full bale
alarm/indicator will sound and the full bale bracket
symbol will be flashing when the bale reaches 80
centimeters.
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15
The near full bale alarm/indicator can be set at 5, 10,
or 15 centimeters before full bale size. Setting the
value to zero will turn off the feature. Refer to
Setup/Diagnostic Item 7 for instructions to change the
setting.
When the bale reaches full size, the full bale size will
be displayed in solid brackets, the Full Bale indicator
light will turn on, and the alarm will sound for three
seconds. After a short delay, the control box will start
the wrapping cycle. The operator should stop forward
motion as soon as the full bale alarm is activated.
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16
After the wrapping cycle is completed, the control box
will send a signal to the operator’s panel to tell the
operator to eject the bale. When the tailgate is closed
after the bale is ejected, the tailgate sensor will be
activated to reset the control box for the next bale and
add 1 to the bale count. The operator’s panel will
beep to indicate the tailgate is latched so the operator
can start forming the next bale.
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1-7
SECTION 1 - GENERAL INFORMATION
OPERATION
CROPCUTTER
Machines can be equipped with a CropCutter. The
CropCutter knives are controlled with tractor
hydraulics. Position indication of the CropCutter
knives is provided to the operator on the panel when
this option is enabled. When the knives have been
fully inserted the knife triangle will be on. The knife
triangle will be off when the knives are not fully
engaged.
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18
CropCutter Hydraulic Reverser
An optional hydraulic reverser is available to unplug
the rotor from the tractor seat. If the rotor plugs, the
cut-out clutch will disengage the baler.
1. Stop the tractor and shut off the PTO.
2. Retract the CropCutter knives.
3. Extend the hydraulic reverser cylinder. This may
be done by:
•
•
Use of the separate hydraulic circuit that
controls the reverser.
Activation of the optional splitter valve on a
rotor cutter baler. Push the splitter valve key
(Slice ON/OFF), 1, on the Bale Command
Plus monitor, to shift from the knife control to
the reverser. The monitor will display “=o”.
Then use the tractor hydraulic lever.
1
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19
4. Each stroke of the cylinder, 1, will rotate the rotor
shaft several ratchet notches, 2, in reverse.
IMPORTANT: Stroke hydraulic reverser cylinder a
maximum of 4 times before attempting to re-feed
crop. Continuous operation of hydraulic reverser
cylinder can force crop into and damage the
strippers.
5. If the pickup is full of material, either when the
rotor plugs or after reversing the rotor, remove
the windguard and pull some of the crop out of the
pickup.
1
2
20022262
6. Repeat the process if necessary until the rotor
will rotate in the normal direction.
20
7. Install the windguard.
8. Close the reversing cylinder.
9. On a baler with a splitter, valve, push the splitter
valve key (Slice ON/OFF) on the monitor.
10. Do not insert the knives until the baler is back to
normal operation.
1-8
SECTION 1 - GENERAL INFORMATION
TWINE WRAPPING CYCLE
When the control box alerts the operator that the full
bale size has been reached, it also sends power to
the twine tube actuator. When the actuator extends,
the twine tubes will drop to the start position. A sensor
will tell the control box that the actuator is fully
extended (twine tubes have dropped completely).
After a programmed delay, the control box will retract
the actuator and move the twine tubes following the
pattern selected.
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21
76073065
22
When the actuator sensor, 1, reaches the “precut”
position, the control box will pause the actuator until
the programmed amount of end wraps are placed on
the bale and then return the actuator to the “home”
position.
As the actuator moves the twine tubes from the
precut to the “home” position, the twine will be cut.
When the actuator reaches the home position, the
control box will send a signal to the operator’s panel
to tell the operator that the cycle is completed and that
the bale can be ejected.
NOTE: If the cycle is interrupted, an error message
will be displayed. The cycle can be interrupted if the
tailgate moves away from the sensor, or if the
operator presses any of the following keys:
AUTO/MANUAL, EXTEND, RETRACT or ON/OFF.
1-9
1
20021995
23
SECTION 1 - GENERAL INFORMATION
1
4
3
2
76073060
24
NET INSERTION
NET WRAPPING CYCLE
When the control box alerts the operator that the full
bale size has been reached, it also sends power to
the net wrap actuator, 1. The actuator will rotate the
duckbill, 2, and insert the net between the fixed
dimpled rolls, allowing the bale to grab the net and
start the wrapping process.
As the duckbill moves to insert the net, the knife, 3,
will be rotated to it’s pre-cut position, and the brake,
4, is moved away from the net to start the wrapping
of the bale.
1-10
SECTION 1 - GENERAL INFORMATION
2
4
1
3
76073061
25
PRE-CUT POSITION
When the bale starts to grab the net and pull it off the
roll, the counter wheel sensor, 1, will send signals to
the control box. After the control box receives the net
start signal, it will energize the actuator, 2, to retract,
and move the duckbill, 3, to the precut position. The
brake, 4, will be applied to the roll to wrap the net
tightly around the bale. The control box will continue
to count the number of revolutions of the counter
wheel to determine how much net is being applied to
the bale.
1-11
SECTION 1 - GENERAL INFORMATION
2
1
76073062
26
CUTTING
When the programmed amount of net has been
wrapped on the bale, the actuator, 1, will be retracted
to the “home” position. A bushing, 2, attached to the
knife linkage and riding in the slot of the duckbill cam,
will encounter a flat spot in the slot. The cam will push
the knife linkage up and rotate the knife, under spring
tension, to the home position cutting the net.
When the actuator reaches the home position, the
control box will send a signal to the operator’s panel
to tell the operator that the cycle is completed and that
the bale can be ejected.
NOTE: If the cycle is interrupted, an error message
will be displayed. The cycle can be interrupted if the
tailgate moves away from the sensor, or if the
operator presses any of the following keys:
AUTO/MANUAL, EXTEND, RETRACT or ON/OFF.
1-12
SECTION 1 - GENERAL INFORMATION
2
3
4
1
76073063
27
HOME POSITION
The figure above shows the knife, 1, in the home
position with the bushing, 2, resting in the upper
portion of the duckbill cam slot. The actuator, 3, is fully
retracted and the duckbill, 4, has been rotated out of
the rolls.
1-13
SECTION 1 - GENERAL INFORMATION
1-14
SECTION 2
INSTALLATION OF TRACTOR-MOUNTED
COMPONENTS
WIRE HARNESSES AND CONNECTOR
BRACKET
1
Install the harness connector bracket, 1, in a
convenient location at the rear of the tractor.
20021693
1
NOTE: The electrical system is designed for use with
12-volt negative ground systems only. THE CONTROLS CANNOT BE USED ON TRACTORS WITH
6-VOLT OR POSITIVE GROUND ELECTRICAL
SYSTEMS.
Route the harness so the multi-pin connector, 1, can
be attached to the operator’s panel, 2, and the power
leads, 3, can be connected to a 12-volt negative
ground power supply on the tractor.
2
1
3
50023222
2
2-1
SECTION 2 - INSTALLATION OF TRACTOR-MOUNTED COMPONENTS
OPERATOR’S PANEL HARNESS CONNECTION
1
2
8
3
4
7
5
6
96101988
3
Power Harness Connection To Tractor 12-volt (-) Negative Ground Electrical System
1.
2.
3.
4.
12-volt Battery (Main Power Source)
Battery (-) Ground Cable
(-) Ground (Tractor Frame)
Black (-) Negative Ground Wire
5.
6.
7.
8.
Power Harness Assembly - includes current breaker, 7
Red (+) Positive Wire
30 A (Amp) Circuit Breaker
Red (+) Positive Wire -- Direct Routing to Battery
Install
1. Ensure tractor electrical system battery, 1, is
12-volt.
4. Connect the red (+) positive wire, 8, to the 12-volt
power source.
2. Disconnect the battery (-) negative ground cable, 2.
5. Attach the black (-) negative ground wire, 4, from
the power wire harness, 5, to an existing tractor
frame bolt for a good grounding source, 3.
3. Attach a 1/2 inch stud terminal end to both the
black (-) negative ground wire, 4, to the end of the
red (+) positive wire, 5, and crimp securely. The
two terminals ends PN #767994 can be procured
locally or from your Service Parts dealer.
6. Reconnect the battery ground cable, 2.
2-2
SECTION 2 - INSTALLATION OF TRACTOR-MOUNTED COMPONENTS
OPERATOR’S PANEL
Install the Bale Command Plus operator’s panel, 1, in
a convenient location on the tractor and connect the
end of the tractor wire harness, 2, to the bottom of the
panel.
1
WARNING
Knife hazard! Retract the knife to the home
position. Only thread the net or perform service
with the knife in the home position. Failure to
comply could result in death or serious injury.
3
2
W0054A
20022698
NOTE: If battery supply voltage drops below 8.2-volt
during operation. A “bAtt” error message appears on
the operator’s panel and the motion of controlled
components is stopped. The net and twine knife may
stop mid-cycle. Disarm the knives with the remote
override rocker switch on the operator’s panel wire
harness. Reference: Remote Override Rocker
Switch Operation in this Operator’s Manual for
additional details.
4
A Slow-Moving Vehicle style mounting socket is
provided to allow the panel to easily be removed from
the tractor. Mount the socket to hold the operator’s
panel in the desired location.
Operator’s panel mounting kits, 3, are available from
your authorized dealer to allow mounting of the
operator’s panel on the front the tractor. The kits can
be modified for use on other tractors.
2-3
SECTION 2 - INSTALLATION OF TRACTOR-MOUNTED COMPONENTS
2-4
SECTION 3
OPERATOR’S PANEL OPERATION
The operator’s panel must be connected to a 12-volt
power source and the baler for it to function.
1
Connect the operator’s panel to the baler and tractor.
With the operator’s panel installed on the tractor and
connected to a 12-volt power supply as described in
Section 2, attach the baler to the tractor drawbar
following the instructions in the baler operator’s
manual.
Connect the baler wire harness, 1, to the connector
bracket on the rear of the tractor.
20021693
1
3-1
SECTION 3 - OPERATOR’S PANEL OPERATION
1
2
10
9
8
7
5
3
13
14
15
16
6
4
11
12
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2
OPERATOR’S PANEL KEYS - FUNCTION
Touch-sensitive keys are located beside and below
the display windows to allow the operator to control
the system. Each key is marked to indicate its
function.
6. - (MINUS) - Used with the BALE SIZE and
NUMBER WRAPS keys to decrease the bale
size or number of wraps.
Any time one of the touch-sensitive keys is
depressed, an audible signal (beep) will sound to
alert the operator that the signal was recognized by
the operator’s panel.
8. NET/TWINE - Used to select between wrapping
the bale with net or twine.
A brief description of the function of each key follows:
10. BALES - Used to display the daily and total bale
counts.
7. WRAP - Used to manually start a wrap cycle.
9. AUTO/MANUAL - Used to select between
automatic and manual operation of the system.
NOTE: Refer to “Operator’s Panel Keys - Operation”
later in this section for detailed instructions for using
each key.
11. CLEAR - Used to cancel the audible alarm and
error display message and also to clear the daily
bale count.
1. ON/OFF - Used to turn the Bale Command Plus
system on or off.
12. EXTEND - Used to manually extend the net or
twine actuator.
2. OPEN BOOK SYMBOL - Used to place the
system in the setup/diagnostic mode.
13. RETRACT - Used to manually retract the net or
twine actuator.
3. BALE SIZE - Used to display or change the
preset full bale size.
14. CROPCUTTER ON/OFF - If CropCutter is
installed, the button will energize or de-energize
the rotor reverser solenoid valve.
4. NUMBER WRAPS - Used to display or change
the amount of twine or net to be wrapped on the
bale.
15. CROPCUTTER EXTEND - Not used. For starter
roll knives. North America only.
16. CROPCUTTER RETRACT - Not used. For
starter roll knives. North America only.
5. + (PLUS) - Used with the BALE SIZE and
NUMBER WRAPS keys to increase the bale size
or number of wraps.
3-2
SECTION 3 - OPERATOR’S PANEL OPERATION
10
1
9
8
2
3
4
5
7
6
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3
MAIN DISPLAY WINDOW INDICATORS
Off When the CropCutter option has been installed,
the knives not fully engaged in the cut position.
Indicator triangles around the outside of the main
display window are used to alert the operator of the
status of the system or components. The function of
each is described below.
7. ACTUATOR
1. AUTO - The system is ready for automatic
operation.
On Steady If net wrap has been selected, the net actuator is
in the home, precut or insert position.
If twine wrap has been selected, the twine actuator
is in the home, extended, or precut position.
2. MANUAL - The system must be controlled
manually.
3. NET - The operator has elected to wrap the bale
with net.
Flashing The net or twine wrap actuators are moving
between one of their preset positions.
4. TWINE - The operator has elected to wrap the
bale with twine.
5. TAILGATE
8. EJECT BALE - The wrap cycle has been
completed and the bale is ready to be ejected.
On Steady The tailgate is latched.
Flashing The tailgate is not fully latched.
9. WRAP BALE - The bale is being wrapped.
10. FULL BALE - The bale has reached the preset
size.
6. KNIFE
On Steady When the CropCutter option has been installed,
the knives are engaged in the cut position.
3-3
SECTION 3 - OPERATOR’S PANEL OPERATION
BALE SHAPE DISPLAY WINDOW
1
The LEFT and RIGHT bar graphs, 1 and 2, indicate
the relative filling of the two sides of the bale. Refer
to Section 4 - “Field Operation.”
2
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4
OPERATOR’S PANEL KEYS - OPERATION
The following section includes information on using
the various keys on the operator’s panel.
The function of some keys changes depending on
whether the twine or net is selected.
ON/OFF KEY
The ON/OFF key is used to turn the Bale Command
Plus system on or off.
NOTE: The system must be ON for all other keys to
function.
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5
To Turn the System ON
Press and hold the ON/OFF key until the display
comes on as shown. Release the key.
To Turn the System OFF
Press and release the ON/OFF key. The display will
go blank.
NOTE: When turned on, the display will briefly light
all segments and the system will perform a system
test. If a problem is detected, the alarm will activate
and an Error message will be displayed. Refer to
Section 6 - “Troubleshooting” for additional information if an error message is displayed.
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6
3-4
SECTION 3 - OPERATOR’S PANEL OPERATION
When the system is turned on and the self-test is
complete, the operator’s panel display will read 75.
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7
NET/TWINE KEY
The NET/TWINE key is used to select the desired
type wrap to be applied to the bale. Pressing the key
will toggle between wrapping the bale with twine and
wrapping the bale with net.
When the NET indicator triangle is on, the bale will be
wrapped with net.
Press the NET/TWINE key to change to wrap the
bale with twine.
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8
When the TWINE indicator triangle is on, the bale will
be wrapped with twine.
Press the NET/TWINE key to change to wrap the
bale with net.
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3-5
SECTION 3 - OPERATOR’S PANEL OPERATION
To Check the Number of Bales Wrapped by Net
NOTE: This operation must not be performed during
a wrap cycle. If the Wrapper Configuration is selected
for Net/Twine, ensure that the baler has been
returned to the Net Wrapper mode, Net indicator on.
If the baler is in Net only mode, press and hold the
NET/TWINE key for one-half second. The display will
show the net bale count for two seconds.
If the baler is in Net/Twine mode, press the NET/TWINE
key to select the Twine Wrap mode. Press and hold the
NET/TWINE key, the wrap mode will switch from twine
to net. Continue to hold the NET/TWINE key for another
one-half second, the display will then show the net bale
count for two seconds.
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NOTE: The number of bales wrapped by net cannot
be cleared.
