998 Square bale wrapper - showmeshortline.com...McHale 998 main component reference section 02-2 Issue 1: 0108 McHale 998 square bale wrapper technical service manual 2.1: Designated

998 Square bale wrapper

Technical Service Manual Issue 1

McHale Engineering Limited,

Castlebar Rd, Ballinrobe Co. Mayo, Ireland.

Tel: +353 94 95 20300 Fax: +353 94 95 20356

Email: [email protected]

WWW.MCHALE.NET

Introduction

Component Reference Section

General and Specific Safety Warnings

Tractor and Wrapper Requirements

Wrapper Field Adjustments

Electronic Control System

Hydraulic System

Drive System

Trouble Shooting

Machine Maintenance

Technical Specifications

Notes

1.

12.

11.

10.

9.

4.

5.

6.

7.

8.

2.

3.

McHale 998 Introduction section 01-1

McHale 998 square bale wrapper technical service manual Issue 1: 0108

Section 1

Introduction Contents: 1.1: Technical manual introduction 1.2: Technical manual part no.

McHale 998 Introduction section 01-2


1.1: Introduction The McHale 998 square bale wrapper design has been carried out on the basis of long term constant research and development in the field of square bale wrappers and balers. Given proper care and attention, the McHale 998 will provide years of reliable and dependable performance. However it is also important that everybody who operates this machine reads and understands the operators manual before operating the machine. If any of the instructions appear unclear do not hesitate to contact your McHale dealer. It is vital to replace defective parts of the machine immediately and to use only genuine McHale spare parts, as these are designed and manufactured to the same specification as the original machine. These may be obtained through your McHale dealer. Description of a fully trained operator: The McHale 998 will require a fully trained operator. This is someone who has read and fully understood all of the contents of the instruction manual. They must be aware of all safety instructions, of all functions and controls, both hydraulic and electrical. The operator is solely responsible for the safe use and maintenance of the machine in accordance with the manual. It is highly recommended that training be sought from the local dealer. The operator must be constantly aware of their surroundings and should always think of safety first. The machine is only to be used for it’s designated purpose as is outlined . Note: The above description is a guideline only, and as a rule, it is highly recommended to get acquainted slowly at first with any new machinery. Take the time to both learn and understand all the features of the machine. Proficiency will increase as more experience is obtained. It is important to quote the machine serial number when ordering spare parts or requesting technical assistance. Space is provided below to record the machine details: 1.2: Technical manual part no. If you require further copies of this instruction manual please quote part number: CLT00098 Due to a policy of continuous product development and improvement, McHale Engineering Ltd. reserves the right to alter machine specifications without prior notice. Please note that all specifications marked with an in this manual relate to certain models or optional equipment. Also these specifications may not be available in all countries.

McHale 998 main component reference section 02-1


Section 2

Component Reference Contents: 2.1: Designated use of machine 2.2: Component location



2.1: Designated use of machine The McHale 998 square bale wrapper is designed to wrap, with plastic stretch film, rectangular section bales of forage for the purpose of storage as fodder for livestock. This designation includes movement of machine, between fields by track or road, incidental to the wrappers main use. The manufacturer will not be held responsible for any loss or damage resulting from machine applications other than those specified above. Any other use the machine may be put to, is entirely at the owners/operators risk.



2.2: Component location

Main Chassis

Bale lift Cradle

Main Conveyer

Main Drawbar

Spare Film Carrier

Top reduction drive Drawbar

pivot point

Film Dispenser

Cut and Hold

Loading Conveyer



McHale 998 Safety section 03-1


Section 3

Health and Safety Contents: 3.1: General safety 3.1.1: Beware of all safety information

3.1.2: Follow all safety instructions

3.1.3: Store all items carefully

3.1.4: Protective clothing

3.1.5: In case of emergencies

3.1.6: Stay clear of rotating elements

3.1.7: Operating the McHale 998 wrapper safely

3.1.8: In the event of a fire

3.1.9: General safety warnings

3.2: Specific safety 3.2.1: Electronic safety warnings

3.2.2: Hydraulic safety warnings

3.2.3: Noise level

3.2.4: Fire precautions

3.2.5: Special safety devices/ instructions

3.2.6: Safety instruction decal location

3.2.7: Description of safety warnings and instructions



3.1: General Safety

3.1.1: Be aware of all safety information The symbol opposite is the symbol used to alert you to safety issues. It appears both in this manual and on some of the safety decals. On the decals it appears on a yellow background while in this manual it appears in black and white. Follow all safety precautions and practice safe operation of all machinery at all times. When reading through this manual, pay attention to where you see the above symbol paying extra care to where you will see the Warning and Caution pointers. 3.1.2: Follow all safety instructions Using this manual, read all safety instructions, messages and be aware of the meanings of all safety decals. Ensure, if safety decals are damaged or missing due to wear and tear or due to component replacement, that they be replaced. Use the Decals section in the provided spare parts book as a handy reference for spare part codes and relevant decals, which are available from your McHale dealer. As with all machinery, learn all operations and use of controls by reading the operators manual thoroughly. Do not attempt to let anyone operate this machine without being fully instructed. 3.1.3: Store all items carefully Store all attachments such as spare net rolls, film rolls and any other stored items in a secure and safe manner so as to prevent items from falling. Keep storage areas clear of bystanders and children. 3.1.4: Protective clothing Always wear clothing and safety equipment that is fit for the job at hand, never wear loose clothing. In the event of loud noises, wear suitable protective hearing devices. Use of radio (walkman) headphones are not recommended while operating machinery as this impairs operators attention.



3.1.5: In case of emergencies In the event of any accident, emergency equipment should be kept close at hand. A first aid kit and fire extinguisher along with emergency phone numbers should always be available to machine operators. 3.1.6: Stay clear of rotating elements Serious injury or death can result from entanglement of clothing or body parts with PTO shafts, drivelines and other rotating and moving components. Keep all guards in place at all times, only wear close fitting clothing and ensure that tractor engine has stopped, key removed and that PTO has stopped turning before carrying out any adjustments, connections or cleaning of PTO driven equipment. 3.1.7: Operating the McHale 998 safely In order to avoid serious injury or even death by being pulled into the machine: 1. Never attempt to feed film through the dispenser or tie it to the baler or attempt

to unplug pick-up area while the wrapper is running. 2. Disengage PTO, shut tractor engine off and remove the key. 3. Stand well clear of baler and tractor when machine is operating.

3.1.8: In the event of a fire In the event of a fire, the following is only given as a guideline procedure, as it is the operators decision to ascertain the seriousness and hence the solution of the situation. 1. Switch control box to manual mode (see section on Electronic control system). 2. Eject bale from wrapper. 3. Move tractor and wrapper away from the flammable material. 4. Disengage PTO, turn off tractor and remove key. Remove all hosing and

electrical looms from the machine. 5. With all connections removed, disengage drawbar from tractor. Drive tractor

away from wrapper. 6. Using a suitable fire extinguisher put out all fires. Note: It is recommended that the wrapper be kept reasonably clean and free of build-ups of grass, lubricants etc., this will help to reduce the risk of fires.



3.1.9: General safety warnings

Read and understand this operator’s manual before using the machine. If any of the instructions appear unclear do not hesitate to contact your McHale dealer.

Only competent persons who have read and fully understood this manual are qualified to operate this machine. The owner of this machine is obliged by law to ensure that every operator must understand all the functions, controls, working processes and safety warnings before operating the machine.

All safety devices such as guards, protection parts and safety controls must be in place and in fully functioning condition. It is forbidden to operate this machine with defective or incomplete safety devices (never disable or defeat any electrical safety circuits).

All safety decals on the machine must be kept in good legible condition. If they are not they must be replaced by genuine McHale decals from your McHale dealer (part numbers are available in this manual).

Before operating this machine the operator must ensure that all covers are closed and all safety devices are in operating mode.

Before operating this machine the operator must ensure that the manufacturer’s instructions for attaching and detaching the machine are followed. This includes the drawbar attachment, the electric and hydraulic lines, in particular the lighting and brake system.



Before operating this machine the operator must ensure that no persons or animals are carried on the machine or are hidden under the machine (on the tractor persons are only allowed to sit on the relevant seats).

Before operating this machine the operator must ensure that there is no person in the “danger zone” (in front of tractor, between tractor and round baler wrapper combination, and a minimum of 5 m behind the machine).

Note: It is the operator’s responsibility to keep all people out of this area! In this area a person is subject to a risk to his/her own health or safety!”

While operating this machine on hilly or sloping ground the operator must take extra precautions, in particular the “danger zone” is increased in such conditions as bales are more likely to roll away causing a potential risk.

While operating this machine the operator must ensure that there is a minimum of 4 m clearance between the machine and any obstacle above, in particular electrical high voltage lines.

Before working on this machine, such as replacing film rolls, clearing forage away from any part of the machine or altering any setting, the operator must ensure that the tractor has definitely stopped moving, handbrake is applied, engine has stopped and ignition key is removed, PTO shaft is removed from pto stub and electric power supply is disconnected. It is forbidden to open any safety guards or to carry out any work on the machine unless the above specified precautions have been carried out.

Warning! If carrying out inspection during machine operation within the danger zone (highly dangerous and not recommended!), then there should be a trained and fully competent second person operating both the tractor and wrapper controls. If at any time the second operator loses sight of the inspector, turn off all tractor power immediately! Such inspection should only be carried out if all guards are fully in place, machine on level ground and a safe distance from the machine maintained from any hazards on the machine e.g. pick-up region.

Maintenance and repair work on this machine should always be carried out in accordance with this manual.

Before travelling on public roads the owner of this machine is obliged by law to ensure that every operator has got a valid driving licence and is familiar with the road traffic regulations relating to the country of use .

When parking both wheels of this machine have to be blocked using wheel chocks according to the road traffic regulations relating to the country of use.



3.2: Specific safety warnings

3.2.1: Electronic safety warnings

This machine is equipped with electronic parts and components which comply to the EMC directive 89/336/EEC but still may be influenced by electromagnetic transmissions of other apparatus, such as welding machines, etc.

Check electric cables regularly for signs of breakage or wear. If in doubt always replace.

3.2.2: Hydraulic safety warnings

The maximum pressure in the hydraulic system of this machine should not exceed 210 bar.

Always ensure system is not under pressure before working on the machine. Oil under pressure can penetrate the skin and cause injury. Beware of pipes under accumulator pressure, depressurise lines by unthreading connections extremely slowly.

Hydraulically actuated devices, should always be blocked mechanically against movement, before working on the machine.

If any hoses are removed or replaced ensure they are marked and re-installed to the correct position during re-assembly.

Check hoses regularly for signs of leakage or wear. If in doubt always replace – the recommended maximum working time of hoses should not exceed 5 years. Only use exact specification, McHale genuine replacement parts.

Do not work on hydraulic systems unless you are qualified to do so, this work should only be carried out by qualified trained persons in the McHale dealeship.



3.2.3 Noise level The European regulation 86/188/EEC directs employers and employees to control the noise level at work. The noise level at field work may differ according to the tractor, to the ground, to the crops and other environmental conditions. In normal conditions the noise level next to the drivers ear of the McHale 998 square bale wrapper does not exceed 70 dB (A) with the rear screen of the tractor cabin open. The common noise level of the machine and the tractor is primarily influenced by the tractor noise (radio is an additional noise source). It is recommended to operate this machine with closed cabin windows. 3.2.4: Fire precautions

Be aware that crops are easily flammable.

Do not smoke or make use of any open fire next to the machine.

A functioning fire extinguisher should always be available on the tractor.

The machine is to be kept cleaned of oil, grease, crops or any other flammable material at all times.

Do not continue work with overheated parts, cables or pipes unless you have identified and eliminated the reason for overheating.



3.2.6: Safety Instruction Decal Locations:



3.2.7: Description of safety warnings and instructions

It is important that all safety warnings and instructions are understood and followed. The part numbers are shown in brackets.

Machine Chassis plate

Danger of rotating parts, foreign objects. Keep clear of machine while working. (CST00014)

All safety decals on the machine must be kept in good readable condition. If they are not or are missing, replacements are avail-able from your McHale dealer.



Keep clear of rotating Dispenser. (CST00040)

Lift machine at these points. (CST00032)

Do not dismantle. Risk of pressure release. (CST00056)



Stop tractor,remove ignition key and read instruction manual before working on the machine. (CST00015)

Read instruction manual before working on any part of the hydraulic system. Injury may be caused by systems under pressure. (CST00016)

Keep hands clear of rotating rollers. (CST00017)



Keep out of drawbar crush area. (CST00018)

Keep hands out of crush area. (CST00019)

Check wheel nuts daily. (CST00020)

Check tyre pressure. (CST00021)



Diagram of plasic film path through Dispenser. (CST00022)

PTO speed to be between 600 and 800 revolutions per minute. (CST00023)

Check oil level (CST00024)



McHale 998 requirements & preparation section 04-1

McHale 998 square bale wrapper Technical Service manual Issue 1: 0108

Section 4

Tractor & Wrapper Preparation

Contents: 4.1: Tractor requirements 4.2: Attaching tractor to machine 4.3: Lighting system 4.4: Attaching 998 to the PTO 4.5: Electronic control unit instillation 4.6: Stand usage


McHale 998 square bale wrapper Technical service manual Issue 1: 0108

4.1: Tractor requirements The minimum recommended size of tractor for operating the wrapper comfortably would be a 60-70 kW. model. However if working in difficult conditions this will need to be increased. The following items on the tractor are required for fitment of the bale wrapper. a) Category 2 Lower Linkage b) 1 3/8” SAE 6 spline PTO Shaft running at 600 - 800 R.P.M. c) One (1) Double acting Spool Valve (Drawbar) d) One (1) Single acting Spool Valve (Conveyor lift) e) One (1) 12V electrical supply (Euro socket or supplied battery power cable) f) One (1) 7 pin lighting socket g) One (1) Hydraulic Brake Coupling or Two (2) Air Brake Couplings