To Check the Number of Bales Wrapped by Twine
Three wrapper configurations are provided, net only,
twine only and net/twine modes. Refer to Setup/Diagnostic Item 2 for instructions on selecting the desired
configuration.
NOTE: This operation must not be performed during
a wrap cycle. If the Wrapper Configuration is selected
for Net/Twine, ensure that the operator’s panel has
been returned to the Twine Wrapper mode, Twine
indicator on.
If the baler is in Twine only mode, press and hold the
NET/TWINE key for one-half second. The display will
show the twine bale count for two seconds.
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11
If the baler is in Net/Twine mode, press the
NET/TWINE key to select the Net Wrap mode. Press
and hold the NET/TWINE key, the wrap mode will
switch from net to twine. Continue to hold the
NET/TWINE key for another one-half second, the
display will then show the twine bale count for two
seconds.
NOTE: The number of bales wrapped by twine
cannot be cleared.
3-6
SECTION 3 - OPERATOR’S PANEL OPERATION
AUTO/MANUAL KEY
The AUTO/MANUAL key is used to select between
the automatic and MANUAL wrapping modes.
Pressing the AUTO/MANUAL key will toggle
between the automatic and manual modes.
When the AUTO indicator triangle is on, the bale will
be wrapped automatically when it reaches the full
bale size and the alarm is activated.
To change to manually wrap the bale, press the
AUTO/MANUAL key.
50022664
Pressing the AUTO/MANUAL key during an
automatic wrap cycle will stop the automatic wrap
cycle.
12
When the MANUAL indicator triangle is on, the bale
must be wrapped manually when it reaches the full
bale size. The full bale alarm will be activated but the
wrapper will not start.
To change to automatically wrap the bale, press the
AUTO/MANUAL key.
NOTE: If a bale is made in the manual mode, it can
be wrapped automatically by pressing the AUTO/
MANUAL key to change to the automatic mode and
then pressing and holding the WRAP key for 2
seconds. Refer to “WRAP Key” later in this section for
additional information.
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13
+ (PLUS) AND - (MINUS) KEYS
The “+” (plus) and “-” (minus) keys are used in
conjunction with the BALE SIZE and NUMBER
WRAPS keys to change a selection. Refer to the
appropriate key information later in this section for
instructions to change the selection.
The “+” (plus) and “-” (minus) keys are also used in
the setup/diagnostic mode to change the setup
selections. Refer to “Setup/Diagnostic Mode” later in
this section.
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3-7
SECTION 3 - OPERATOR’S PANEL OPERATION
BALE SIZE KEY
The BALE SIZE key is used to check the full bale size.
It is also used with the “+” (plus) or “-” (minus) keys
to change the full bale size. This is the size at which
the alarm will be activated to alert the operator to stop
forward motion of the baler so that additional material
will not be added to the bale. The selected wrapper
cycle will also be started when the full bale size is
reached.
Checking the Bale Size
Pressing and holding the BALE SIZE key will display
the bale size the system is programmed to wrap.
When the key is released, the full bale size will remain
on the display for 2 seconds and then the display will
return to the previous readout.
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15
Changing the Bale Size
Press and hold the BALE SIZE key. Use the “+” (plus)
key to increase the full bale size or the “-” (minus) key
to decrease the full bale size.
NOTE: The minimum bale size the operator’s panel
can be set at is 90 centimeters when wrapping the
bale with twine or net. The maximum bale size the
operator’s panel can be set for is 150 centimeters for
the Models BR7060 and 180 centimeters for the
Models BR7070.
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16
3-8
SECTION 3 - OPERATOR’S PANEL OPERATION
NUMBER WRAPS KEY
When the net mode is selected, the NUMBER
WRAPS key is used to check the number of wraps of
net to be placed on the bale.
When the twine mode is selected, the NUMBER
WRAPS key is used check the number of wraps of
twine and end wraps of twine to be placed on the bale.
The NUMBER WRAPS key is also used with the “+”
(plus) and “-” (minus) keys to change the number of
wraps of net or twine and the number of end wraps of
twine.
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Checking the Number of Net Wraps
The system must be in the net wrap mode to check
the amount of net to be wrapped on a bale.
The amount of net wraps will be displayed in
quarter-wrap steps. Example: 3.25 is three and
one-quarter wraps. The minimum number of wraps
that can be applied is 1.5. The maximum number of
wraps is 6.0.
NOTE: When wrapping some small diameter bales,
more than 1.5 wraps may be applied when set at the
1.5 wraps setting due to the mechanical speed
limitation of the duckbill to return home and cut the
net.
Pressing and releasing the NUMBER WRAPS key
will display the number of wraps of net to be wrapped
on the bale. After the number of wraps is displayed for
2 seconds, the display will return to what it was before
the key was pressed. Pressing and holding the
NUMBER WRAPS key will keep the number of wraps
displayed until 2 seconds after the key is released.
Changing the Number of Net Wraps
To change the number of net wraps:
Press and hold the NUMBER WRAPS key.
Use the “+” (plus) key to increase the number of
wraps or the “-” (minus) key to decrease the number
of wraps in quarter-wrap steps.
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3-9
SECTION 3 - OPERATOR’S PANEL OPERATION
Checking the Number of Twine Wraps and End
Wraps
The system must be in the twine wrap mode to check
the number of twine wraps and end wraps to be
placed on a bale.
Pressing and releasing the NUMBER WRAPS key
will display the number of wraps and end wraps to be
wrapped on the bale. After the selection is displayed
for 2 seconds, the display will return to the previous
readout. Pressing and holding the NUMBER WRAPS
key will keep the numbers displayed for 2 seconds
after the key is released.
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Three pre-programmed twine wrap selections are
available to wrap the bales. All selections default to
two end wraps, but can be changed to provide three
or four end wraps. One custom pattern, PAt4, is
available to wrap the bale if the standard patterns are
not suitable. Refer to “Setup/Diagnostic Mode”, Item
2, Section 3.
The twine wrap selections will place the following
amount of wraps and end wraps on a bale:
Display
Number of Wraps
14-2 . . . . . . . . . . . . 14 wraps including 2 end wraps
18-2 . . . . . . . . . . . . 18 wraps including 2 end wraps
22-2 . . . . . . . . . . . . 22 wraps including 2 end wraps
. . . . . . . . . . . . . . . . . on a Model BR7060 or BR7070
24-2 . . . . . . . . . . . . 24 wraps including 2 end wraps
. . . . . . . . . . . . . . . . . on a Model BR7080 or BR7090
. . . . . . . . . . . . . . . . . . . . . . . . . . (North America Only)
PAt 4- The number of wraps depends on how the
operator’s panel was custom programmed by the
operator. If nothing is programmed in PAt 4, it will
wrap the bale with 22 wraps on Models BR7060 and
BR7070 or 24 wraps on the Models BR7080 and
BR7090 (North America Only).
Be sure the operator’s panel is programmed for the
model baler it is operating. Refer to “Setup Items,
Item 9” later in this section. Not all baler models are
available in all markets.
NOTE: The number of twine wraps placed on the
bale is based on a PTO speed of 540 or 1000 RPM,
depending on the machine. If the PTO speed is
lowered during the wrapping cycle, less wraps will be
placed on the bale. The operator’s panel moves the
twine arms based on the time it takes for a full size
bale to make a complete revolution when the PTO is
operated at 540/1000 RPM.
3-10
SECTION 3 - OPERATOR’S PANEL OPERATION
Changing the Number of Wraps
To change the number of wraps:
Press and hold the NUMBER WRAPS key to display
the number of wraps the system is set for.
While still holding the NUMBER WRAPS key, use the
“+” (plus) key to increase the number of wraps or the
“-” (minus) key to decrease the number of wraps.
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20
Changing the Number of Twine End Wraps
To change the number of end wraps:
Press and release the NUMBER WRAPS key to
display the number of wraps and end wraps the
system is set for. While the number is displayed,
press and hold the NUMBER WRAPS key to display
only the current number of end wraps.
While still holding the NUMBER WRAPS key, use the
“+” (plus) key to increase the number of end wraps or
the “-” (minus) key to decrease the number of end
wraps.
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The end wraps can be set at 2, 3, or 4 for the selected
number of twine wraps. When a different amount of
wraps is selected, the end wraps will automatically
return to 2.
21
Selecting a Custom Pattern
Select PAt 4 by pressing and holding the NUMBER
WRAPS key and then pressing the “+” (plus) key.
To program or clear a custom twine wrapping pattern
in PAt 4, refer to item 2 in “Setup/Diagnostic Mode”
(Open Book Symbol) later in this section.
Press and hold the NUMBER WRAPS key and then
press the “-” (minus) key to return to a preprogrammed amount of wraps.
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3-11
SECTION 3 - OPERATOR’S PANEL OPERATION
WRAP KEY
The WRAP key is used to manually start the
automatic wrapping cycle.
The WRAP key can also be used to restart the
automatic wrap cycle if there was a problem when the
bale was initially wrapped. Example: If the twine does
not start on one side, the WRAP key can be used to
repeat the wrap cycle after the problem is corrected.
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Manually Starting a Wrap Cycle
To manually start a wrap cycle:
Make sure the selected wrapper actuator is in the
home position.
Be sure the operator’s panel indicates that the
system is set for automatic operation.
Press and hold the WRAP key. After two seconds, the
automatic wrap cycle will start and the alarm will be
activated for three seconds.
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3-12
SECTION 3 - OPERATOR’S PANEL OPERATION
CROPCUTTER ON/OFF KEY (For Units
Equipped with Hydraulic Rotor Reverse)
The CropCutter on/off key is used to energize or
de-energize the hydraulic rotor reverse solenoid
valve. When energized, the display will show the “=o”
symbol. If equipped with the hydraulic splitter valve,
power will go to energize the valve and hydraulic oil
flow will be diverted from the rotor knife cylinder to the
rotor reverse cylinder for operation of the hydraulic oil
rotor reverse feature. When de-energized, the
display will show normal bale size and hydraulic oil
flow is diverted to the rotor knife cylinder for normal
operation.
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25
The display will show the “=o” symbol or normal bale
size even if the unit does not have the hydraulic rotor
reverse solenoid valve when the control box is
programmed for rotor cutter/feeder function in setup
item 3.
NOTE: The CROPCUTTER EXTEND and CROPCUTTER RETRACT keys are disabled in normal
operation mode when the control box is programmed
for CropCutter function.
To Check the Number of Rotor Cut Bales
With the hydraulic rotor reverse valve OFF
(De-energized), press and hold the CROPCUTTER
ON/OFF key for one-half second. The display will
show the number of rotor cut bales that have been
produced. When the key is released the hydraulic
rotor reverse will be ON (energized). Press the
CROPCUTTER ON/OFF key a second time to
de-energize the hydraulic rotor reverse valve and
return to normal operation.
NOTE: For the rotor cut bales to be counted, the cutter
knives must be in the cut position when the wrapped
bale is ejected and the tailgate closed.
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26
3-13
SECTION 3 - OPERATOR’S PANEL OPERATION
KNIFE EXTEND AND KNIFE RETRACT KEYS
Not used. For Starter roll knives (North America
only).
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27
EXTEND AND RETRACT KEYS
Pressing and holding the EXTEND key will extend the
actuator for the selected wrap system.
Pressing and holding the RETRACT key will retract
the actuator for the selected wrap system.
The EXTEND and RETRACT keys can be used when
the system is in either the automatic or manual mode.
NOTE: Pressing the EXTEND or RETRACT key will
stop an automatic wrap cycle. The actuator then has
to be manually returned to the home position by using
the RETRACT key.
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If the EXTEND or RETRACT key is held and the
actuator stalls for 5 seconds, the operator’s panel will
automatically turn the actuator OFF for 10 seconds,
activate the alarm, and display an Error message.
The actuator will be “locked out” while the Error
message is displayed.
3-14
SECTION 3 - OPERATOR’S PANEL OPERATION
BALES KEY
The BALES key is used to display daily bale count,
total bale count, bales wrapped by twine or net, and
cut bales. The daily bale count is the number of bales
made since the system was last cleared. The total
bale count is the total bales made using the Bale
Command Plus system and cannot be cleared.
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29
To Check the Daily Bale Count
Press and release the BALES key. The daily bale
count will be displayed for two seconds. After the
number of bales made is displayed for two seconds,
the display will return to the previous readout.
Pressing and holding the BALES key will keep the
number of bales made displayed for two seconds
after the key is released.
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To Clear the Daily Bale Count
Press and hold the BALES key to display the daily
bale count. While holding the BALES key, the daily
bale count is displayed. Press the CLEAR key to
reset the count to zero.
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3-15
SECTION 3 - OPERATOR’S PANEL OPERATION
To Check the Total Bale Count
Press and release the BALES key, 1, to display the
daily bale count. While the daily bale count is still
displayed, press the BALES key a second time to
display the total bale count on the baler.
1
NOTE: The total bale count cannot be cleared.
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CLEAR KEY
The CLEAR key is used to cancel the audible and
visual alarms plus the “----------” (Error) message on
the display when a problem is detected.
The CLEAR key is also used while holding the
BALES key to reset the daily bale count to “0.”
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33
HORN
To Change the Volume Level
Open or close the gate on the horn, 1, to increase or
decrease the horn volume.
1
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3-16
SECTION 3 - OPERATOR’S PANEL OPERATION
OPEN BOOK KEY
The OPEN BOOK symbol key is used to enter the
setup/diagnostic mode. The setup/diagnostic mode
is used to program and calibrate the control box, and
to test some of the components. When in the
setup/diagnostic mode, a flashing number at the
left-hand side of the display will indicate which of the
following functions is being checked.
Item Number/Function
1. Bale size calibration.
2. Twine Learn - custom twine pattern programming
for Twine only or Net/Twine wrapper configuration.
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35
Or
Wrapper configuration selection (Europe only).
3. CropCutter function on machines with Rotor
options.
Or
Starter roll knife insert on North America models.
Or
Buffer zone, three dashes on non-cutter units.
4. Buffer zone, three dashes will be shown when
CropCutter function is selected in Setup item 3.
Or
Starter roll knife withdrawal size selection for
uncut outer crop layer on North American
models.
Or
Buffer zone, three dashes on non-cutter units.
5. Bale shape alarm selection (on/off).
6. Bale shape alarm threshold selection.
Or
Bale shape-sensitivity selection.
7. Near full bale alarm/indicator size selection.
8. Inch/metric selection.
9. Model number selection.
10. Buffer zone (three dashes).
11. Buffer zone (three dashes).
12. Bale size sensor adjustment.
3-17
SECTION 3 - OPERATOR’S PANEL OPERATION
13. Net wrapper actuator sensor adjustment and
calibration.
Or
Buffer zone, three dashes will be shown if Twine
only wrapper is selected in Setup Item 2.
14. Twine wrapper actuator sensor adjustment and
calibration.
Or
Buffer zone, three dashes will be shown if Net
only wrapper is selected in Setup Item 2.
15. Bale shape left-hand sensor adjustment and
calibration.
16. Bale shape right-hand sensor adjustment and
calibration.
17. CropCutter knife “cut” position sensor adjustment/testing, if CropCutter function is selected in
Setup Item 3.
Or
Starter roll knife actuator sensor adjustment and
calibration on North American models.
Or
Buffer zone, three dashes on non-cutter units.
18. Tailgate latch sensor adjustment/diagnostic.
19. Net counter roll sensor testing.
Or
Buffer zone, three dashes will be shown if Twine
only wrapper is selected in Setup Item 2.
20. Software version level display (the item number
20 will not be displayed).
21. Operator’s panel display and key tests (the item
number 21 will not be displayed).
22. Battery voltage display (the item number 22 will
not be displayed).
23. Duckbill dwell time in inserted position adjustment and calibration.
Refer to “Setup/Diagnostic Mode” section for
additional information on each item.
3-18
SECTION 3 - OPERATOR’S PANEL OPERATION
SETUP/DIAGNOSTIC MODE
The setup/diagnostic mode is used to program and
calibrate the operator’s panel and also to test some
of the components. When in the setup/diagnostic
mode, a flashing number at the left-hand side of the
display will indicate which function is active.
Item 1 is used to calibrate the bale size display to
match the size bale made.
Items 2 through 9 are used to select and/or program
operational features in the control box.
50022664
Items 10 and 11 are buffer zones and show three
dashes to separate the setup items from the
diagnostic and sensor calibration items.
36
Items 12 through 21 and 23 are used to test the
position sensors, adjust and/or calibrate the
potentiometer-style sensors, show software version
and test operator’s panel display.
Item 22 is battery voltage at the control box.
To Enter the Setup/Diagnostic Mode
Press and hold the OPEN BOOK symbol key for two
seconds. The alarm will sound to indicate that the
operator’s panel has been placed in the setup/diagnostic mode. The display should indicate “1”
(flashing) and the full bale size the operator’s panel
is set for.
To Advance to the Next Setup/Diagnostic Item
Press and release the OPEN BOOK symbol key; the
number on the left-hand side of the display will
advance by 1. Press the OPEN BOOK key
repeatedly to advance through setup items 1-23 in
sequence.
To Exit the Setup/Diagnostic Mode
Press and hold the OPEN BOOK symbol key for two
seconds. The alarm will sound to indicate that the
control box has been taken out of the setup/diagnostic mode and returned to normal operation.
3-19
SECTION 3 - OPERATOR’S PANEL OPERATION
SETUP ITEMS
ITEM 1 - Bale Size Calibration
The bale size calibration is used to calibrate the
operator’s panel to make a bale that is the same size
as is shown on the display panel. Calibration should
be performed when the size of bale made is not the
same as the full bale size displayed and whenever
the bale size sensor or control box has been adjusted
or replaced.
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37
When starting a new baler or whenever the bale size
sensor or control box has been adjusted or replaced,
set the bale size at least 30 centimeters below the
maximum full bale size but greater than 120
centimeters.
Make a bale and wrap it in the normal automatic
mode.
Measure the bale diameter both horizontally and
vertically and average the two measurements.
38
If the measured bale size is not the same as the
displayed size, calibrate the operator’s panel as
follows:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size desired. The “1” and FULL BALE indicator
should be flashing.
2. Use the “+” (plus) or “-” (minus) key to change the
bale size displayed to the measured size.
3. Press and hold the BALE SIZE key for one
second. The alarm will be activated and the FULL
BALE indicator will turn on steady for one second
indicating that the calibration is complete.
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39
4. Press and hold the OPEN BOOK key for two
seconds to exit the setup/diagnostic mode and
return to normal operation. The alarm will sound
to indicate that the control box has been taken out
of the setup/diagnostic mode and returned to
normal operation.
OR
To advance to setup item 2 - Press and release
the OPEN BOOK symbol key.
3-20
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 2 - Twine Learn or Wrapper Configuration
Item 2 is used to program a custom twine wrapping
pattern in PAt 4 or to select a specific wrapper
configuration.
Twine Learn
NOTE: Any existing custom pattern must be cleared
before a new pattern can be programmed into the
operator’s panel.
To enter a custom pattern:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
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40
2. Press the OPEN BOOK key again to advance to
item 2. The display should indicate “2” and there
should be a number on the right-hand side of the
display. The number at the right-hand side of the
display indicates the number of steps in the
custom pattern. Fourteen steps are in the
program shown. A custom program can contain
a maximum of thirty-two steps. The TWINE and
ACTUATOR indicators should be on and the
WRAP BALE indicator should be flashing.
3. The operator’s panel must be cleared before
entering a new pattern. Clear the pattern by
pressing and holding the CLEAR key for one
second. If a “0” is displayed, there is no custom
pattern programmed and the operator’s panel
can be programmed.
NOTE: When a “0” is displayed, there is no custom
pattern programmed in the operator’s panel. If PAt 4
is selected, the bale will be wrapped with 22 wraps.
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41
3-21
SECTION 3 - OPERATOR’S PANEL OPERATION
4. Enter a new custom program.
Use the EXTEND and RETRACT keys to move
the actuator and twine tubes to enter the new
program. When the actuator moves from the
home position, the ACTUATOR indicator will start
to flash.
It takes approximately two seconds for a 120
centimeter bale and approximately 3 seconds for
a 180 centimeter bale to make a revolution. Allow
sufficient dwell time at each step to place a wrap
on the bale.
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Custom Wrap Pattern
42
Press and hold the EXTEND key to extend the
actuator and move the twine tubes to the twine
start position at the center of the bale. When the
actuator reaches the “twine start” position,
release the EXTEND key. The ACTUATOR
indicator will turn on steady and the alarm will
beep when the twine tubes reach the “twine start”
position. The indicator on the front of the twine
box should also be at the left-hand side of the
decal.
Allow sufficient dwell time for the number of
starting center wraps to be placed on the bale and
then press and release the RETRACT key to
retract the actuator in steps to place the twine on
the bale in the desired pattern. When the actuator
reaches the precut position, the alarm will beep
and the ACTUATOR indicator will be on steady.
When the beep is heard, allow sufficient time for
the correct amount of end wraps to be placed on
the bale and then return the actuator to the home
position and cut the twine. The alarm will beep
when the sensor reaches the home position
magnet. Release the RETRACT key as soon as
the actuator reaches the home position.
NOTE: If more than 32 steps are attempted to be
programmed or if the actuator is allowed to dwell for
two minutes, the alarm will be activated and the
EJECT BALE indicator will flash, indicating the
programming of the custom wrap pattern has ended.
3-22
SECTION 3 - OPERATOR’S PANEL OPERATION
Automatic Dwell
In the custom wrap pattern previously described,
each bale will be wrapped exactly as programmed. If the bale diameter is changed from
the size originally programmed, it will have an
effect on the number of wraps wrapped on the
bale. To maintain the programmed twine spacing
and insure that sufficient wraps are on the
starting and end wraps, the “Automatic Dwell”
feature can be activated. To activate the
“Automatic Dwell” press the AUTO/MANUAL
key. The “Auto” pointer will turn on.
NOTE: Activation of the “Automatic Dwell” can only
be done with the system in item #2 of the
“Setup/Diagnostic Mode.”
With the “Automatic Dwell” turned on, the custom
programmed wrap pattern will automatically
place two starting and two end wraps on each
bale.
5. Press the OPEN BOOK key again to save the
change to the custom pattern. The display may
freeze momentarily, and the alarm will be
activated briefly. The display will then advance to
setup/diagnostic item 3.
6. To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
NOTE: With the “Automatic Dwell” turned on
additional end wraps can be added in the same
manner as the factory program patterns. See
“Changing the Number of Twine End Wraps.”
3-23
SECTION 3 - OPERATOR’S PANEL OPERATION
Wrapper Configuration Selection
Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
Press the OPEN BOOK key again to advance to item
2. Press and hold the NET/TWINE key for two
seconds to enter or change the wrapper configuration. The alarm will sound for one second when a
selection is changed. Three configurations are
available, Net/Twine, Net only and Twine only.
In the Net/Twine configuration, when in normal
operation, the operator is able to switch between Net
and Twine wrapping simply by pressing the
NET/TWINE key. This configuration is shown by a “2”
flashing at the left-hand side of the display, the Twine
pointer is solid and the Wrap Bale pointer is flashing.
50022664
43
In the Twine only configuration, the baler will
perform Twine only wrapping. This will prevent the
operator from inadvertently switching from Twine
wrap to Net wrap, when in normal operation. This
configuration is shown by a “2” flashing at the
left-hand side of the display, the Twine and Wrap Bale
pointers are flashing.
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44
In the Net only configuration, the baler will perform
Net only wrapping. This will prevent the operator from
inadvertently switching from Net wrap to Twine wrap,
when in normal operation. This configuration is
shown by a “2” flashing at the left-hand side of the
display with three dashes to the right-hand side.
The control box is usually configured at the factory to
match the base unit wrapper configuration. A new
control box from Service Parts is always preset in the
Net/Twine wrapper configuration.
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45
3-24
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 3 - CropCutter Selection or Starter Roll
Knife Insert Size or Buffer Zone on all Other
Machines
NOTE: If the unit is equipped with the CropCutter
option, be sure the unit is programmed as described
above. Units improperly programmed for starter roll
knife insert which is not available in Europe will not
operate properly.
Item 3 is used to select the CropCutter functions or
Starter Roll Knife Insert Size. When selected for
CropCutter functions the “3” on the left-hand side of
the display and the KNIFE indicator will be flashing.
The symbol “=o” will be on the right-hand side of the
display. When selected for knife insert size the “3” on
the left-hand side of the display and the KNIFE
indicator will be flashing. A number will be on the
right-hand side of the display. All other machines will
show three dashes for a Buffer Zone.
To toggle between the CropCutter function or Starter
Roll Knife Insert Size, press and hold the
CROPCUTTER ON/OFF key for two seconds. The
alarm will sound for one second when the selection
is changed.
CropCutter Function Selection
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
2. Press and release the OPEN BOOK key two
more times to advance to item 3.
3. Press and hold the CROPCUTTER ON/OFF key
for two seconds to toggle between the selections.
Select CropCutter function indicated by the
flashing “3”, flashing KNIFE indicator and the
symbol “=o”, on the right-hand side of the display.
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4. To advance to setup item 4, press and release the
OPEN BOOK symbol key.
46
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol key for two seconds. The alarm
will sound to indicate that the control box has been
taken out of the setup/diagnostic mode and returned
to normal operation.
NOTE: When setup item 3 is selected for CropCutter
function and the operator’s panel is returned back to
normal operation mode, the number of CropCutter
cut bales will be counted by the operator’s panel. The
CropCutter knives must be in the cut position when
the bale is ejected and the tailgate closed.
3-25
SECTION 3 - OPERATOR’S PANEL OPERATION
Starter Roll Knife Insert Size Selection
The knife insert size is used to set the bale size at
which the operator’s panel will insert the knives. This
option is not available in Europe. The knife insert size
is shown only in units with the starter roll knife option.
CropCutter units will show “3” with the “=o” symbol.
All other models will show three dashes.
ITEM 4 - Buffer Zone or Starter Roll Knife
Withdrawal
Item 4 should display three dashes unless improperly
programmed in setup item 3. Be certain setup item 3 is
programmed for CropCutter function if the unit is
equipped with a CropCutter.
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ITEM 5 - Bale Shape Alarm
The bale shape alarm can be turned on to warn the
operator when there is a different degree of fill on both
sides of the bale. The alarm can be turned off if
desired. This is often selected when baling full width
windrows.
To turn the alarm on or off:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
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2. Press and release the OPEN BOOK key
repeatedly to advance to item 5. The bottom
segment of both BALE SHAPE bar graphs should
be flashing and either On or OFF (1 or 0 on metric
balers) should be displayed.
48
3-26
SECTION 3 - OPERATOR’S PANEL OPERATION
3. Press either the “+” (plus) or “-” (minus) key to
turn the alarm On (1) or OFF (0).
4. To advance to setup item 6 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
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49
ITEM 6 - Bale Shape Alarm Threshold or Bale
Shape Sensitivity
Bale Shape Alarm Threshold
The bale shape alarm threshold is used to set the
sensitivity of the bale shape alarm. The alarm can be
set to turn on when there is a differential of 20% - two
bars, 30% - three bars, 40% - four bars, 50% - five
bars, or 60% - six bars between the two sides. Each
bar segment of the graphs is equal to 10% of the
range of sensor movement. The initial factory setting
for the threshold is 40 indicated by four bars.
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To set the threshold level:
50
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
2. Press and release the OPEN BOOK key
repeatedly to advance to item 6. Segments at the
bottom of both BALE SHAPE bar graphs should
be flashing, and the setting number should be
displayed.
3. Press the “+” (plus) key to increase the
differential level. Press the “-” (minus) key to
decrease the differential level.
4. To advance to setup item 7 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
3-27
SECTION 3 - OPERATOR’S PANEL OPERATION
Bale Shape Sensitivity
Used to adjust the sensitivity of the bar graphs for
bale shape by changing the time interval between
readings processed by the operator’s panel. The
higher the number the slower the response of the
graphs. The lower the number the faster the
response of the graphs.
To change the sensitivity:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
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51
2. Press and release the OPEN BOOK key
repeatedly to advance to item 6.
Press and hold the Bale Size key.
The left-hand side of the display should read “6”
and the right-hand side of the display should be
between 2 and 50. The bottom Bale Shape
segments will be flashing.
3. While holding the Bale Size key, press the “+”
(plus) key to increase the number and reduce the
sensitivity level. Press the “-” (minus) key to
decrease the number and increase the sensitivity
level. The sensitivity can be set between 2 and 50
in steps of 2. The factory setting is 32.
4. To advance to setup item 7 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
3-28
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 7 - Near Full Alarm/Indicator Size Selection
Item 7 is used to select the near full bale alarm size,
or turning it off when zero is selected.
To set the near full bale size alarm:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
2. Press and release the OPEN BOOK key
repeatedly to advance to item 7. The display
should show “7” flashing at the left-hand side of
the display and a number between 0 and 15 will
be displayed on the right-hand side. When “10” is
displayed on the right-hand side, the near full
bale indicator/alarm is set at 10 centimeters
before the bale reaches full size. For example, if
making a 150 centimeter bale, the near full bale
alarm will sound at 140 centimeters and the
brackets will be flashing.
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52
3. Use the “+” (plus) or “-” (minus) keys to select the
desired near full bale alarm size. The near full
alarm size can be set to sound the alarm at 5,10
or 15 centimeters before reaching full bale. The
near full alarm/indicator can be turned off be
selecting zero.
4. To advance to setup item 8 - Press and release
the OPEN BOOK symbol key.
Or
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
ITEM 8 - Inch/Metric Selection
The Bale Command Plus system can be set to
display the bale size in either inches or centimeters.
To change the inch/metric selection:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
2. Press and release the OPEN BOOK key
repeatedly to advance to item 8. When set to
display the bale size in inches, “USA” will be
displayed as shown. When set to display the bale
size in centimeters, “Eur” will be displayed.
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3-29
SECTION 3 - OPERATOR’S PANEL OPERATION
3. Press either the “+” (plus) or “-” (minus) key to
change the display between inches and
centimeters.
4. To advance to setup item 9 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
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54
ITEM 9 - Model Number Selection
Item 9 in the setup/diagnostic mode displays the
model the operator’s panel is programmed to
operate. For the Bale Command Plus system to
operate properly, the operator’s panel display must
match the baler model number. The Bale
Command Plus system is programmed to operate
the following baler models: BR7060, BR7070.
To check and/or change the model number:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
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55
2. Press and release the OPEN BOOK key
repeatedly to advance to item 9. The display
should indicate “9” and the model number. In the
example, Model BR7060 is shown.
3. Press either the “+” (plus) or “-” (minus) key to
scroll through the model numbers available.
Pressing “+” (plus) repeatedly will scroll up
through the model choices while pressing
“-” (minus) repeatedly will scroll down through
the model numbers.
4. To advance to setup item 10 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
3-30
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEMS 10 and 11 - Buffer
Items 10 and 11 are used as a buffer zone to separate
the setup from the diagnostic and calibration
adjustments. When selected, the item number and
three dashes will be displayed,
To advance to the setup item 12 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
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56
DIAGNOSTIC AND CALIBRATION ITEMS
ITEM 12 - Bale Size Sensor
Item 12 is used to adjust the bale size sensor mount
for the “empty” position and to check operation of the
bale size sensor.