A

B

CD

EF

G

Fig. 1



4.2: Attaching tractor to machine

1) If using tractor quick couplers secure the lower link balls into the hitch bar using the pins provided. Otherwise remove pins from hitch bar. 2) Reverse tractor up to wrapper and attach lower links either hooking up the quick couplers or attaching directly with the pins provided. 3) Cut PTO shaft according to the PTO manufacturers recommendations attached to the shaft. This only applies to machines being fitted for the first time or if the tractor working the machine is changed. 4) Fit PTO shaft. 5) Plug the hydraulic pipe, with the tap, into a single acting spool valve. This lifts the front conveyor. The tap may now be turned on by lining the handle up with the pipes. Ensure there is nobody near the front conveyor before carrying this out. 6) Plug the remaining two hydraulic fittings into a double acting spool valve. These operate the drawbar hydraulic cylinder. 7) Plug the hydraulic/air brake pipe/pipes into the appropriate fittings on the tractor. 8) Plug the 7 pin lighting plug into the 7 pin socket on the tractor. 9) Place the electronic box in the tractor cab and secure to the glass in an appropriate place using the suction pad on the rear. Safety strap must be secured to prevent box from accidental damage. If there is no cab on the tractor secure as appropriate bearing in mind the box is not waterproof. 10) Screw 37pin socket on electronic box and 37pin plug on machine together. 11) Connect control box to tractor euro socket or battery using the power cable provided. There must be a good 12V supply to the control box. 12) Raise machine on tractor linkage and swing parking stand into working position.(Sec. 4.1.5) 13) Move tractor linkage so that wrapper is parallel to the ground. 14) Check that all above functions operate correctly. 15)The machine is now ready to work.

Always ensure tractor is stopped, handbrake applied, engine stopped and ignition key removed before working on machine. Always follow manufacturers instructions when attaching/detaching machine from tractor.



1. Lower link arm attachment 2. Gearbox shaft to P.T.O. 6 spline 3. 37 pin loom connector 4. 7 pin light socket 5. Conveyer raise/ lower hose 6. Double acting hoses for drawbar 7. Hydraulic brake connection 4.3: Lighting system The 7 pin plug of the lighting system on the machine must be connected to the 7 pin socket on the tractor. Note: Before travelling on a public road the operator must ensure that the (complete tractor and machine) lighting system is in a fully functioning condition.

1

42

5 67 8 104 3

Fig. 2

Fig. 3



4.4: Attaching the 998 to the tractor PTO Caution: The McHale 998 should be driven with a standard PTO 6 splined shaft. (recommended PTO speed = 650 rpm, a PTO speed above 800 rpm is likely to cause damage to machine components). Do not use any faster PTO speed other than the above specified! All mechanical functions are related to the correct PTO speed. Follow the instructions as supplied with the PTO unit for correct assem-bling of the PTO shaft to the tractor.

Correct machine height level Fig. 4



4.5: Control box installation The electronic control box must be located inside the tractor cab in the operator’s field of vision, and within easy reach. It is secured to the glass using the suction pad on the rear. Ensure that the cable to the machine is not under tension and not near sharp edges etc. The electric power supply is obtained from the euro socket in the tractor. The control box is to be connected to a 12V/ 20 Amp power supply. The euro lead is supplied as standard or a fused lead direct to battery is available. A good power supply is critical for proper machine operation as the electronic control box is the main interface between the operator and the machine. Caution! Do not use any other electric power supply for the electronic system, otherwise damage may occur! 4.6: Stand Usage Shown in Fig. 5 is the stand in working position. When moved in direction A it is in Parking position. The location of the securing pin for both uses is shown in Fig. 5.

PARKING

WORKING

11Fig. 5

A

McHale 998 field operation and adjustments section 5-1


Section 5

Wrapper field operation & adjustment

Contents: 5.1: Standard Machine Cycle 5.2: Bale Guides 5.3: P.T.O. Speed 5.4: Bale Length 5.5: Dispenser Height 5.6: Cradle Height 5.7: Film Layers 5.8: Cut and Hold



5.1: Standard Machine Cycle: 1. With the control box in Auto pressing the Auto start button starts the cycle by

rotating the conveyer to pick up the bale. 2. Once the bale has passed the trip wheels on the conveyer the bale loading

sensor pulses. This signals the bale to stop after the pre-determined amount of time. (set in operator set up)

3. The cradle will lift the bale to the required height for that bale type, taking the signal from the bale height potentiometer.

4. Once the height is reached the rollers will roll to level the bale. 5. The dispensers will rotate .5 revolutions and then the bale will commence

turning. 6. After 2 revolutions the plastic is released from the cut & hold. After the

pre-determined number of layers of plastic is applied the dispensers will slow down for the last turn.

7. The cut and hold will go up in the last half turn, when the dispensers reach the correct position the cut & hold come back down with the film.

8. The bale is then levelled and put down on the conveyer. 9. The rollers return to their lowest position signalled to the box by the cradle fully

down sensor. The bale is ejected on the starting of the next cycle.



5.2: Bale Guides There are two bale guides (A) on the front section of the conveyer to guide the bale up the conveyer. These can be moved in or out depending on the width of the bale being wrapped. The best position for these is at their widest position to allow the operator to collect the bale easily. 5.3: P.T.O. Speed The P.T.O unit on the front of the 998 wrapper is driving the main hydraulic pump. This pump has to run at a certain speed to allow every function to work correctly on the wrapper. The recommended speed is from 650 rpm to 800 rpm. There is a standard 6 spline shaft on the gearbox. Generally 1000 rpm is selected in the tractor cab and engine revs are kept low enough to have PTO speed at 650 rpm.

Fig. 2

Fig. 1

A



5.4: Bale Length The length of the bale being wrapped is important to know so the operator can position the bale central on the wrapping cradle (Fig. 3). As the bale is collected by the conveyer it passes over two trip wheels on the front section of the main conveyer. Once the end of the bale is passed these wheels they send a signal to the electronic control unit to stop the bale a certain time after this, depending on bale length. This time delay setting on the electronic control unit is changed by the operator to best suit the length of bale. 5.5: Dispenser Height The dispenser is mounted to the aluminium arm of the machine where it is possible to adjust it in height. Unless it is 100% necessary, there is only one position for the dispenser to be located for the wrapping of square bales. This is shown in Fig. 4 below.

Fig. 4

Fig. 3



5.6: Cradle Height The height of the cradle is determined by the bale type selection in the electronic control unit. It is important that the bale height on the cradle is suitable to the bale being wrapped. The application of film to the bale should be as close as possible to the middle of the bale (Fig. 5). If the bale is to low (small bale): • Then the film will slide over it and cause it to tear or miss a section of the bale. If is to high (Cradle max height with big bale: • There is a chance it will tear on the plastic rollers of the cradle. The height of the cradle is adjusted by the electronic control unit depending on the bale type selected. If the height selection of a particular bale type is not suited to the actual bale being wrapped, (ie. bad or soft bales) cradle height can be changed in operator set-up. See electronic control section 6. 5.7: Film Layers The application of film on the 998 bale wrapper is achieved with the two dispensers. The overlap of the film is such that is will never be less than 50% on any section of the bale. To determine the required no. of layers on square bales is as follows: • Every 1/2 rotation of the bale is two layers of film. (using both dispensers). • Therefore for 4 layers of film is one full rotation of the bale . • And 6 layers is 1.5 rotations of the bale. This is irrespective of the length, height or width of the bale.

Fig. 5



5.8: Cut and Hold The cut and hold mechanism on the 998 wrapper is very simply operated. A hydraulic ram pushes up a slider unit (A Fig. 6). As the film comes around into it (Fig. 7) it is held and cut. The gathering together of the film to one point makes the film very strong and easy to hold. There is no adjustment on the holder necessary for any particular size of bale. The most important thing is that the surface which the film slides on, (C) as the cut and hold closes is not damaged in any way. This could cause the film to tear before it has gathered all of the film to one point (Fig. 8). It is important to keep this surface clean from the build up of film glue residue also. As the unit cannot be held open in a safe manor from the valve or electronic unit, the safe way to dismantle the cut and hold unit is to remove nut B (Fig. 8) and the slider unit will freely slide up and out without the need to remove any hydraulic hoses. To cut and hold the film in manual mode from the control unit is as follows. • Press the cut and hold button to raise them up to the top • Within 1 second press and hold the arm rotation button. • Let go of the button when the plastic film dispenser has rotated round enough to

get the film into the cut and hold unit. • The dispensers will stop and the cut and hold will return to its lower position with

the film.

Fig. 7 Fig. 8

C

B

Fig. 6

A

McHale 998 electronic control system section


06-1

Section 6

Electronic System Contents: 6.1: Electronic schematic 6.1.1A: Main loom (Pre 250100) 6.1.1B: Main loom (Post 250100) 6.1.2: Top arch loom 6.1.3: Input / Output test

6.2: Electronic control unit 6.2.1: Electronic control unit functions 6.2.2: Display 6.2.3: Menu structure 6.2.4: Menu 6.2.5: Custom bale set-up

6.3: Bale height potentiometer 6.4: Bale loading sensor 6.5: Cradle fully down sensor 6.6: Rotation sensor 6.7: Safety switch 6.8: PWM module 6.9: Bale levelling potentiometers and comparator 6.10: Potentiometer testing 6.11: Film sensor operation 6.12: Film sensor testing 6.13: Reed sensor testing 6.14: Uploading expert software



06-2

Connectors viewed from wiring side

1

2

3

4

5

6

12

3

12

3

1

2

1

2

1

2

12

3

12

3

15 yellow/vio

20 green/red

1 grey/grn

17 grey/brn

28 wht/vio

25 grn/blk

26 brn/blk

8 org/grn

5 yel/brn

33 red/blu

23 blu/blk

21 grn/blu

35 turquoise

27 yel/grn

34 yel/red

g/y

strip

edg/

y sp

iral

bale down

conv. fwd

conv. rev

c&h open

c&h release

bale up

current sense

spare out

spare in

spare in

spare inspare in

spare out

spare out

5 Volt

rotate sensor

disp. safety

half speed

disp. enable

rotate fwd

rotate rev

beacon

x connect

12 volt

12 volt loop

12 volt loop

12 volt loop

12 volt loop

bale height

rolls down

rolls level

film break

bale position

safety loop

32 org/blu

9 wht/grn

31 yel/blu

29 wht/red

6 black

10 grey/blu

30 violet

3 red/blk

36 red/brn

18 blue

forward

orange/black

wht/blk

16 orange

19 wht/brn

13 grey

24 red

7 white

4 wht/blu

11 brown

22 yellow

2 pink

12 vio/blk

14 green

1

2

3

1

2

3

1 2

3

12

3

12

3

1

2

3

4

1

56

2

3

4

1

2

3

4C

EL00

618

L

oom

998

Mk2

Cha

ssis

P O

'C

08-0

4-20

06

yello

w

yellow

yellow

beeper

1

2

3

4

X

X

L

S

H

D

C

B

T

1600

500

400

yello

wtu

rquo

ise

blac

k

Gasket fitted to Connector

6.1.1: Main loom (Pre S/n 250725)



06-3

6.1.2: Main loom (Post S/n 250725)



06-4

Note: On the previous 2 pages there are two hydraulic schemes. The loom was changed so that the two solenoids on the roller rotation valve are now powered from separate inputs. On machines previous to this, one power supply powered both solenoids. During the change over of this loom for some machines which were distributed to customers an extra loom section was fitted. This addition meant that the machines fitted with this now have the same wiring structure as the new loom. If the new loom is fitted to an older machine then the electronic unit has to be updated to program version 33 or above.



06-5

6.1.

2:

Top

arch

loom



06-6

6.1.3: Input / Output test

Comparator



06-7

6.2: Electronic control unit

Mounted in cab using suction pad to window Good 12 volt power supply essential (displayed on screen) Full control over each function in manual To start Auto cycle Press Auto start button (A) To skip conveyer movement at start of the cycle press start 2 (B). Red button for on/ off and emergency stop To reset box factory settings:

1. Turn box off 2. Press and hold up arrow on circular dial 3. While pressed turn on box and then let go 4. Press Enter button (big arrow) 5. SET DEFAULT 6. DEFAULT SET will show on screen if completed correctly. 7. Press ENTER to change between screens: • Bale count • Plastic layers • Voltage • Bale type • Man/ Auto • Satellite RPM

Fig. 1 A B



06-8

6.2.1: Electronic control unit functions The Electronic Control box is the main interface between the operator and the machine. While the machine is fully automatic, setting up is required before wrapping commences. It is also possible to work the machine manually through the buttons on the box.

2

1

6

5

3

4

14 13

12 11

10 9

8 7

18 17

16 15



06-9

No. Function

1 Display up

2 Escape back to main display, or cancel error

3 Enter

4 Display down

5 Stop button-Twist clockwise to restart the control box!

6 Display

No. Manual Function Automatic Function

7 Select Automatic Select Manual

8 Wrap bale Pause bale index

9 Release plastic from cut & hold Not used

10 Cut & hold plastic Not used

11 Index bale forward Not used

12 Index bale reverse Not used

13 Lift bale up Not used

14 Lower bale down Not used

15 Move bale to front Move bale to front

16 Move bale to rear Move bale to rear

17 Wrap bale Auto start (from front conveyor)

18 Rotate dispensers (no index) Auto start 2 (bale is in position on conveyor)

Control box functions

No function Pause bale index / Slow bale index



06-10

6.2.2: Display Working display When the control box is first switched on it displays "Expert Series" followed by the programme version number, followed by the selected language.The working language can be changed at this point if required. The language is changed by pressing the arrow up or arrow down button to scroll to the desired language when the default language “English“ is displayed. After a short delay the working display appears. The working display is in two halves: • The upper half displays the bale current count and the word Layers, • The lower half displays the machine status manual or automatic, a question

mark or a short line and under Layers is the number of layers of plastic selected to be applied.

Pressing enter toggles between three working display options. The second display also in two halves: • The upper half displays the selected bale type, • The lower half displays the height the bale is raised, the question mark (as

above) and the voltage the control box is getting from the power source. The question mark in the middle of the lower line of both displays changes to a short line when the first bale is lifted. This line rotates as the bale indexes. The question mark appears each time the control box is switched on. The third screen shows the speed of the satallite when wrapping. Bale counters The Expert Series control box contains ten different bale counters (A - J) which can be reset and a grand total counter which can not be reset.

Voltage Monitor The Expert Series control box monitors its operating voltage and displays it secondary working display during wrapping. If the voltage falls below a safe level LOW BATT is flashed on the display. The usual causes of low voltage are a bad battery or a defective charging circuit, loose or corroded connections or fuses or a faulty power lead to the control box.