To adjust the sensor mount for the “empty” position:
1. Be sure the bale chamber is empty and the
take-up arm is in the home position.
Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
2. Press and release the OPEN BOOK key
repeatedly to advance to item 12.
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57
The left-hand side of the display should read “12”
and the FULL BALE indicator triangle should be
flashing. A number should appear in the
right-hand side of the display.
3. Loosen the mounting cap screws, 1, and rotate
the sensor and mount. The number on the
display should change as the sensor is rotated.
Adjust the sensor “empty” position for a reading
of 28 - 32.
1
4. To advance to setup item 13 - Press and release
the OPEN BOOK symbol.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
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3-31
SECTION 3 - OPERATOR’S PANEL OPERATION
To check operation of the sensor:
5. Enter the setup/diagnostic mode as described in
steps 1 and 2 above.
The left-hand side of the display should read “12”
and the FULL BALE indicator triangle should be
flashing. A number should appear in the
right-hand side of the display. This number
should be 28 - 32.
1
6. Remove the bolt connecting the sensor lever, 1,
to the take-up arm bracket and rotate the lever.
The number on the display should change as the
lever is rotated. Move the lever from “empty” to
“full” and back again.
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IMPORTANT: Do not force or drop the lever as the
sensor may be damaged.
As the lever is moved to the “full” position the
numbers on the display should increase steadily.
As the lever is moved to the “empty” position, the
numbers on the display should decrease
steadily.
The operating range for the sensor is 20 to 250
(full sensor range is approximately 0 - 255). If the
numbers decrease at any time while moving
toward the full position or if the number abruptly
goes to approximately 0 or 255, check the wiring
harness for damage or a loose connection. If the
wiring harness and connection are good, check
for possible damage to the sensor or contact your
authorized dealer for assistance.
7. To advance to setup item 13 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
NOTE: If the bale size sensor is replaced, be sure to
adjust the “empty” position of the sensor mounting
bracket. The operator’s panel must then also be
calibrated using setup Item 1 after making and
wrapping the first bale in automatic mode.
3-32
SECTION 3 - OPERATOR’S PANEL OPERATION
Item 13 - Net Actuator Sensor or Buffer Zone (in
Twine Only Configuration)
Item 13 is used for adjusting, calibrating and testing
the net wrapper sensor.
NOTE: Before using the setup/diagnostic mode of
the operators panel, the mechanical linkage of the
duckbill must be set correctly.
Net Wrapper Mechanical Adjustment
This procedure covers all the round balers. The
pictures will vary depending on the options and the
model of the baler.
DANGER
Impact hazard! Make sure the area surrounding the
tailgate is clear of all persons and domestic animals
before opening or closing the tailgate. Failure to
comply will result in death or serious injury.
D0026A
DANGER
Crushing hazard! Make sure the area surrounding
the tailgate is clear of all persons and domestic
animals before opening or closing the tailgate.
Failure to comply will result in death or serious
injury.
D0034A
1. Open the tailgate and apply the tailgate lock, 1.
DANGER
Crush hazard! The tailgate may close faster than
you can move away. ALWAYS make sure the
tailgate lockout valves are in the OFF (locked)
position before working under a raised tailgate.
In the event of a sudden loss of hydraulic
pressure, the tailgate will fall if the lockout valves
are not engaged. Stand clear of the tailgate
before disengaging the lockout valves. Failure to
comply will result in death or serious injury.
1
D0002A
20102111
60
2. Place a small piece of ferrous metal on the
tailgate latch sensor, at 1 to simulate the tailgate
is closed making the Bale Command Plus system
operational.
1
50033905
61
3-33
SECTION 3 - OPERATOR’S PANEL OPERATION
3. Insert the duckbill with the extend key, 1.
1
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62
4. Loosen the two bolts in the lower actuator
mounting, 1.
A
5. Adjust the position of the mounting to insert the
duckbill as far as possible without any
interference.
1
Your unit is equipped with a mechanical stop for
the duckbill Insert position. You may need to
increase or decrease the stop length by
loosening the jam nuts, 2, and threading the stop,
3, in or out to have a clearance, A, of
approximately 2 mm (5/64 in), as shown. After
adjustments have been made, tighten the jam
nuts, 2.
2
3
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63
The interference can be the end of the duckbill hitting
the notch in the frame, 1.
The interference can also be the baffle, 2, on the
duckbill hitting the stationary dimpled roll, 3.
A
Between the duckbill and slot end in side sheet, 4,
ensure there is a distance, A, of 60 ± 2 mm (2-3/8 ±
1/16 in) on a 1.83 m (6 ft) tall unit and a distance, B,
of 42 ± 2 mm (1-5/8 ± 1/16 in) on a 1.52 m (5 ft) tall
unit.
B
4
1
2
3
76073070
64
3-34
SECTION 3 - OPERATOR’S PANEL OPERATION
6. Remove the idler spring tension.
1
7. Rotate the PTO to bring the drive chain connector
link (master link) between the drive sprocket and
idler sprocket.
8. To check the clearance remove the drive chain,
1, from the stationary dimpled roll.
9. Rotate the stationary dimpled roll to check the
clearance for interference.
10. Position the actuator mount to just remove either
of the two interference above and tighten it in
position.
10030800
65
11. Make sure the spring mounting bracket, 1, is set
to trip the knife over center. If not adjust it in the
slots, 2.
2
1
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66
12. Set the knife link length, at 1. The cam follower
bearing, 2, must be centered in the curved slot
and have clearance to the end of the slot when
actuator, 3, fully extended.
3
2
1
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67
3-35
SECTION 3 - OPERATOR’S PANEL OPERATION
13. Move duckbill to the home position with the
retract key.
1
4
14. Check that the cam follower bearing, 1, does not
hit the end of the notch in the cam.
If it does adjust the length of the knife link.
15. Recheck the cam follower clearance at both ends
of it’s travel in the cam slot.
2
16. With the duckbill in the home position, adjust the
knife spring, 2, to a length, A, of 289 - 295 mm
(11-3/8 - 11-5/8 in) inside the hooks.
76073063
17. With the duckbill in the home position and the four
holes in the brake drum, 3, at the quarter hour
position, adjust the eyebolt, 4, to slightly tension
spring for 13.5 ± 2 N⋅m (120 ± 18 lb in) of torque
on brake drum, 3.
3
A
68
18. Move the duckbill to the inserted position.
The brake, 1, must have a clearance, A, 2 - 4 mm
(1/16 - 3/16 in) off the brake drum.
2
A
The adjustment can be made at the link length, 2, or
the brake arm pivot, 3, as required.
When the mechanical adjustments are complete,
proceed to the electronic setup.
3
1
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69
3-36
SECTION 3 - OPERATOR’S PANEL OPERATION
Net Wrapper Electronic Adjustment
Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
Press and release the OPEN BOOK key repeatedly
to advance to item 13. The display should show “13”
flashing at the left-hand side and a number showing
the net wrapper actuator sensor reading on the
right-hand side. The NET pointer should be on and
the ACTUATOR pointer should be flashing.
Before Adjusting the Sensor:
Make sure all the linkages connected to the net
wrapper sensor move freely.
“Insert” Position Adjustment:
50022664
Use the EXTEND key to extend the net actuator and
move the duckbill to the “insert” position.
70
“Insert” Position Adjustment with Mechanical
Duckbill Stop:
A
Your unit is equipped with a mechanical stop for the
duckbill Insert position. You may need to increase or
decrease the stop Length by loosening the nuts, 1,
and threading the stop, 2, in or out to have a
clearance, A, of approximately 2 mm (5/64 in), as
shown. After adjustments have been made, tighten
nuts, 1.
1
2
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71
With the duckbill in the “insert” position, verify the
reading is between 23 - 27. If not, loosen the sensor
mounting bolts, 1, and rotate the sensor to obtain a
reading between 23 - 27.
1
NOTE: The net actuator adjustment must be made
with the net actuator fully extended in the “insert” net
position.
NOTE: If the sensor needs adjusted, be sure to
calibrate the “home”, “precut” and “insert” positions.
If the sensor is replaced, be sure to adjust the “home”
position and then calibrate the “home”. “precut” and
“insert” positions.
50046175
“Insert” Position Calibration:
With the actuator fully extended, the sensor reading
should be between 23 - 27. Due to manufacturing
production procedures the sensor reading may vary
as much as 23 - 40 on models from the factory.
72
Press and hold the “+” (plus) key for one second. The
alarm will sound for one second and the ACTUATOR
pointer will turn on solid for one second.
3-37
SECTION 3 - OPERATOR’S PANEL OPERATION
NOTE: The control box will not calibrate if the sensor
“insert” reading is not between 15 and 40. An “Error”
message will be displayed on the right-hand side of
the display and alarm will sound with three short
beeps.
To Test the Sensor:
Manually extend and retract the net wrap actuator to
rotate the sensor. The number on the display should
change as the sensor is rotated. As the sensor is
rotated to the “insert” position, the numbers on the
display should decrease steadily. As the sensor is
rotated to the “home” position, the numbers on the
display should increase steadily.
“Precut” Position Calibration:
Use the EXTEND or RETRACT key to extend or
retract the net actuator and move the duckbill to the
desired “precut” position.
The normal operating range for the sensor is from 15
to 250. The sensor end to end range is approximately
0 – 255. If while moving the sensor the number
abruptly goes to approximately 0 or 255, check the
wiring harness for a loose connection. A zero
displayed on the operator’s panel indicates a broken
wire or open circuit. If the wiring and connections are
good, check for possible damage to the sensor, or
contact your authorized dealer for assistance.
The precut position is when the knife trip roller is
approximately 25.4 mm (1 in) from exiting the narrow
cam slot in the duckbill. See Section 1, Figure 24.
Press and hold the “NUMBER WRAPS” key for one
second. The alarm will sound for one second and the
ACTUATOR pointer will turn on solid for one second.
To advance to Setup Item 14 – Press the OPEN
BOOK symbol.
NOTE: The control box will not calibrate if the sensor
“precut” reading is not between 41 and 190. An “Er”
error message will be displayed on the right-hand
side of the display and alarm will sound with three
short beeps.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
“Home” Position Calibration:
Use the RETRACT key to move the duckbill to the
“home” position.
The home position is where the actuator is fully
retracted.
Press and hold the “-” (minus) key for one second.
The alarm will sound for one second and the
ACTUATOR pointer will turn on solid for one second.
NOTE: The control box will not calibrate if the sensor
“home” reading is not between 150 and 249. An
“Error” message will be displayed on the right-hand
side of the display and alarm will sound with three
short beeps.
3-38
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 14 - Twine Actuator Sensor or Buffer Zone
(in Net Only Configuration)
Item 14 is used for adjusting, calibrating and testing
the twine actuator sensor.
Enter the setup diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
Press and release the OPEN BOOK key repeatedly
to advance to item 14. The display should show “14”
flashing at the left-hand side of the display and a
number showing the twine wrapper actuator sensor
reading on the right-hand side of the display. The
TWINE pointer should be on and the ACTUATOR
pointer should be flashing.
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73
Before Adjusting the Sensor:
Make sure all the linkages connected to the twine
actuator sensor move freely.
“Home” Position Adjustment:
Use the RETRACT key to fully retract the twine
actuator and move the twine tubes to the “home”
position.
With the twine tubes in the “home” position, verify the
sensor reading is between 20 - 30. If not, loosen the
sensor mounting bolts and rotate the sensor, 1, to
obtain a reading between 20 - 30.
NOTE: If the sensor is adjusted, be sure to calibrate
the “home”, “precut” and “insert” positions. If the
sensor is replaced, be sure to adjust the “home”
position and then calibrate the “home”, “precut” and
“insert” positions.
“Home” Position Calibration:
Verify the actuator is in the fully retracted position, the
twine tubes are in the “home” position, and the sensor
reading is between 20 - 30.
20021995
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74
Press and hold the “-” (minus) key for one second.
The alarm will sound for one second and the
ACTUATOR pointer will turn on solid for one second.
NOTE: The control box will not calibrate if the sensor
“home” reading is not between 15 and 40. An “Er”
error message will be displayed on the right-hand
side of the display and and alarm will sound with three
short beeps.
3-39
SECTION 3 - OPERATOR’S PANEL OPERATION
If while moving the sensor, the number abruptly goes
to approximately 0 or 255, check the wiring harness
for a loose connection. If the wiring and connections
are good, check for possible damage to the sensor,
or contact your authorized dealer for assistance.
“Precut” Position Calibration:
Use the EXTEND or RETRACT key to extend or
retract the twine actuator and move the twine tubes
to the desired “precut” position. The “pre-cut” position
is where the twine tubes have just passed upward
through the open knives and just before the twine
knives start to close.
For Flax Bailing Only
For customers who wish to disable the audible alarm
associated with twine tube out of home position
warning when bailing flax. The alarm On/Off function
allows user/dealer to disable or enable the audible
alarm associated with twine tube out of home position
warning in the setup/diagnostic mode in item 14.
Press and hold the NUMBER WRAPS key for one
second. The alarm will sound for one second and the
ACTUATOR pointer will turn on solid for one second.
NOTE: The control box will not calibrate if the sensor
“precut” reading is not between 35 and 190. An
“Error” message will be displayed on the right-hand
side of the display and alarm will sound with three
short beeps.
IMPORTANT: It is possible that the twine tubes will
be damaged when bailing with the twine tubes in the
“INSERT” position. When finished with custom
bailing be sure to enable/restore the alarm warning.
“Insert” Position Calibration:
To access this feature, the user will have to enter the
setup/diagnostic mode and go to setup item 14, press
and hold the “NET/TWINE” key for 2 seconds to enter
this alarm On/Off function.
Use the EXTEND key to fully extend the twine
actuator.
Press and hold the “+” (plus) key for one second. The
alarm will sound for one second and the ACTUATOR
pointer will turn on solid for one second.
1. The audible alarm will start “beeping” and the
warning indicator lamp will be flashing if the twine
tube out of home position alarm is enabled (On),
the display shall show “14 On” or “14 1” (metric
mode) with “14” flashing.
NOTE: The control box will not calibrate if the sensor
“insert” reading is not between 150 and 250. An
“Error” message will be displayed on the right-hand
side of the display and an alarm will sound with three
short beeps.
or
2. The audible alarm will sound and the warning
indicator amp will turn on for 1 second if the twine
tube out of home position alarm is disabled (Off),
the display shall show “14OFF” or “14 0” (metric
mode) with “14” flashing.
To Test the Sensor:
Rotate the sensor. The number on the display should
change as the sensor is rotated. As the sensor is
rotated to the “insert” position, the numbers on the
display should increase steadily. As the sensor is
rotated to the “home” position, the numbers on the
display should decrease steadily.
Use the “+” (plus) or “-” (minus) key to enable or
disable the twine tube out of home position alarm.
When the alarm is disabled, the display shall show
“14OFF” or “14 0” (metric mode), the audible alarm
will stop “beeping” and the warning indicator lamp will
turn off. When the alarm is enabled, the display shall
show “14 On” or “14 1” (metric mode), the audible
alarm will be “beeping” and the warning indicator amp
will be flashing.
The normal operating range for the sensor is 15 to
250. The sensor end to end range is approximately
0 – 255.
To advance to Setup Item 15 – Press and release the
OPEN BOOK symbol.
Press and hold the “NET/TWINE” key for 2 seconds
to exit this alarm On/Off function, the audible alarm
will sound and the warning indicator lamp will turn on
for 1 second, the display shall show “14xxx” where
“xxx” is the twine actuator sensor reading.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-40
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 15 - Bale Shape - Left Sensor
Item 15 is used for adjusting, calibrating and testing
the BALE SHAPE - LEFT sensor.
To adjust and calibrate the sensor:
1. Check to be sure the sensor arm is at the empty
position. If it is not, move it to the empty position.
If the linkage is binding, it should be freed before
proceeding.
2. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
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3. Press and release the OPEN BOOK key
repeatedly to advance to item 15.
The left-hand side of the display should read “15,”
the bottom segment of the LEFT bar graph
should be ON and flashing. A number should
appear in the right-hand side of the display. This
number should be between 20 and 30 when in the
empty position.
4. Adjust the sensor empty position by loosening
the sensor mounting bolts, 1, and rotating the
sensor. The number on the display should
change as the sensor is rotated. Rotate the
sensor until the number is between 20 and 30 and
tighten the mounting bolts.
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5. Calibrate the “empty” position by pressing and
holding the “-” (minus) key for one second until
the alarm activates. The lower five segments of
the LEFT bar graph will be turned on steady.
NOTE: The control box will not calibrate if the sensor
home position reading is not between 11 and 79. An
“Er” error message will be displayed and the alarm
will sound three short beeps.
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3-41
SECTION 3 - OPERATOR’S PANEL OPERATION
6. Calibrate the full position by moving the sensor
arm, 1, to the full position and installing a 3 mm
(1/8 in) cotter pin, 2, in the hole in the arm. Allow
the cotter pin to rest against the outside of the
bale chamber.
1
2
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7. Press and hold the “+” (plus) key for one second
until the alarm activates. All segments of the
LEFT bar graph will turn on solid.
NOTE: The control box will not calibrate if the sensor
full position reading is not between 101 and 249. An
“Er” error message will be displayed at the right-hand
side and the alarm will sound three short beeps.
8. To clear an incorrect calibration, press and hold
the CLEAR key for one second until the alarm
activates. The bottom segment of the LEFT bar
graph will be flashing.
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Repeat the calibration procedure.
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SECTION 3 - OPERATOR’S PANEL OPERATION
To test operation of the sensor:
1
9. Enter the setup/diagnostic mode as described in
steps 1 through 3.
10. Move the sensor arm, 1, in and out to rotate the
center of the sensor. The number on the display
should change as the arm is moved. Move the
arm from empty to full and back again.
IMPORTANT: Do not force the lever as the sensor
may be damaged.
The range for the display is approximately 0 to
255. If while moving the sensor to the maximum
position the number abruptly goes to approximately 0 or 255, the wiring harness or the sensor
should be checked for damage or a loose
connection. If the wiring and connections are
good, check for possible damage to the sensor or
contact your authorized dealer for assistance.
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11. Adjust the sensor and calibrate to the empty and
full positions as described in steps 1 through 8.
NOTE: If the sensor is replaced, be sure to adjust the
empty position and then calibrate to the empty and
full positions.
12. To advance to setup item 16 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
ITEM 16 - Bale Shape - Right Sensor
Item 16 is used for adjusting, calibrating and testing
the BALE SHAPE - RIGHT sensor.
To adjust and calibrate the sensor:
1. Check to be sure the sensor arm is at the empty
position. If it is not, move it to the empty position.
If the linkage is binding, it should be freed before
proceeding.
2. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
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3. Press and release the OPEN BOOK key
repeatedly to advance to item 16.
81
The left-hand side of the display should read “16”, the
bottom segment of the RIGHT bar graph should be
ON and flashing. A number should appear in the
right-hand side of the display. This number should be
between 20 and 30 when in the empty position.
3-43
SECTION 3 - OPERATOR’S PANEL OPERATION
4. Adjust the sensor empty position by loosening
the sensor mounting bolts, 1, and rotating the
sensor. The number on the display should
change as the sensor is rotated. Rotate the
sensor until the number is between 20 and 30 and
tighten the mounting bolts.
1
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5. Calibrate the “empty” position by pressing and
holding the “-” (minus) key for one second until
the alarm activates. The lower five segments of
the RIGHT bar graph will be turned on steady.
NOTE: The control box will not calibrate if the sensor
home position reading is not between 11 and 79. An
Error message will be displayed and the alarm will
sound three short beeps.
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6. Calibrate the full position by moving the sensor
arm, 1, to the full position and installing a 3 mm
(1/8 in) cotter pin, 2, in the hole in the arm. Allow
the cotter pin to rest against the outside of the
bale chamber.
1
2
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SECTION 3 - OPERATOR’S PANEL OPERATION
7. Press and hold the “+” (plus) key for one second
until the alarm activates. All segments of the
RIGHT bar graph will turn on solid.
NOTE: The control box will not calibrate if the sensor
full position reading is not between 101 and 249. An
Error message will be displayed at the right-hand
side and the alarm will sound three short beeps.
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8. To clear an incorrect calibration, press and hold
the CLEAR key for one second until the alarm
activates. The bottom segment of the RIGHT bar
graph will be flashing.
Repeat the calibration procedure.
To test operation of the sensor:
9. Enter the setup/diagnostic mode as described in
steps 1 through 3.
10. Move the sensor arm, 1, in and out to rotate the
center of the sensor. The number on the display
should change as the arm is moved. Move the
arm from empty to full and back again.
1
IMPORTANT: Do not force the lever as the sensor
may be damaged.
The range for the display is approximately 0 to 255.
If while moving the sensor to the maximum position
the number abruptly goes to approximately 0 or 255,
the wiring harness or the sensor should be checked
for damage or a loose connection. If the wiring and
connections are good, check for possible damage to
the sensor or contact your authorized dealer for
assistance.
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11. Adjust the sensor and calibrate to the empty and
full positions as described in steps 1 through 8.
NOTE: If the sensor is replaced, be sure to adjust the
empty position and then calibrate to the empty and
full positions.
12. To advance to step item 17 – Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-45
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 17 - CropCutter Knife Position Sensor or
Starter Roll Knife Actuator Sensor or Buffer Zone
on Non-cutter Units
Item 17 is used for adjusting and testing the rotor crop
cutter knife position sensor or starter roll knife
actuator sensor adjusting calibrating and testing
depending on the selection in Setup Item 3.
CropCutter Knife “Cut” Position Sensor Adjustment and Testing:
To adjust and test the sensor, enter the setup/diagnostic mode by pressing and holding the OPEN
BOOK key for two seconds. The display should
indicate “1” and the full bale size.
Press and release the OPEN BOOK key repeatedly
to advance to item 17.
The display should show “17” flashing at the left-hand
side of the display and a “Lo” or “Hi” on the right-hand
side of the display. A “Lo” indicates the sensor switch
is closed and the Knife pointer should be on solid
when a ferrous metal target is in front of the sensor.
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A “Hi” indicates the sensor switch is opened and the
Knife pointer should be off when the ferrous metal
target is away from the sensor.
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3-46
SECTION 3 - OPERATOR’S PANEL OPERATION
To Test the Sensor:
Retract the knife hydraulic cylinder to the home
position. Place a piece of ferrous metal plate in front
of the sensor sensing face, the alarm should sound
with a short “beep”, the display should change from
“Hi” to “Lo” and the knife pointer should turn on solid.
Remove the ferrous metal plate from the sensor
sensing face, the alarm should sound with a short
“beep”, the display should change from “Lo” to “Hi”
and the knife pointer should turn off.
When Setup Item 3 is Set for CropCutter:
Make sure the hydraulic cylinder actuating the
CropCutter knives is in the fully extended position
keeping the knives in the cut position.
“Cut” Position Adjustment:
With the hydraulic cylinder fully extended and the
knives in the cut position. Adjust the sensor for a 3-7
mm (1/8-1/4 in) clearance gap between the sensor
and knife arm assembly. The display should show a
“Lo”, the knife pointer should turn on solid and the
alarm should have sounded with a short “beep”
during the transition from “Hi” to “Lo”.
To advance to Setup Item 18 – Press and release the
OPEN BOOK symbol key.
OR
Verify sensor adjustment. Retract the knife hydraulic
cylinder, the alarm should sound with a short “beep”
as the knife arm assembly moves away from the
sensor, the display should change from “Lo” to “Hi”
and the knife pointer should turn off. Extend the knife
hydraulic cylinder, the alarm should sound with a
short “beep” as the knife arm assembly reaches the
cut position in front of the sensor, the display should
change from “Hi” to “Lo” and the Knife pointer should
turn on solid.
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
Starter Roll Knife Actuator Senor
This option is not available for European units. Be
certain Setup Item 3 is set for CropCutter function.
3-47
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 18 – Tailgate Sensor
Item 18 is used for adjusting and testing the tailgate
sensor.
Check to be sure the tailgate is closed and the
cylinders fully retracted. If the tailgate is not closed,
use the tractor hydraulics to move it to the closed
position.
Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds. The
display should indicate “1” and the full bale size.
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Press and release the OPEN BOOK key repeatedly
to advance to item 18. The display should show “18”
flashing at the left-hand side of the display and a “Lo”
on the right-hand side of the display. A “Lo” indicates
the sensor is closed. The TAILGATE pointer should
be on solid with the display showing a “Lo”.
“Closed” Position Adjustment:
Make sure the tailgate is closed and latched.
With the tailgate closed and latched, adjust the
sensor for a 3-7 mm (1/8-1/4 in) clearance gap
between the sensor and the flat of the tailgate latch
pin. The display should show “Lo”, the TAILGATE
pointer should be on solid and the alarm should have
sounded with a short “beep” during the transition from
“Hi” to “Lo”.
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Verify sensor adjustments. Open the tailgate, the
alarm should sound with a short “beep”, the display
should change from “Lo” to “Hi” and the TAILGATE
pointer should be flashing. Close the tailgate, the
alarm should sound with a short “beep”, the display
should change from “Hi” to “Lo” and the TAILGATE
pointer should be on solid.
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3-48
SECTION 3 - OPERATOR’S PANEL OPERATION
If the switch is not adjusted correctly, the display will
read “Hi”. A reading of “Hi” indicates the sensor is
open. The tailgate pointer will be flashing.
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To Test the Sensor:
Open the tailgate. Manually actuate the sensor to the
closed position by placing a piece of ferrous metal
plate in front of the sensor face, the alarm should
sound with a short “beep”, the display should change
from “Hi” to “Lo” and the TAILGATE pointer should be
on solid. Remove the ferrous metal plate from the
sensor sensing face to open the sensor, the alarm
should sound with a short “beep”, the display should
change from “Lo” to “Hi” and the TAILGATE pointer
should be flashing.
To advance to Setup Item 19 – Press and release the
OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-49
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 19 - Net Counter Roll Sensor or Buffer Zone
(in Twine Only Configuration)
Item 19 is used to check operation of the net counter
roll sensor.
To check operation of the sensor:
1. Check to be sure the magnet is under the sensor,
1, and the gap is correct. If not, rotate the counter
roll to move the magnet so it is positioned in front
of the sensor. Check the adjustment of the sensor
to magnet clearance. Adjust the sensor for a 1.5
mm (1/16 in) clearance gap, A, between the
sensor and the magnet.
A
2. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
1
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3. Press and release the OPEN BOOK key
repeatedly to advance to item 19.
The left-hand side of the display should read “19,”
the NET and WRAP BALE indicator triangles
should be on. The display should read “Lo.”
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94
4. Rotate the counter roll to move the magnet, 1,
away from the sensor, 2.
1
2
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3-50
SECTION 3 - OPERATOR’S PANEL OPERATION
The display should change to “Hi” and the WRAP
BALE indicator triangle should be flashing.
NOTE: If the magnet is not in front of the sensor, the
WRAP BALE indicator should be flashing and
displays “Hi.”
The WRAP BALE indicator should be on steady
when the magnet is in front of the sensor and the
display should read “Lo”, Figure 94. The WRAP
BALE indicator should be flashing when the
sensor is not over the magnet and the display
should read “Hi”, Figure 96. The alarm will also
beep when the display changes.
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5. To advance to setup item 20 - Press and release
the OPEN BOOK symbol key.
OR
To exit the setup/diagnostic mode, press and
hold the OPEN BOOK symbol for two seconds.
The alarm will sound to indicate that the control
box has been taken out of the setup/diagnostic
mode and returned to normal operation.
3-51
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 20 - Software Version
Item 20 is used to display the software version level
used in the operator’s panel and control box. The
setup/diagnostic mode item number (20) is not
displayed. An “o” at the left-hand side of the display
indicates that the displayed version is for the
operator’s panel. The number to the right-hand side
of the display indicates the version level of the
software.
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A “c” at the left-hand side of the display indicates that
the displayed version is for the operator’s panel. The
number to the right-hand side will change with each
version.
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A “C_” at the left-hand side of the display indicates
that the version displayed is for the operator’s panel
and that the software loaded is special “After Sales
Support” software. The number to the right-hand side
will change with each revision.
To change the display:
Press the “+” (plus) or “-” (minus) key to change the
display between the operator’s panel and control
box.
To advance to setup item 21 and automatically start
the display test - Press and release the OPEN BOOK
symbol key.
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99
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-52
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 21 - Operator’s Panel Display and Key Tests
Item 21 is used to check the segments of the
operator’s panel display and also the operation of the
keys on the operator’s panel.
NOTE: To skip this test, press the OPEN BOOK
symbol key twice to advance to Item 22.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
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Checking the display:
When the OPEN BOOK key is pressed and released
after checking the software version (item 20), the
operator’s panel will advance to the display check
and key test. All segments on the display will turn on
briefly and then the display will automatically cycle
through all segments of the display. The alarm will
also be activated briefly during each part of the cycle.
Watch the display carefully as the test sequence will
not be stopped if a segment does not turn on.
The segments will be cycled in the following
sequence:
a. 000.00, AUTO indicator.
b. 11111, MANUAL indicator, one segment on each
bar graph.
c. 22222, NET indicator, two segments on each bar
graph.
d. 33333, TWINE indicator, three segments on
each bar graph.
e. 44444, TAILGATE indicator, four segments on
each bar graph.
f.
55555, KNIFE indicator, five segments on each
bar graph.
g. 66666, ACTUATOR indicator, six segments on
each bar graph.
h. 77777, EJECT BALE indicator, seven segments
on each bar graph.
i.
88888, WRAP BALE indicator, eight segments
on each bar graph.
j.
99999, FULL BALE indicator, nine segments on
each bar graph.
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SECTION 3 - OPERATOR’S PANEL OPERATION
At the end of the automatic test there will be five
dashes shown across the display to indicate that the
display test is complete.
Testing the keys:
Pressing a key will cause a number associated with
the key to be displayed as follows:
Key Pressed
Number Displayed
CLEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EXTEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BALES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AUTO/MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CROP CUTTER ON/OFF . . . . . . . . . . . . . . . . . . . . 6
NET/TWINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
KNIFE EXTEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KNIFE RETRACT . . . . . . . . . . . . . . . . . . . . . . . . . 10
+ (plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- (minus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPEN BOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BALE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NUMBER WRAPS . . . . . . . . . . . . . . . . . . . . . . . . . 15
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When the 9 key is released, the display will return to
the 5 dashes. (----------)
After all the keys have been pressed, the number for
the last key will not be displayed. Instead the word
PASS will appear on the display for one second.
Press and release the OPEN BOOK symbol to
advance to Item 22.
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
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3-54
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 22 - Battery Voltage Display
The item number 22 is not displayed.
Item 22 is used to display the battery supply voltage.
The voltage shown on the display is the battery
supply voltage measured at the control box.
To Enable the Twine Wrapper Actuator:
Press the NET/TWINE key and the TWINE indicator
will turn on. Use the EXTEND or RETRACT key to
move the twine actuator and monitor the voltage on
the display.