To Select Bale Counter From the working display press the down arrow once to select "To Change Total" display, press enter to move to the "To Select Total" display, select desired counter (A -J) using up and down arrow buttons and when correct press enter to select, press up arrow or ESC to return to the working display.



06-11

ESC ENTERESCAPE

MENU UP

MENU DOWN

Use & to move up and down through the menu options, use (enter) to select the option and use ESC to return to the previous level.

Grand Total 267

Expert Series EX305 - 006

Total A 0 ( To Reset )

Enter Pin

Enter Pin

0000

0000

Technician

Technician 2

Setup

Setup

Reserved for McHale engineers

English

Programme version no.

4, 6, 8, etc Layers

Off / On / Alert

To Select Contrast

To Select Film Sensor

To Select Square Layers

To Select Bale Type

Operator Setup

To Change Total A 0 A - J

To Select Total A 0

1.0 secs To Select

Conveyor Extra

Press to Zero

16.0 Turns To Select

Round Bale Wraps

To SelectZero Height Set

H - H 80x50 x 1H - H 80x50 x 2H - H 80x70H - V 80x70H - H 80x80H - V 80x80H - H 80x90H - V 80x90H - H 90x60H - H 120x70V - H 120x70H - H 120x70 x 2H - H 120x80V - H 120x80H - H 120x90V - H 120x90H - V 120x90V - V 120x90H - H 120x130RND RoundH - H Custom 1H - H Custom 2

Off / On / Repeat To Select

Extra Care

095 To SelectRaised Height

Contrast

MAN0 Layers MAN ? 10

MANH - H 80x70 h = 90% ? 12.9V

6.2.3: Menu structure



06-12

6.2.4: Menu Operator Set-up The Expert Series control box has a number of options that can be selected or adjusted by the operator. To enter the operator set up menu press the down arrow twice, press enter once to move to the operator adjustable factors; Bale Type, Extra Care, Conveyor Extra, Raised Height, Zero Height Set, Round Bale wraps, Continuous Cycle, Film Sensor, Square Layers and Contrast. Bale Type Select a bale type from the menu to match the dimensions of the bale being wrapped. The letters before and after the different bale types represent the start and finish orientation of the bale i.e. (H - V Horizontal start and Vertical finish). There are two custom bale options and a round bale option. The custom bale option allow the operator to define all the bale parameters to their own requirements. Extra Care The “Extra Care” wrapping cycle applies extra film on certain places on rectangular bales (i.e. Claas Quadrants 1200) if so desired. This helps to wrap these bales evenly. Extra Care can be switched Off, On or to Repeat. If “On “ is selected each extra care is applied on the bale once. If “Repeat” is selected each extra care will be repeated every time the bale indexes one revolution. Conveyor Extra Conveyor Extra sets the time the bale moves past the bale sensor. The time should be increases for shorter bales and decreases for longer bales. Raised Height This is the height the bale is raised for wrapping. Each bale option has a suitable preset value but this may need adjusting for some conditions. Zero Height Set Zero height set calibrates the height sensor. Set the control box to manual and press the cradle down button until the cradles are fully down then press the display down button twice and press enter to enter the operators menu. Press the display down button four times and press enter to zero the height sensor. Press ESC to return to the working display. If the height reading on the display is not matching the bales raised height (Cradle fully up = 100%) then a zero height reset maybe required. A 0-5% of over shoot is however possible with light bales.



06-13

Round Bale Wraps To determine the number of dispenser rotations required to wrap a bale carry out the following procedure. 1. Count the number of dispenser revolutions required to cover the bale completely

with plastic film. 2. Add 1 to this number. 3. Multiply this resultant figure by 2 (for 4 layers) or 3 (for 6 layers). Example Number of rotations to cover a bale: 5 Number of rotation to apply 4 layers of film to the bale = (5+1) x 2 = 12 rotations. Film Sensor The film sensor monitors the passage of film through the dispenser rollers. If one dispenser stops feeding film due to a roll coming to an end the control box will give an audible alarm and flash “1 Dispenser Only”; bale rotation goes into half speed mode, rotating the bale at half speed so applying the correct film coverage and wrapping of the bale can be completed. If the second dispenser empties the dispensers will rotate slowly and stop at the loading position, the control box will display “Out of Film” and wait. • The film sensor may be switched off if desired • The film sensors may also be switched to alert, where electronic control unit

will alert the operator but not change the index speed of the bale. Square Layers Square layers is the number of plastic film layers applied to a square bale. • Every 1800 rotation of the bale is 2 layers of film. It is recommended that a minimum of six (6) layers of film are applied to the bale. If the material being wrapped is of a hard or stemmy nature it may be necessary to apply eight (8) layers to ensure a good airtight package. The operator needs to ensure that the bale is correctly wrapped. Contrast Extreme of temperature may affect the contrast of the display which is adjustable from the contrast menu. Custom bale set-up See following pages.



06-14

6.2.5: Custom Bale Set-up There are two custom bales in the bale type menu. The operator can define the set-up of each of these bales. When a custom bale is selected the operator set-up menu remains the same as any other bale options but the technical 2 menu which is reserved for McHale engineers is replaced with custom bale set-up. The adjustable factors in the custom bale set-up are Orientation Type, Horizontal Rev, Vertical delay, Pre Wrap Pulses, EC1 After Duration, EC Delay 1, Duration 1, Pulse Before C & H, Half Speed Valve, Rotate Bale Time.

Orientation Type The start and finish orientation of the bale is define using a H for horizontal and a V for vertical. There are four options for square bales: H - H, H - V, V - H and V - V. There is also a round bale option called RND Round.

Horizontal Rev Horizontal reverse is the indexing back of the bale for a selected period of time after the has levelled but before the dispenser start to rotate. The wrappings cycle the starts form this position. This can aid in preventing the plastic film slipping over the lower corner of the bale on the first rotation of the dispenser. Vertical Delay Vertical delay is used when a bale is wrapped on a vertical start orientation (v - H or V - V). The index of the bale can be held for a selected period of time when the dispensers have started rotating.

Pre Wrap Pulses A number of dispenser rotations can be applied before the bale starts to index. This is most commonly used when wrapping double stacks of bales. One or two dispenser rotations before the bale starts to index will secure the top bale from slipping out of line with the lower bale when it is indexing through the first ninety degrees.

Extra Care Each extra care has three adjustable factors. The first factor is EC1 After Trans which short for Extra Care 1 After Transition. The second is factor is EC Delay 1 which is the delay after the selected transition in seconds before the Extra Care starts. The third factor for extra care is Duration 1 which is duration of extra care applied to the bale in seconds.



06-15

Pulse Before Cut & Hold After the select number of layers of plastic film have been applied to the bale extra dispenser rotations can be applied if necessary. The bale will also index for these rotations. Half Speed Valve The half speed valve indexes the bale at half the normal wrapping speed. This is set to on when wrapping using 500mm plastic film. This will give the correct over lap when the valve is set to suit 500mm plastic film however the default setting for the valve is set for one dispenser only on 750mm plastic film. Rotate Bale Time This time is set for round bales that have a flat bottom. If the bale finishes wrapping with this flat near the bottom of the bale it can cause the bale to roll of centre on the conveyor. The plastic film can be damaged if it catches the rollers as it is unloads. Set the time to suit the bales being wrapped so the flat spot is not near the bottom. The following two pages show the default settings for each bale type, these should be used as a reference when setting up a custom bale.