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To Enable the Net Wrapper Actuator:
Press the NET/TWINE key and the NET indicator will
turn on. Use the EXTEND or RETRACT key to move
the net actuator and monitor the voltage on the
display.
NOTE: Be sure to return the twine, or net actuator to
their home position when the test is completed.
To Display the Lowest Voltage Captured During
Test:
Press and hold the “-” (minus) key.
To Display the Highest Voltage Captured During
The Test:
Press and hold the “+” (plus) key.
To Disable the Actuator, Reset the Lowest and
Highest Voltage Reading:
Press and hold the CLEAR key for one second. The
alarm will sound for one second.
To advance to setup item 23, press the OPEN BOOK
key.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK symbol for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-55
SECTION 3 - OPERATOR’S PANEL OPERATION
ITEM 23 - Duckbill Dwell Time at Insert Position
Item 23 is used for adjusting the duckbill for better
feeding of the net.
To adjust the duckbill dwell time:
1. Enter the setup/diagnostic mode by pressing and
holding the OPEN BOOK key for two seconds.
The display should indicate “1” and the full bale
size.
2. Press and release the OPEN BOOK key twenty
two more times to advance to item 23.
3. The display will show 23 on the left-hand side and
a number between 4 and 15 to the right-hand
side. The number on the right-hand side
represents the number of revolutions the net
counter wheel will make before the duckbill will
retract from the rolls.
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4. Use the “+” (plus) or “-” (minus) keys to increase
or decrease the value to obtain a desired setting.
Greater values increase dwell time.
5. Re-adjust these settings as required.
NOTE: Higher number settings may put more wraps
of net on bale when making smaller diameter bales.
6. To advance to setup item 1, press the OPEN
BOOK key.
OR
To exit the setup/diagnostic mode, press and hold the
OPEN BOOK key for two seconds. The alarm will
sound to indicate that the control box has been taken
out of the setup/diagnostic mode and returned to
normal operation.
3-56
SECTION 4
FIELD OPERATION
ATTACH THE BALER TO THE TRACTOR
With the operator’s panel installed on the tractor and
the power supply wire harness connected to a 12-volt
power supply as described in Section 2, attach the
baler to the tractor drawbar following the instructions
in the baler operator’s manual.
1
Connect the baler wire harness, 1, to the connector
bracket on the rear of the tractor.
Lower the pickup.
20021693
1
4-1
SECTION 4 - FIELD OPERATION
OPERATOR’S PANEL SETTINGS
NOTE: Refer to Section 3 for additional information
on using the operator’s panel keys.
Turn the Bale Command Plus system on by pressing
the ON/OFF key.
Check the display to see if the operator’s panel is set
for the desired operation. To automatically wrap a
bale with net, the AUTO, NET, and TAILGATE
indicator triangles should be on. To automatically
wrap a bale with twine, the AUTO, TWINE and
TAILGATE indicator triangles should be on. The
display should read 30. Figure 2 shows the
operator’s panel ready to automatically wrap a bale
with net.
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2
If the MANUAL indicator triangle is on, select the
automatic mode using the AUTO/MANUAL key.
Select net or twine using the NET/TWINE key.
Select the number of wraps of net or twine using the
NUMBER WRAPS and “+” (plus) or “-” (minus) keys.
Set the bale size using the BALE SIZE and “+” (plus)
or “-” (minus) keys.
NOTE: For the first bale on a new baler, the BALE
SIZE should be set at least 30 centimeters below the
maximum size for the baler, but not under 120
centimeters. After the first bale is made, measure it
and calibrate the control box if required. Refer to
setup/diagnostic item 1 in Section 3.
To make a bale using the bale shape alarm and bar
graphs as a guide, check setup/diagnostic items 5
(alarm on/off), and 6 (alarm threshold and bale shape
sensor sensitivity) per the instructions in Section 3.
BALE FORMATION
Start baling following the instruction in the baler
operator’s manual for making a core. When the core
of the bale reaches 75 centimeters, the display will
start to increase as the bale increases in size.
The display will continue to increase until the bale
reaches the full bale size.
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4-2
SECTION 4 - FIELD OPERATION
Bale Shape Indicator Bar Graphs
The bale shape indicator bar graphs at the right-hand
side of the display can be used by the operator to
assist in filling the bale uniformly. When making a
bale, the objective is to keep both graphs at the same
height.
While building the bale core, the bottom segment of
both graphs will be flashing.
After the core is formed, the BALE SHAPE - LEFT
and RIGHT bar graphs will display the relative filling
of each side of the bale. When one bar graph is lower
than the other, drive to fill the side of the bale with the
low graph. Example: Figure 4 shows a lower bar
graph on the right-hand side indicating that the
operator should drive to fill the right-hand side of the
bale.
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4
If the alarm is turned on, it will sound two short beeps
and the segments of the lower graph will flash if the
difference between the graphs reaches the preset
level. Refer to setup/diagnostic items 5 and 6 in
Section 3. If the uneven condition is not corrected
within 10 seconds, the alarm will beep continuously.
The alarm will turn off automatically and the lower
graph will stop flashing when the uneven bale shape
condition is corrected.
The uneven bale alarm will not sound if there is a
FULL BALE or EJECT BALE signal.
The sensitivity of the bar graphs can be adjusted to
match field conditions. Refer to setup/diagnostic item
6 in Section 3.
Near Full Bale Alarm/Indicator
When the bale being made reaches the preset near
full bale alarm/indicator size, the alarm will sound for
one-half second and the full bale bracket symbol will
be flashing until the bale reaches full size.
NOTE: If the near full bale alarm/indicator size is set
at 15 centimeters, and the full bale size at 90
centimeters, the near full bale alarm/indicator will
sound and the full bale bracket symbol will be flashing
when the bale reaches 80 centimeters.
The near full bale alarm/indicator size can be
changed in Setup Item 7. The near full bale
alarm/indicator can be set at 5, 10 or 15 centimeters
before full bale size. Setting it at zero in Setup Item
7 will turn off the near full bale alarm/indicator.
50022664
5
4-3
SECTION 4 - FIELD OPERATION
FULL BALE ALARM
When the bale reaches the preset full bale size, the
alarm will be activated and the display will indicate the
full bale size surrounded by brackets. The FULL
BALE indicator triangle will also be turned on. When
the full bale alarm is activated, stop forward motion of
the tractor. DO NOT disengage the PTO.
If the system is in the automatic mode, the automatic
wrap cycle will start soon after the full bale alarm is
activated.
If the system is in the manual mode, the operator can
wrap the bale by using the EXTEND and RETRACT
keys or by changing to the automatic mode and then
pressing and holding the WRAP key for 2 seconds.
50022664
6
4-4
SECTION 4 - FIELD OPERATION
WRAPPING THE BALE
Wrapping the Bale with Net
Soon after the full bale alarm is activated, the control
box will send power to the actuator to move the
duckbill to the insert position. When the bale grabs
the net and starts to pull it off the roll, the counter roll
magnet will rotate past the sensor and send a signal
to the control box. After the control box senses start
of the counter roll, the WRAP BALE indicator triangle
will turn on indicating the net has started and it will
also move the actuator to the precut position. After
the counter roll magnet has rotated past the sensor
the correct number of times as determined by the
bale size and number of wraps selected, the control
box will move the duckbill to the home position and
release the knife to cut the net.
50022664
7
The operator can observe that net is being pulled
from the roll and is cut by watching through the
openings in the net/twine box cover, 1.
If the net does not start within seven seconds after the
duckbill has started to extend to insert net, the control
box will automatically return the duckbill to the precut
position and stop the wrap cycle. The WRAP BALE
indicator triangle will start flashing, an Error message
displayed as five dashes, “----------” (Figure 9) will be
displayed and the alarm will be activated.
1
NOTE: The ACTUATOR indicator triangle will be
flashing if the duckbill has not returned to the precut
position.
50046172
8
Stopping the Wrap Cycle
Should a malfunction occur during the wrap cycle or
for whatever reason, the wrap cycle can also be
stopped by pressing the AUTO/MANUAL or
EXTEND or RETRACT keys. Press the RETRACT
key to return the actuator and duckbill to the home
position. Disengage the PTO and stop the tractor
engine. Determine the cause of the problem and
correct before restarting the wrap cycle.
The wrap cycle will also be stopped if the tailgate
latch pin moves away from the sensor.
50022664
NOTE: If the wrap cycle is interrupted or stopped, the
alarm will be activated and an “----------” (Error)
message will be displayed along with a flashing
WRAP BALE indicator triangle. If an “----------” (Error)
message is displayed, press the CLEAR key to stop
the audible alarm.
9
4-5
SECTION 4 - FIELD OPERATION
Restarting the Net Wrap Cycle
Before attempting to restart the wrap cycle, be sure
the duckbill and actuator are in the home position.
Use the RETRACT key to return the actuator to the
home position. Determine the cause of the problem
and correct before restarting the wrap cycle.
Press and hold the WRAP key for two seconds to
restart the wrap cycle.
NOTE: The operator’s panel must be set in the
automatic mode and the AUTO indicator must be on
to restart the wrap cycle.
50022664
10
Wrapping the Bale with Twine
Soon after the full bale alarm is activated, the control
box will send power to the actuator to move the twine
tubes to the twine start position. The control box will
then retract the twine tubes in a start-stop pattern to
place the twine on the bale based on the number of
wraps (or custom pattern) selected.
NOTE: The number of wraps placed on the bale
depends on the PTO speed. The wrap pattern is
based on time only. The cycle will be completed in the
same amount of time regardless of the PTO speed.
If the PTO speed is reduced, there will be fewer wraps
placed on the bale. Changing the bale size when
using a custom pattern (PAt 4) can also affect the
number of wraps on the bale. Refer to item 2 in
“Setup/Diagnostic Mode.”
50022664
11
4-6
SECTION 4 - FIELD OPERATION
The operator can observe that twine starts, continue
to be pulled from the twine box, and are cut by
watching the rotating twine indicators, 1, front
left-hand side and right-hand side of the baler.
1
1
50046172
12
Stopping the Twine Wrap Cycle
Should a malfunction occur during the wrap cycle or
for whatever reason, the wrap cycle can be stopped
by pressing the AUTO/MANUAL or RETRACT or
EXTEND keys. Press the RETRACT key to return the
actuator and twine tubes to the home position.
Disengage the PTO and stop the tractor engine.
Determine the cause of the problem and correct
before restarting the wrap cycle.
The wrap cycle will also be stopped if the tailgate
latch pin moves away from the sensor.
50022664
NOTE: If the wrap cycle is interrupted or stopped, the
WRAP BALE indicator triangle will start flashing, an
“----------” (Error) message will be displayed, and the
alarm will be activated. If an “----------” (Error) message
is displayed, press the CLEAR key to stop the audible
alarm. The ACTUATOR indicator triangle will be
flashing if the actuator is not at home, precut or insert
position.
13
4-7
SECTION 4 - FIELD OPERATION
Restarting the Twine Wrap Cycle
Before attempting to restart the wrap cycle, it is best
if the twine tubes and actuator are in the home
position. Use the RETRACT key to return the actuator
to the home position. Determine the cause of the
problem and correct before restarting the wrap cycle.
The twine wrap cycle can be restarted regardless of
where the twine tubes are positioned.
Press and hold the WRAP key for two seconds to
restart the wrap cycle.
NOTE: The operator’s panel must be set in the
automatic mode and the AUTO indicator must be on
to restart the wrap cycle.
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14
BALE EJECTION
When the wrap cycle (net or twine) is completed, a
row of dashes on the bottom of the display and the
EJECT BALE indicator triangle will be turned on to
indicate that the bale is ready to be ejected.
Open the tailgate fully using the tractor hydraulics to
eject the bale. When the bale is clear of the baler,
close the tailgate and check to be sure it is latched.
The alarm will beep when the sensor indicates the
tailgate is latched.
As the tailgate is opened and closed, the signal from
the sensor on the tailgate latch will also change. When
the control box senses that the tailgate has been
opened and closed, it will add 1 to the bale count and
reset itself so it is ready to form and wrap the next bale.
50022664
15
Net-wrapped Bales
After the first bale is ejected, it should be inspected
to see if it is wrapped as desired. If it is not, change
the number of wraps for the next bale.
Twine-wrapped Bales
After the first bale is ejected, it should be inspected
to see if it is wrapped as desired. If it is not, select a
different amount of wraps or modify the custom
program (PAt 4) for the next bale.
NOTE: For the first bale on a new baler, the bale size
should be set at least 30 centimeters below the
maximum size for the baler, but not under 120
centimeters. After the first bale is made, measure it
and calibrate the control box if the size is not the same
as the display is set for. Refer to setup/diagnostic
item 1 in Section 3.
4-8
SECTION 4 - FIELD OPERATION
CONTINUED OPERATION
When the bales are wrapped as desired, continue
baling using these operating hints:
Be sure the tailgate is closed and latched before
starting each bale.
Drive to form as uniform a bale as possible by
watching the belts and the bale shape bar graphs.
Stop forward motion as soon as the full bale alarm
sounds - DO NOT disengage the PTO.
Be sure the twine tubes or duckbill move to the twine
or net start position and that the twine or net starts to
wrap on each bale.
Be sure that the twine tubes or duckbill are in the
home position and the twine or net has been cut
before ejecting the bale.
MANUAL OPERATION OF THE ACTUATORS
With the Bale Command Plus system turned on,
pressing the EXTEND key or RETRACT key on the
operator’s panel will cause the actuator for either the
net or twine, as selected by the NET/TWINE key, to
extend or retract. The EXTEND and RETRACT keys
will control the actuator in both the automatic and
manual modes.
50022664
16
REMOTE OVERRIDE ROCKER SWITCH
OPERATION
If the operator’s panel or rocker switch will not
activate the wrapper (net or twine), bales can be
wrapped by using the remote override rocker switch
installed on the tractor and baler wire harness.
Monitoring functions such as bale size, full bale, or
bale shape may or may not be operational depending
on the problem.
Disengage the PTO and stop the tractor engine.
Place the tractor in neutral and engage the
emergency brake.
76093641
17
Open the right-hand side shield of the baler.
Unplug the applicable wrapper motor connector.
4-9
SECTION 4 - FIELD OPERATION
Plug in the remote override connector, 1, to the
applicable wrapper motor. The remote override wire
harness lead is coiled up and strapped to the baler
frame channel in front of the control box. After
connecting the remote override wire harness to the
applicable motor, secure the excess wire harness out
of the way so that it does not entangle in any moving
parts.
Close the right-hand side shield of the baler.
Start the tractor and engage the PTO. Ensure the PTO
is operating at the rated speed of 540 or 1000 rpm if
the 540 rpm to 1000 rpm gearbox conversion kit is
installed.
1
50022670
18
If the monitoring functions are operational, continue
to build the bale as normal. If the monitoring functions
are not operating, build a bale weaving back and forth
using a timed sequence. Visually observe the belt
take up arm height above the baler and other clues
such as the profile of the bale by looking through the
belts to determine full bale size. Do not over fill the
baler. When approximate full bale size is reached,
stop forward motion.
Locate the remote override rocker switch on the
tractor wiring harness below the operator’s panel.
The rocker switch has icons for extend, 1, and retract,
2.
1
2
76093642
19
Twine Wrapping
While observing the twine tubes:
Press the rocker switch to extend the twine tubes to
the center position. Pause to apply the desired center
wraps to the bale.
Momentarily press the rocker switch to retract the
twine tubes in a stop/start manor. Retract the twine
tubes in a sequence that will apply the desired
number of twine wraps. Use the twine wrapper
indicator on the baler as an aid in locating the twine.
Stop the twine tubes at the precut position and apply
the desired number of end wraps.
Fully retract the twine tubes to cut the twine.
Use the tractor hydraulics to eject the bale. Be sure
the tailgate is fully closed and “locked” before starting
the next bale.
4-10
SECTION 4 - FIELD OPERATION
CROPCUTTER
Net Wrapping
While observing the net:
Units equipped with a CropCutter have this feature
enabled through Setup Item 3.
Press the rocker switch to extend the duckbill,
approximately three seconds. The bale should catch
the net and start wrapping as can be seen by the net
roll spinning through the openings.
Use tractor hydraulics to engage or disengage the
CropCutter knives. The KNIFE pointer is on solid
when the knives are fully engaged, and off when the
knife arm assembly moves away from the sensor.
When the net roll starts to spin immediately press the
retract side of the rocker switch to retract the duckbill
to the precut position, approximately two second.
CropCutter Reverser
Units equipped with a CropCutter have this feature
enabled through Setup Item 3.
Pause at the precut position to apply the desired
number of net wraps. It will take approximately two
seconds for a 122 centimeter (48 in) bale and
approximately three seconds for a 182 centimeter
(72 in) bale to make one revolution (wrap).
During operation, the CropCutter may become
clogged with material. A hydraulic reverser is
provided to clear the material. To operate the
reverser, fully retract the CropCutter knives (if
equipped) and press the CROPCUTTER ON/OFF
key. A solenoid/shuttle/splitter valve will shift to
supply tractor hydraulics from the CropCutter
cylinder to the reverser cylinder. The symbol (=o) will
appear in the display to indicate that the hydraulic
solenoid valve to the reverser cylinder has been
enabled. Operate the same tractor hydraulics lever
previously used for the cutter knives to extend and
retract the reverser cylinder. The CropCutter will be
ratcheted in the reverse direction, clearing the
material from the CropCutter.
When the desired number of wraps are applied,
press the rocker switch to retract the duckbill to the
home position and cut the net.
Use the tractor hydraulics to eject the bale. Be sure
the tailgate is fully closed and “locked” before starting
the next bale.
After a bale has been ejected, inspect the bale to
determine if the desired number of twine or net wraps
were applied. Modify the procedure to achieve the
desired wrap.
When the rotor feeder has been unplugged, operate
tractor hydraulics to fully retract the reverser cylinder.
Press the CROPCUTTER ON/OFF key, the symbol
(=o) will no longer be displayed to indicate the knife
engagement cylinder has been enabled. Continue
normal baler operation and engage the CropCutter
knives, if equipped.
NOTE: The Remote Override operation is provided
as aid to allow continued baling until proper repairs
can be made to the control box or operator’s panel.
See your authorized dealer as soon as possible for
proper repairs.
See the baler operator’s manual for detailed
instructions on the use of the CropCutter.
4-11
SECTION 4 - FIELD OPERATION
4-12
SECTION 5
MAINTENANCE
WARNING
connectors should be protected when they are
disconnected.
Maintenance hazard! Observe the following
safety precautions before performing any lubrication or maintenance.
1. Shut off tractor engine and remove key.
For the Bale Command Plus system to operate
properly, all of the sensors and magnets must be
adjusted correctly.
2. Disengage PTO drive.
The EXTEND and RETRACT keys can be used to
manually move an actuator. When the actuator is in
the desired position, turn the Bale Command Plus
system off so the actuator cannot be moved
accidentally when working on the baler.
3. Engage tractor parking brake.
4. Engage tailgate lockout valves if tailgate is
raised.
5. Make sure all guards and shields are
installed.
WARNING
Failure to comply could result in death or serious
injury
Unexpected movement! To prevent accidental
movement of an actuator during service, turn the
operator’s panel system OFF once the actuator is
in the desired service position. Failure to comply
could result in death or serious injury
W0035A
Electrical connections should be kept properly
connected and free from rust or corrosion. Dielectric
grease is recommended for use on the electrical
connector pins. This grease lubricates the pins
reducing the possibility of corrosion and provides
good electrical continuity between mating parts. This
grease will collect dust and dirt if left exposed. All
W0055A
To make sure the Bale Command Plus system
operates properly, all sensors must be adjusted
properly.
5-1
SECTION 5 - MAINTENANCE
TAILGATE SENSOR (ALL MODELS)
With the tailgate closed and both latches in the locked
position, adjust the sensor, 1, for a 3 - 7 mm (1/8 - 1/4
in) clearance gap between the sensor and the flat of
the tailgate latch pin, 2.
3
1
Assembly of the sensor onto the frame tab is critical
for proper operation. A plastic spacer, 3, must be
located between the metal tab, 4 and switch 1. A
second plastic spacer, 5 must be installed on top of
the sensor tab flush with the sensor body. Stainless
steel, non-magnetic hardware, 6, must be used to
secure the assembly to the frame tab. The ferrous
proximity switch must be isolated from the frame so
only the ferrous metal of the tailgate latch pin
activates the target area of the switch.
6
2
4
5
20021994
1
CROPCUTTER CYLINDER SENSOR
4
With the CropCutter knives fully engaged, adjust the
sensor, 1, for a 3 - 7 mm (1/8 - 1/4 in) clearance gap
between the sensor and the cylinder linkage, 2.
2
3
Assembly of the sensor onto the frame tab is critical
for proper operation. A plastic spacer, 3, must be
located between the metal tab, 4 and switch 1. A
second plastic spacer, 5 must be installed on top of
the sensor tab flush with the sensor body. Stainless
steel, non-magnetic hardware, 6, must be used to
secure the assembly to the frame tab. The ferrous
proximity switch must be isolated from the frame so
only the ferrous metal of the cylinder linkage
activated the target area of the switch.
5
1
6
50022689
2
NET COUNTER ROLL SENSOR
Adjust the clearance between the counter roll sensor,
1, and the magnet, 2, in the ring on the counter roll
shaft to 1.5 mm (1/16 in). The sensor should be
centered over the magnet.
2
1
20021996
3
5-2
SECTION 5 - MAINTENANCE
OPERATOR’S PANEL - Backlights, Relay, Circuit
Breaker, and Horn
The only serviceable parts inside the operator’s
panel are the circuit breaker, 1; relay, 2; backlights, 3;
and audible alarm (horn), 4. Send the complete
operator’s panel to an authorized service center if the
electronic components require repair.
2
1
3
To replace a backlight, circuit breaker, relay, or horn:
Separate the display panel and cover by removing
the eight screws from the face of the display panel
and then lifting the panel away from the case. Do not
touch the electronic components on the panel.
50022002
4
3
4
Circuit Breaker
Remove the circuit breaker by pulling it from the
display panel. Install a new circuit breaker by pushing
it onto the sockets until it seats tightly into position. A
slight rocking motion may be required to remove or
install the circuit breaker.
If the circuit breaker is not attached securely to the
sockets, it may be necessary to remove the circuit
breaker and gently crimp the sockets with a pair of
pliers. DO NOT over crimp the socket; there should
be a small opening for the circuit breaker blade
terminal.
Relay
Remove the relay by pulling it from the sockets on the
display panel. A slight rocking motion may be
required. Install a new relay by pushing it into the
sockets. A slight rocking motion may be required.
Light Bulb and Holder
A light bulb and holder can be removed from the
socket by twisting it counterclockwise. Place a new
bulb and holder in the socket and turn it clockwise to
lock it in position. Align the holes in the bottom of the
panel with the holes in the cover and install the
screws.
50022001
5
5-3
SECTION 5 - MAINTENANCE
Horn (Audible Alarm)
Disconnect the red and black wires from the spade
terminals on horn, 1. Unscrew retaining ring, to
remove and install a new horn. Reinstall the retaining
ring. Install the red wire female (socket) terminal to
the “+” (positive) terminal and the black wire female
(socket) terminal to the “-” (negative) terminal of the
horn.
NOTE: Installing the wires incorrectly will result in the
horn not working.
50022002
1
6
CONTROL BOX
Internal Relays
The only serviceable parts inside the control box are
relays. The standard control box contains only one
relay, 1, for net/twine wrapper actuator selection.
1
19985315
7
The control box with CropCutter option contains
three relays: net/twine wrapper actuator selection, 1,
hydraulic rotor reverse solenoid valve selection, 2,
and system continuity, 3.
To replace the relay(s), remove the control box from
the baler. Separate the control box panel from the
cover by removing 16 nuts from the back of the cover.
Lift the cover away from the panel. Do not touch the
electronic components on the panel.
Remove the relay by pulling it from the socket on the
control box panel. Install a new relay by pushing it into
the socket. A slight rocking motion may be required
for removal and installation.
19985316
3
2
1
8
NOTE: On the control box with three relays, all three
relays are required to be installed at the same time in
order for the system to operate.
5-4
SECTION 5 - MAINTENANCE
External Relays
External power relays, 1, is located on the control box
mount. The relays, energized by the operator’s
panel, will provide power for the control box, position
sensors, and associated actuators.
1
76093643
9
SENSORS
Ferrous Proximity Sensor
Ferrous proximity sensors are used to determine the
position of the tailgate and CropCutter knife (if
equipped). As a ferrous material is brought close to
the sensing zone, A, marked on the sensor, a
magnetic switch closes allowing current flow. Ferrous
material in the vicinity will effect the range of the
sensor. Stainless steel hardware, 1, and plastic
spacers, 2, must be used to mount the sensor to the
baler.
A
1
2
50022003
10
Potentiometer
Potentiometers, 1, are used to determine the
positions of various actuators and report the bale size
to the Bale Command Plus control box panel.
Movement at the various sensing points causes the
resistance of the potentiometer to change. This
change in resistance is converted into a numeric
value by the control box and used to display the
status of the baler on the operator’s panel, and wrap
the bale. The potentiometer is spring loaded to
maximum resistance.
1
When replacing a potentiometer, ensure that the
dowel pin is properly engaged into the center section
of the rotor. With the dowel pin not engaged, the
potentiometer will not turn and the baler will not
function properly.
20021998
11
Do not over torque the mounting screws when
installing the sensor. Tightening the screws too much
will cause the casing to bend and prevent the rotor
from turning freely.
5-5
SECTION 5 - MAINTENANCE
STORAGE
The operator’s panel is not waterproof and should not
be left exposed to the weather.
When the baler will not be in use for extended periods
of time, be sure the unit is stored with the tailgate and
door shielding closed. Place the operator’s panel in
a shielded location such as inside the twine storage
compartment face down. This will minimize the
exposure of electrical components to weather and
moisture. Should the operator’s panel or control box
be contaminated with condensation, remove as
much of the condensation as possible with
compressed air. Then allow the components to dry to
eliminate any moisture that could affect operation.
5-6
SECTION 6
TROUBLESHOOTING
Dielectric grease is recommended for use on the
electrical connector pins. This grease lubricates the
pins, reducing the possibility of corrosion, and
provides good electrical continuity between mating
parts. This grease will collect dust and dirt if left
exposed so all connectors should be protected when
they are disconnected.
The troubleshooting section of this manual is
arranged in the following sequence:
General Information
Electrical diagram
Error messages
NOTE: Before troubleshooting the electronic portion
of the Bale Command Plus system, be sure that the
correct model and display measurement system are
selected and, if possible, that the system is
calibrated. Refer to the setup/diagnostic information
in Section 3.
Self-diagnostic tests
Actuator tests
Troubleshooting Charts listing problems, possible
causes and solutions.
GENERAL INFORMATION
IMPORTANT: Before performing any test or
replacing any parts, check to be sure that all electrical
connections are clean and free of rust or corrosion
and that they are connected together properly.
6-1
SECTION 6 - TROUBLESHOOTING
ELECTRICAL DIAGRAMS
The source of many electrical problems can be
located by referring to an electrical diagram and
using either the operator’s panel diagnostic test
mode or digital/volt/ohmmeter to test the circuits
involved.
76093643
1
6-2
SECTION 6 - TROUBLESHOOTING
86633804--1
A-01 =
A-02 =
Control Box
Operator’s Panel
M-02 =
R-01 =
B-01 =
Net Wrap Counter Sensor
R-05 =
Twine Actuator Position Sensor
G-01 =
K-02 =
Battery
Relays
Q-01 =
X012 =
Circuit Breaker
Tractor/Baler Connector
X013 =
Remote Override Connector
/K-03
M-01 =
Net Actuator
6-3
Twine Actuator
Net Actuator Position Sensor
SECTION 6 - TROUBLESHOOTING
86633804--2
A-01 =
A-02 =
Control Box
Operator’s Panel
R-03 =
R-04 =
H-01 =
Audible Alarm (Internal to A-02)
S-02 =
Tailgate Latch Switch - Right-hand
R-02 =
Bale Shape - Right-hand Sensor
S-03 =
Remote Override Switch
6-4
Bale Shape - Left-hand Sensor
Bale Size Sensor
SECTION 6 - TROUBLESHOOTING
86633804--3
A-01 =
L-01 =
Control Box
Rotor Reverse Hydraulic Cylinder Solenoid 1
M-03 =
R-06 =
Bale-Slice Actuator
Bale-Slice Position Sensor
L-02 =
Rotor Reverse Hydraulic Cylinder Solenoid 2
S-07 =
CropCutter Knife Position Switch
6-5
SECTION 6 - TROUBLESHOOTING
86633804--4
A-01 =
Control Box
6-6
SECTION 6 - TROUBLESHOOTING
ERROR MESSAGES AT START-UP
The Bale Command Plus system goes through a self
test when it is turned on. If a problem is found, the
operator is alerted by the audible alarm and an Error
message and/or flashing pointer on the display on the
operator’s panel.
If Error is displayed, there will also be an indicator
triangle on the display to indicate what circuit of the
system is causing the problem.
Pressing the CLEAR key will cancel the alarm.
Determine the cause of the Error message and
correct the problem.
The following are errors that may appear:
Error and the FULL BALE pointer is flashing - Bale
size sensor circuit
The bale size should indicate 75 when the system is
turned on with an empty bale chamber.
Check to be sure the sensor is adjusted correctly and
that the take-up arm is in the home position before
checking the wiring or testing the sensor.
50022664
2
Error and TAILGATE pointer is flashing - Tailgate
sensor circuit
The sensor must indicate that the tailgate is closed
and latched before starting to make a bale.
Check to be sure the sensor is adjusted correctly and
that the tailgate is closed and latched before
checking the wiring.
50022664
3
6-7
SECTION 6 - TROUBLESHOOTING
Error and BALE SHAPE - LEFT bar graph flashing Left bale shape sensor circuit
The sensor should indicate one bar, when the system
is turned on with an empty bale chamber.
Check to be sure the sensor is adjusted and
calibrated correctly before checking the wiring and
testing the sensor.
50022664
4
Error and BALE SHAPE - RIGHT bar graph flashing
- Right bale shape sensor circuit
The sensor should indicate one bar, when the system
is turned on with an empty bale chamber.
Check to be sure the sensor is adjusted and
calibrated correctly before checking the wiring or
testing the sensor.
50022664
5
Error and ACTUATOR pointer is flashing - Net or
Twine actuator circuit. The net or twine pointer will
indicate the respective circuit with the problem.
The sensor must indicate that the actuator is in the
home position before starting to make a bale.
Check to be sure the sensor is adjusted correctly and
that the actuator is in the home position before
checking the wiring or testing the sensor.
50022664
6
6-8
SECTION 6 - TROUBLESHOOTING
ERROR MESSAGES WHILE OPERATING
The operator’s panel will provide a visual and/or
audible warning if the control box detects a problem
while forming the bale, while wrapping the bale, or
after the bale is ejected. The pointers on the display
will flash if a problem is detected and, depending on
the problem, an Error message will also be displayed.