06-16

FU

NC

TIO

N

RA

NG

E

Def

ault

B

ale

Type

1 o

r 2 x

H c

m x

V c

m

80

x50x

1 80

x50x

2 80

x70

80x7

0 80

x80

80x8

0 80

x90

80x9

0 90

x60

Set

Sta

rt/Fi

nish

orie

ntat

ion

or R

ound

H

-H; V

-H; H

-V;

(d

efin

es w

hich

par

ts o

f seq

use

d)

V-V

; Rou

nd

H-H

H

-H

H-H

H

-V

H-H

H

-V

H-H

H

-V

H-H

H

eigh

t bal

e ra

ised

(

0 - 1

00 )

0 -

100

95

95

95

95

95

95

95

95

95

R

ever

se b

ale

befo

re s

tart.

Hor

izon

tal o

nly

0 -

5 0

0 0

0 0

0 0

0 0

Del

ay w

rap

afte

r 45.

Ver

tical

sta

rt on

ly

0-9.

9 Se

cs

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

Pre

-wra

p. (X

-con

nect

on)

, dis

p pu

lses

0-

10 P

ulse

s 0.

1 0

0 0

0 0

0 0

0 E

C1

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

1 1

1 1

1 1

1 1

1 D

elay

1*

0-9.

9 Se

cs

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

Dur

atio

n 1

* 0-

9.9

Secs

0

0 0

0 0

0 0

0 0

EC

2 af

ter t

rans

ition

no.

* 0-

99 tr

ansi

tions

2

2 2

2 2

2 2

2 2

EC

del

ay 2

* 0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

2 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C3

afte

r tra

nsiti

on n

o.*

0-99

tran

sitio

ns

3 3

3 3

3 3

3 3

3 E

C d

elay

3 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

3 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C4

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

4 4

4 4

4 4

4 4

4 E

C d

elay

4 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

4 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C5

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

5 5

5 5

5 5

5 5

5 E

C d

elay

5 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

5 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C6

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

6 6

6 6

6 6

6 6

6 E

C d

elay

6 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

6 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C7

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

7 7

7 7

7 7

7 7

7 E

C d

elay

7 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

7 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 E

C8

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

8 8

8 8

8 8

8 8

8 E

C d

elay

8 *

0-

9.9

Secs

0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

8 *

0-9.

9 Se

cs

0 0

0 0

0 0

0 0

0 A

dditi

onal

pul

ses

afte

r lev

el, b

efor

e C

&H

0 - 1

0 1

0 0

0 0

0 0

0 0

1 d

isp

only

' act

ion;

hal

f spe

ed (o

r 50/

50)

Y/N

Y

ES

N

O

NO

N

O

NO

N

O

NO

N

O

NO



06-17

FU

NC

TIO

N

RA

NG

E

D

efau

lt

Bal

e Ty

pe 1

or 2

x H

cm

x V

cm

120x

70

120x

70

120x

70x2

12

0x80

12

0x80

12

0x90

12

0x90

12

0x90

12

0x90

12

0x13

0 S

et S

tart/

Fini

sh o

rient

atio

n or

Rou

nd

H-H

; V-H

; H-V

;

(d

efin

es w

hich

par

ts o

f seq

use

d)

V-V

; Rou

nd

H-H

V

-H

H-H

H

-H

V-H

H

-H

V-H

H

-V

V-V

H

-H

Hei

ght b

ale

rais

ed

( 0

- 100

) 0

- 1

00

84

84

84

84

84

80

80

80

80

75

Rev

erse

bal

e be

fore

sta

rt. H

oriz

onta

l onl

y 0

- 5

0 0

0 0

0 0

0 0

0 0

Del

ay w

rap

afte

r 45.

Ver

tical

sta

rt on

ly

0-9.

9 S

ecs

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

9.9

Pre

-wra

p. (X

-con

nect

on)

, dis

p pu

lses

0-

10 P

ulse

s 1

1 1

1 1

1 1

1 1

1 E

C1

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

1 1

1 1

1 1

1 1

1 1

Del

ay 1

* 0-

9.9

Sec

s 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 0.

5 D

urat

ion

1 *

0-9.

9 S

ecs

0 0

0 0

0 0

0 0

0 0

EC

2 af

ter t

rans

ition

no.

* 0-

99 tr

ansi

tions

2

2 2

2 2

2 2

2 2

2 E

C d

elay

2*

0-9.

9 S

ecs

0.5

0.5

0.5

0.5

1 0.

5 1

0.5

1 0.

5 D

urat

ion

2 *

0-9.

9 S

ecs

0 1.

5 0

0 1.

7 0

2 0

2 0

EC

3 af

ter t

rans

ition

no.

* 0-

99 tr

ansi

tions

3

3 3

3 3

3 3

3 3

3 E

C d

elay

3 *

0-

9.9

Sec

s 0.

5 0.

1 0.

5 0.

5 0.

1 0.

5 0.

1 0.

5 0.

1 0.

5 D

urat

ion

3 *

0-9.

9 S

ecs

0 1.

5 0

0 1.

5 0

1.5

0 1.

5 0

EC

4 af

ter t

rans

ition

no.

* 0-

99 tr

ansi

tions

4

4 4

4 4

4 4

4 4

4 E

C d

elay

4 *

0-

9.9

Sec

s 0.

5 0.

1 1

1 1

1 1

1 1

0.5

Dur

atio

n 4

* 0-

9.9

Sec

s 1.

5 1.

5 2

1.7

1.5

2 1.

5 2

1.5

1 E

C5

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

5 5

5 5

5 5

5 5

5 5

EC

del

ay 5

*

0-9.

9 S

ecs

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

0.1

Dur

atio

n 5

* 0-

9.9

Sec

s 1.

5 1.

5 1.

5 1.

5 1.

7 1.

5 2

1.5

2 1

EC

6 af

ter t

rans

ition

no.

* 0-

99 tr

ansi

tions

6

6 6

6 6

6 6

6 6

6 E

C d

elay

6 *

0-

9.9

Sec

s 0.

1 0.

5 1

1 0.

5 1

0.5

1 0.

5 0.

1 D

urat

ion

6 *

0-9.

9 S

ecs

1.5

0 1.

5 1.

5 0

1.5

0 1.

5 0

1 E

C7

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

7 7

7 7

7 7

7 7

7 7

EC

del

ay 7

*

0-9.

9 S

ecs

0.1

0.5

0.1

0.1

0.5

0.1

0.5

0.1

0.5

0.1

Dur

atio

n 7

* 0-

9.9

Sec

s 1.

5 0

2 1.

7 0

2 0

2 0

1 E

C8

afte

r tra

nsiti

on n

o. *

0-99

tran

sitio

ns

8 8

8 8

8 8

8 8

8 8

EC

del

ay 8

*

0-9.