When the Error message appears, the operator’s
panel will also beep. The flashing pointer will indicate
which circuit caused the problem.
Error and the FULL BALE pointer is flashing - Bale
size sensor circuit.
Pressing the CLEAR key will cancel the alarm.
50022664
7
Error and Tailgate Pointer is flashing - Tailgate sensor
circuit.
If the tailgate sensor is open for 15 seconds, an Error
message will appear and the alarm will sound.
Pressing the CLEAR key will clear the Error message
and alarm.
Check to be sure the sensor is adjusted correctly and
that the tailgate is closed and latched before
checking the wiring.
50022664
NOTE: If the tailgate sensor fails on a net/twine
machine and the operator is using only net or only
twine, a sensor can be borrowed from the other
system until a replacement is obtained.
8
6-9
SECTION 6 - TROUBLESHOOTING
Error and ACTUATOR pointer is flashing - Net
actuator sensor circuit.
If the net actuator is out of the home or pre-cut
position for 10 seconds, an Error message will
appear and the alarm will also sound.
Pressing the CLEAR key will clear the Error message
and alarm.
Check that the net actuator is fully retracted in the
home position. Check that the sensor is adjusted
correctly and calibrate the home position.
50022664
9
Er 1
An Er 1 error code indicates that the net or twine
actuator stalled for 5 seconds when the extend or
retract key is held pressed for 5 seconds or more. The
alarm will also sound.
The error code and alarm will clear itself after 10
seconds.
50022664
10
6-10
SECTION 6 - TROUBLESHOOTING
bAtt
A bAtt error code indicates that supply voltage to the
operator’s panel has dropped below the safe
operational limit of 8.2-volt. The bAtt error code is
accompanied with an audible alarm.
WARNING
Knife hazard! Retract the knife to the home
position. Only thread the net or perform service
with the knife in the home position. Failure to
comply could result in death or serious injury.
96104239
W0054A
11
NOTE: If battery supply voltage drops below 8.2-volt
during operation. A “bAtt” error message appears on
the operator’s panel and the motion of controlled
components is stopped. The net and twine knife may
stop mid-cycle. Disarm the knives with the remote
override rocker switch on the operator’s panel wire
harness. Reference: Remote Override Rocker
Switch Operation in this Operator’s Manual for
additional details.
Clear the bAtt error code by pressing the “Clear”
button after the supply voltage recovers and rises
above 9-volt.
If the voltage does not recover, refer to the Service
Manual and to Service Bulletin 0709-H1 (Controller
Failure and ‘Wrap Bale’ Error Message) for additional
information.
6-11
SECTION 6 - TROUBLESHOOTING
DIAGNOSTIC TESTS
The Bale Command system includes diagnostic tests
as part of the setup/diagnostic mode to allow the
sensors to be tested and/or calibrated without the use
of special tools.
NOTE: If the source of a problem with a sensor circuit
cannot be located and corrected by using the
setup/diagnostic tests and the wiring diagrams,
contact your authorized dealer for assistance.
Refer to the appropriate item in the setup/diagnostic
mode section for additional information on the
following:
Setup/
Diagnostic
Item
12
13
14
15
16
17
18
19
50022664
12
Description
Bale size sensor adjustment
Net actuator sensor adjustment
and calibration, or buffer zone
Twine wrapper actuator sensor adjust
and calibrate, or buffer zone
Bale shape left sensor adjustment
and calibration
Bale shape right sensor adjustment
and calibration
CropCutter knife position
sensor testing or buffer zone
Tailgate sensor testing
Net counter roll sensor testing or
buffer zone
6-12
SECTION 6 - TROUBLESHOOTING
ACTUATOR TESTS
Net and Twine Actuator Test Procedure
Step
1.
Test
Result
Correction
Turn on the Bale Command Plus The operator’s panel will not Check the battery voltage, (minioperator’s panel.
energize.
mum of 11 volts).
Verify that the wiring harness is
properly connected to the battery, operator’s panel, baler and
control box.
Verify the 30A in line circuit
breaker is operating properly.
Inside the operator’s panel,
verify the 20A circuit breaker
and power relay are functioning
properly.
The operator’s panel energizes, Verify the actuator motor power
but the display remains blank.
relay mounted on the side of the
control box is operating properly.
The operator’s panel energizes Proceed to Step 2.
and performs the startup self
check.
2.
Perform the operator’s panel The operator’s panel fails the Contact your authorized dealer.
display and key test in accor- test.
dance with Section 3, Item 21.
The operator’s panel passes the Proceed to Step 3.
test.
3.
In accordance with Section 3, The net or twine actuator does Proceed to Step 5. Verify wire
select NET or TWINE as the not extend.
harness is properly connected to
wrapper configuration. Press
control box and actuator.
the EXTEND key on the operator’s panel.
The actuator extends.
4.
Press the RETRACT key on the The net or twine actuator does Proceed to Step 5. Verify wire
operator’s panel.
not retract.
harness is properly connected to
control box and actuator.
The actuator retracts.
5.
Proceed to Step 4.
Perform net or twine actuator
sensor position calibration in
accordance with Section 3.
Unplug the actuator electrical The actuator will operate in only Replace the defective actuator.
connector. Attach a known one direction or not at all.
voltage source (battery) to the
actuator. Switch the wires and
attempt to operate the actuator
in both directions.
or
Use remote override switch and
operate the actuator.
The actuator operates in both Verify the wiring harness is intact
directions.
and all connections are clean.
See your authorized dealer for
assistance.
6-13
SECTION 6 - TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
CORRECTION
Harness not connected to operator’s panel, baler control box or
power source.
Be sure all harness connections
are properly secured.
Power supply wires reversed.
Verify that the red wire is connected
to the positive post and the black
wire is connected to the negative
post of battery.
Low voltage.
Check battery and charging system on tractor. Verify that a
minimum of 11-volts is available.
Defective operator’s panel or
control box.
Contact your authorized dealer.
Failed circuit breaker.
Replace the circuit breaker.
Damaged wire harness.
Repair or replace the harness.
Defective power relay in operator’s
panel or on the side of control box
panel mount.
Replace the relay.
Tailgate is open or unlatched.
Close and latch the tailgate.
Tailgate sensor not adjusted
correctly.
Adjust the sensor.
Defective tailgate sensor.
Replace the tailgate sensor.
Damaged wire harness or
connector.
Repair the harness. Clean and
check the connector.
Damaged wire harness or
connector.
Repair.
Sensor disconnected.
Connect the sensor.
Defective sensor.
Replace.
“----------” (Error) and ACTUATOR
indicator on at startup.
Actuator not in the home position.
Use the RETRACT key to return
actuator to the home position.
OR
Sensor not adjusted or calibrated
correctly.
Adjust or calibrate sensor.
“----------” (Error) and ACTUATOR
indicator flashing while baling.
Defective net or twine actuator
sensor.
Replace.
Damaged wire harness or
connector.
Repair.
Display will not turn on.
“----------” (Error) and TAILGATE
indicator flashing.
“----------” (Error) and FULL BALE
indicator flashing.
6-14
SECTION 6 - TROUBLESHOOTING
PROBLEM
“----------” (Error) and WRAP BALE
indicator flashing, but the actuator
did not move.
“----------” (Error) and the WRAP
BALE indicators are flashing. The
net or twine actuator started to
move but did not complete the
cycle. If the actuator is out of
position, the ACTUATOR indicator
will also be flashing.
POSSIBLE CAUSE
Low voltage.
Check the battery voltage. Verify
that a minimum of 11 volts is
available.
Loose connection.
Check that connections are clean
and attached properly.
Damaged harness or connector.
Repair.
Defective actuator.
Replace.
Defective control box.
Replace.
Net started to be pulled from the roll
before the bale was full size due to:
Net was not cut properly leaving a
long tail OR the duckbill was not in
the home position due to damaged
linkage.
Check the mechanical knife operating linkage and knife sharpness.
The wrap cycle was interrupted by
the operator pressing the EXTEND,
RETRACT or AUTO/MAN key OR
by the tailgate opening and closing.
Poor or loose connection.
Damaged wire harness.
Defective actuator.
Defective control box.
“----------” (Error) and WRAP BALE
indicator flashing. The twine actuator extends to start twine, but would
not retract to complete the twine
wrap cycle. The actuator is fully
extended and the ACTUATOR
indicator flashing.
“----------” (Error) and the WRAP
BALE indicator flashing - The net
actuator stopped at the precut
position. The bale is not wrapped.
CORRECTION
Incorrect sensor adjustment or
calibration.
Sensor disconnected.
Defective sensor.
Damaged wire harness or connector.
The control box did not receive a
signal from the counter roll sensor
because the net did not start to
feed.
6-15
Use the RETRACT key to return
the actuator to the home position
and restart the wrap cycle using the
WRAP key or adjust tailgate
sensor.
Check that connections are clean
and properly connected.
Repair.
Replace.
Replace.
Adjust sensor and calibrate home,
precut and inset position.
Connect sensor.
Replace sensor.
Repair.
The Bale Command Plus system is
working correctly. Check for a
mechanical problem or empty net
roll.
SECTION 6 - TROUBLESHOOTING
PROBLEM
Error and WRAP BALE indicator is
flashing. The net actuator stopped
at the precut position. The bale is
wrapped.
POSSIBLE CAUSE
CORRECTION
The control box did not receive a
signal from the counter roll sensor
because of:
a. The net not contacting the
counter roll properly.
a. Check the brake linkage and net
routing.
b. Incorrectly adjusted sensor.
b. Adjust the sensor.
c. Damaged wire or connector.
c. Repair.
d. Defective sensor or magnet.
d. Replace.
The bale size on the display does
not match the size bale made.
The control box and bale size
sensor are not calibrated to each
other.
Enter the setup/diagnostic mode
and recalibrate.
The display does not return to 75
when a bale is ejected.
Bale size sensor not adjusted.
Adjust the sensor.
Defective sensor.
Replace the sensor.
Sensor linkage damaged or disconnected.
Repair or reconnect the linkage.
OR
The WRAP BALE indicator does
not turn on when the net starts.
The bale count is not accurate (not
counting correctly).
The tailgate sensor is not sending a
signal to the control box due to:
a. Sensor is not adjusted correctly.
a. Adjust the sensor.
b. Damaged wire harness or loose
connection.
b. Repair or replace the harness.
Check the connector.
c. Defective sensor.
c. Replace the sensor.
d. Control box was turned off after
wrapping the bale.
d. Leave the control box on until the
wrapped bale is ejected.
6-16
SECTION 6 - TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
CORRECTION
The net or twine is not wrapped on
the bale when the cycle is
completed. An error message
would appear for net wrap.
Out of twine or net.
Install new balls of twine or a new
roll of net.
Mechanical interference with the
twine or net or a mechanical
problem with the wrapping system.
Refer to the baler operator’s
manual.
Er 1 - Error code displayed when
extend or retract key is held
pressed for 5 seconds.
The actuator stalled for more than 5
seconds.
Remove the obstruction, retract or
extend the actuator to verify proper
operation.
The bale shape bar graphs do not
operate properly.
Sensors not calibrated correctly for
empty and full positions.
Calibrate the sensors. Refer to the
setup/diagnostic mode section.
Sensor linkage frozen or broken
leaf spring.
Free and lubricate the linkage or
replace leaf spring.
Defective sensor.
Replace the sensor.
The alarm is not turned ON.
Turn the alarm on. Refer to item 5
in the setup/diagnostic mode.
The alarm threshold is set too high.
Reset the alarm threshold. Refer to
item 6 in the setup/diagnostic
mode.
The bale shape alarms too easily.
Alarm threshold set too low.
Reset the alarm threshold. Refer to
item 6 in the setup/diagnostic
mode.
The BALE SHAPE bar graphs
respond too slowly.
The sensitivity is set too low.
Set the sensitivity higher. Refer to
Item 6 in the setup/diagnostic
mode.
The BALE SHAPE bar graphs
respond too fast and are constantly changing.
The sensitivity is set too high.
Set the sensitivity lower. Refer to
Item 6 in the setup/diagnostic
mode.
The bale shape alarm does not
work.
6-17
SECTION 6 - TROUBLESHOOTING
6-18
INDEX
+ (Plus) and - (Minus) Keys . . . . . . . . . . . . . . . . . 3-7
Actuator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Attach the Baler to the Tractor . . . . . . . . . . . . . . . 4-1
Auto/Manual Key . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Bale Command Plus System Components . . . . 1-1
Bale Ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Bale Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Bale Formation - Net or Twine . . . . . . . . . . . . . . . 1-6
Bale Shape Display Window . . . . . . . . . . . . . . . . 3-4
Bale Size Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Baler-Mounted Components . . . . . . . . . . . . . . . . 1-3
Bales Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Clear Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Continued Operation . . . . . . . . . . . . . . . . . . . . . . . 4-9
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Cropcutter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8, 4-11
Cropcutter Cylinder Sensor . . . . . . . . . . . . . . . . . 5-2
Cropcutter On/Off Key (For Units
Equipped with Hydraulic Rotor Reverse) . . . 3-13
Diagnostic and Calibration Items . . . . . . . . . . . . 3-31
Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Error Messages at Start-Up . . . . . . . . . . . . . . . . . 6-7
Error Messages While Operating . . . . . . . . . . . . 6-9
Extend and Retract Keys . . . . . . . . . . . . . . . . . . 3-14
Field Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Full Bale Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General Information . . . . . . . . . . . . . . . . . . . . 1-1, 6-1
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
How the Bale Command Plus
System Operates . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Installation of Tractor-Mounted Components . . . 2-1
Knife Extend and Knife Retract Keys . . . . . . . . 3-14
Machine Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Main Display Window Indicators . . . . . . . . . . . . . 3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Manual Operation of the Actuators . . . . . . . . . . . 4-9
Net Counter Roll Sensor . . . . . . . . . . . . . . . . . . . . 5-2
Net Wrapping Cycle . . . . . . . . . . . . . . . . . . . . . . 1-10
Net/Twine Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Number Wraps Key . . . . . . . . . . . . . . . . . . . . . . . . 3-9
On/Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Open Book Key . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operator’s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operator’s Panel Harness Connection . . . . . . . . 2-2
Operator’s Panel Keys - Function . . . . . . . . . . . . 3-2
Operator’s Panel Keys - Operation . . . . . . . . . . . 3-4
Operator’s Panel Operation . . . . . . . . . . . . . . . . . 3-1
Operator’s Panel Settings . . . . . . . . . . . . . . . . . . 4-2
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Precautionary Statements . . . . . . . . . . . . . . . . . . 0-2
Remote Override Rocker Switch Operation . . . . 4-9
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Setup Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Setup/Diagnostic Mode . . . . . . . . . . . . . . . . . . . . 3-19
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Tailgate Sensor (All Models) . . . . . . . . . . . . . . . . 5-2
Tractor-Mounted Components . . . . . . . . . . . . . . . 1-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 6-1, 6-14
Twine Wrapping Cycle . . . . . . . . . . . . . . . . . . . . . 1-9
Wire Harnesses and Connector Bracket . . . . . . 2-1
Wrap Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Wrapping the Bale . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
6-19
6-20
Dealer’s stamp
CNH America LLC reserves the right to make improvements in design and changes in specifications
at any time without notice and without incurring any obligation to install them on units previously sold.
Specifications, descriptions, and illustrative material herein are as accurate as known
at time of publication, but are subject to change without notice.
Availability of some models and equipment builds varies according to the country
in which the equipment is being used. For exact information about any particular product,
please consult your New Holland dealer.
Printed in U.S.A.
Copyright © 2010 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.