9 S

ecs

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

0.5

Dur

atio

n 8

* 0-

9.9

Sec

s 0

0 0

0 0

0 0

0 0

0 A

dditi

onal

pul

ses

afte

r lev

el, b

efor

e C

&H

0 - 1

0 0

0 0

0 0

0 0

0 0

0 1

dis

p on

ly' a

ctio

n; h

alf s

peed

(or 5

0/50

) Y/

N

NO

N

O

NO

N

O

NO

N

O

NO

N

O

NO

N

O



06-18

6.4: Bale loading sensor As the bale is loaded up the conveyer it pushes back the trip wheels moving the magnet away from the sensor (A) for a few seconds. When the trip wheels return to home position (magnet in front of sensor) the pulse starts a time delay in the control unit to stop the conveyer. This delay should be set so the bale is in the correct position for lifting depending on the length of the bale. If the sensor is faulty or the magnet is damaged:

Auto Start 2 cycle may not begin, (damaged open circuit) The Conveyer will not stop when the bale trips the wheels, (damaged closed circuit)

It is a standard REED sensor

Position on machine A

6.3: Bale height potentiometer The bale height sensor is a potentiometer. As the cradle raises the resistance reading through it will change. When the cradle is in its lowest position the control box will display this position as H=O%. If this is not correct the zero height set can be re-set in the operator set-up menu on the electronic control unit. The % height will show on the screen from 0% (cradle at its lowest position) to 100% (cradle at its highest position) as the cradle is moved up and down. This feature makes it very easy to test this component.

Fig. 2

Fig. 3



06-19

6.5: Roller fully down sensor This sensor signals the control box at the end of a cycle that the cradle is at its lower position. It is a standard REED sensor A faulty sensor or magnet:

Will cause the pump to keep downward pressure (for 5 extra seconds) on cradle at end of cycle.

It is possible to operate the machine without this sensor.

Position on machine

6.6: Rotation sensor The rotation sensor monitors the rotations of the dispenser arms from a magnet on each arm. It counts rotations of the dispensers for the round bale setting. Its main purpose on any square bale setting is to signal the correct time to release the plastic at the beginning and to raise the cut & hold slides at the end of the cycle. The arms will go into slow speed and slides raise after its second last pulse. They will only come back down once the sensor gets another pulse when the dispensers stop. It is a standard REED sensor.

Position on machine Fig. 5

Fig. 4



06-20

Gearbox shaft with slip ring unit in position.

6.7: Safety switch The purpose of the safety arm switches is to stop the arms of hitting an object at full speed. The spring loaded arm is shown below with the arm in its working position. If the circuit is broken (arm moved back) power is lost to rotate the dispenser arms.

Position on machine

Power to the switches is supplied via a slip ring unit through the top rotation gearbox shaft. The unit is in three separate components: 1. Top slip ring connector 2. Mercury filled transfer rotor switch 3. Lower slip ring connector which is rotating with the arms.

1 2

3

Fig. 7

Fig. 6



06-21

U'P

re

d/b

lk

=

pin

k

gr

n/y

el

wh

t/g

rn

gr

n/y

el

re

d/b

lu

br

n

blu

ye

l/g

rn

sa

fety

sw

itc

hs

afe

ty s

wit

ch

ro

tar

y c

on

ne

cto

r

(

sli

p r

ing

)

dis

pe

ns

er

e

na

ble

so

len

oid

br

n

blu

ye

l/g

rn dis

pe

ns

er

po

sit

ion

+_

br

nb

lu

12

v.

0 v

.

sa

fety

mo

nit

or

99

8 E

lec

tric

al

Co

nn

ec

tio

n

The

wiri

ng o

f the

saf

ety

switc

hes

is a

s sh

own

in th

e di

agra

m.



06-22

6.8: PWM module The Pulse Width Modulation constant current module is connected between the control unit and the proportional hydraulic valve. It’s purpose is to stabilise the slow speed of the satellite arms against voltage and temperature variations. It’s supplied with a constant 12 Volt supply and a variable rotate PWM signal from the control box. It monitors the current through the solenoid valve by a sensing resistor in the ground circuit and keeps the current through the valve at the desired level. Connections: 1 = black, 2 = blue, 3 = yellow, 4 = red, 5 = white, 6 = green. Testing There is no simple test for the PWM module except by substitution with a known good module. If there is no rotation of the cradle rollers in forward direction (Using roller rotation button with control unit in manual), the PWM can be eliminated by doing the following: • Unplug the PWM from the loom • Join the wires in the loom 6 pin plug as shown in the diagram below. • Make a loop from: Pin 3 (Orange/black) to Pin 5 (Blue) (A below) • Make a loop from: Pin 1 (Green/Yellow) to Pin 6 (White/black). (B below) • There now should be full rotation of the rollers in both directions. • If this is the case then the PWM is faulty.

Fig. 8

B

A



06-23

Slotted link arm shown holds the fork of the pot in position and moves with the cradle to give angle change. Ensure this arm is not bent.

6.9: Bale levelling potentiometer and comparator The bale levelling is carried out by two potentiometers, one on each set of rollers (cradle) on the machine. As the bale is rotated the angle of each set of rollers is changing. When the bale is in horizontal, Vertical or at a 45 degree position the angle of each potentiometer is the same. Both pots are connected to a comparator which has an LED. This will change colour (green/ red) and send a signal to the control box each time the bale passes one of the three positions. If the LED does not change colour a potentiometer is possibly faulty. As well as knowing when the bale is level from these it also counts the rotations of the bale on the cradle. Each 1/2 rotation of the bale is 2 layers of plastic (with film applied from both dispensers). If the bale is not being dropped in the correct position either pot can be adjusted to drop it more to the left or right. (A) below shows two allen head bolts holding the pot in position. The holes are elongated (10 MM) for adjustment. If there is not enough adjustment on one the other can then be adjusted. The pin (B) which holds the pot on the cradle is held in place with a roll pin. If this fails and the pin can rotate the pot will not work. (pot testing next page).

A

B

LED

Fig. 9



06-24

6.10: Potentiometer testing With the notch (curved area) Facing away from the wire it should read opprox. 500 ohms between pin 1 &2 and also 500 ohms between pin pins 2 & 3. Total potentiometer resistance is 1000 ohms.

Fig. 10

With the multi meter on pins 2 & 3, rotating the potentiometer anticlockwise should increase the resistance while rotating it clockwise should decrease it.



06-25

6.11: Film sensors Function Film sensor monitoring can be switched on or off from the operator set-up menu on the electronic control unit. The film monitoring circuit consists of a pair of dispenser mounted radio transmitters, one Even code and one Odd code, sending signals to a machine mounted receiver which decodes the signals and passes film status information to the electronic control unit. The transmitters are a sealed battery powered unit with a 5 year battery life which transmit a code when a magnet on the dispenser gear passes over them. Each transmitter has a unique code which must be taught to the receiver, this means that two 998 machines can operate in the same field without mutual interference. One odd code (O) and one even (E) code transmitter must be fitted. The receiver decodes the signals and sends a high frequency ( 1100Hz) to the control box when both dispensers are feeding film, a low frequency ( 550Hz) when only one dispenser is feeding film and no signal when pulses are absent. If one dispenser stops feeding film the electronic control unit displays ‘1 Dispenser Only’ and switches to 50/50 mode where the bypass valve is switched on effectively wrapping the bale with one film roll. If film pulses are absent the electronic control unit displays ‘Out of Film symbol’ and brings the dispensers to a halt in the loading position where film can be loaded and wrapping resumed. Testing Transmitters With the control box switched on, and hydraulic oil off, rotating either dispenser roller should cause the receiver Light Emitting Diode to flash. If the LED does not flash an attempt to teach the codes to the receiver should be tried and the dispenser gear magnets should be inspected. Receiver There are no serviceable parts inside the receiver, it’s 12 Volt supply can be checked but flashing of the LED on power up will show that it is getting a supply. The film signal can be monitored from the Input/Output test menu, see Input/Output test section 11.8. Blue = ground, brown = 12V, green/yellow = signal Teaching This is detailed in the section on film sensor replacing (next page).

E

O

Fig. 11



06-26

6.12: Film sensor programming



06-27

6.13: Reed sensor testing Function There are three standard 12 mm reed sensors on the 998. • Arm rotation • Conveyer trip wheels • Cradle fully down These contain a glass reed switch in series with a 100 Ohm resister. The switch closes when there is a magnet placed in front of it, 25 mm approx. The magnet should be mounted with a stainless steel bolt.



06-28

Switch off the control unit by pushing the red stop button. Launch the upload programme by double clicking the "RDS UPDATE" icon. Select the Com port that the serial cable is connected to. Click on "UPLOAD" to open the "file select" window. Select the desired program and click OK. The computer will try to connect. Switch on the control box by turning the red stop button to release. Data will be transferred to the control unit, the current and the upgrade software versions will be displayed and a progress indicator will indicate programme transfer. "Transfer complete" will be displayed when programme is uploaded. Click "Stop" to clear the connection. Click "Quit" to exit or "Upload" if another unit is to be uploaded. Switch control unit off and then on, as the unit powers up it should display the new software version number, it is now ready for use.

6.14: Uploading expert software New control box programs are easily uploaded to the Expert control box using a computer and a special serial cable (CEL00254). Computer requirements. Windows computer with pre installed uploading software and a free 9 pin COM port. USB computers will require a 'USB to COM' port adaptor. The uploading software can be downloaded from the dealer area on www.mchale.net The program for the control box can be sent via email or the latest version can also be downloaded from the McHale website. Connect "McHale-Expert" serial cable to a spare serial port, Com1 or Com2 on the computer. Connect other end of cable to Expert control box. NOTE:- This cable is a non standard cable and must not be used on any other instrument. Connect a 12 Volt power supply to the Expert control box. The connections to the battery or power supply must be secure, a power failure during uploading will corrupt the program making the unit unable to accept any further software, a new chip will have to be fitted. DO NOT USE a battery charger as a power source, the voltage may be too high.

McHale 998 hydraulic systems overview section 7-1


Section 7

Hydraulic System Contents: 7.1: Hydraulic schematic 7.2: Hydraulic system 7.2.1: Hydraulic reservoir 7.3: Component location 7.4: Main valve 7.4.1: Valve components 7.4.2: Valve assembly 7.5: Roller rotation valve 7.5.1: Valve assembly 7.6: Dispenser rotation valve 7.6.1: Valve assembly 7.7: Diverter and flow control valves 7.8: Hydraulic motor drives 7.9: Accumulator test 7.10: Cradle lift hydraulic circuit



7.1:

Hyd

raul

ic s

chem

atic





7.2: Hydraulic system: The oil reservoir (Fig. 1) on the front of the machine supplies oil to the PTO driven load sensing pump mounted beside it. Filters on the top and bottom of reservoir tank should be checked and changed after every season (Fig. 3).

Port for testing system pressure underneath drawbar.

3 : 1 Ratio gearbox between PTO and pump.

Fig. 2 below shows the pump and marked A is the oil flow setting of the pump. This is factory set and rarely needs to be changed. The oil flow can be increased by adjusting it in. Using a pressure clock on the test port a stand-by pressure of 20-25 bar should read on the clock when the machine is idle.

Main oil reservoir

A

Fig. 2

Fig. 1



7.2.1: Hydraulic reservoir

Fig. 3



Main control load sensing valve

Main hydraulic component location.

Flow control for roller speed

Diverter valve Roller rotation valve

7.3: Component location



A

7.4: Main valve The main valve in conjunction with the pump is load sensing therefore only pumping oil when a function on the machine is operated. The lever pivot boxes showing the 4 main functions of the machine: 1. Dispenser and roller rotation 2. Cut & hold 3. Conveyor rotation 4. Cradle up/ down

A in fig. 4 above shows the flow adjusters to set the speed of each function on the machine. One screw for each direction of movement. Turning clockwise will slow the function down. These should be re-set after changing the flow setting on the pump.

1 2 3 4

Fig. 4



7.4.1: Valve components



7.4.2: Valve assembly



7.5: Roller rotation valve The purpose of this valve is to allow :

the rollers to rotate in opposite directions (using a cross over valve in a closed circuit) while lifting and lowering the bale. This keeps the bale in a more level position. The Dispensers to rotate without the rollers (control box in manual). Both

Both solenoids on this valve should always receive power together. If the solenoid marked A is faulty or is not receiving power when bale rotation is being paused the cradle rollers will rotate in opposite directions.

A

Fig. 5






7.6: Dispenser arm rotation valve The purpose of the valve is to:

Allow the rollers to rotate the bale without the dispenser arms. This is done through the solenoid (A in Fig. 6). This is normally open and needs power to rotate. The safety switches circuit goes through this solenoid. If one safety switch is open there is no power to this solenoid. Ensure there is a minimum of 40 bar pressure in the feed line before the pilot directional valve (No. 1. longer of the two) is open to lift off the brake (B). Ensure there is a minimum of 100 bar pressure in the feed line before the motor will operate. This is achieved through the over centre valve (No. 2. short one).

A

B

C CVA00153 VALVE ROTATION 998 1 1 CVA00287 CTE PRESSURE REDUCING HS & 998 1 2 CVA00312 OVER CENTRE VALVE ASSY 1 3 CVA00071 CTE 991BJS DETENT VALVE 1

1

2

3

C

Fig. 6






7.7: Diverter and flow control valves When the diverter (Fig. 7A) is activated the oil flows through the flow control valve (Fig. 7) to give the rollers 50% speed. This is necessary when one roll of plastic is not being applied to the bale. It is activated from the control box after the film sensors have given the signal that only one roll is being applied. The speed of the rollers can be adjusted on this valve to ensure it is at 50%. The oil is fed through the diverter valve and direct to rotation, but when 50% speed is required solenoid A is powered to divert the oil through the flow control valve.

Flow control valve

Diverter valve

A

Fig. 7A

Fig. 7



7.8: Hydraulic motor drives

Conveyer motor

Cradle roller motor

Dispenser arm motor

Fig. 8



7.9: Accumulator test. There are two sets of accumulators on the machine. 1. The Cut and hold: These hold pressure in the cylinder to operate the down

stroke and to keep it closed when the film is cut. 2. The Conveyer cylinder: This accumulator is to give the front conveyer float

while it is being used. If the conveyer is run slightly off the ground it will go down when the weight of the bale is on it.

To test either accumulator: Warning! Ensure there is no pressure in the relative hoses on the machine.

1. Remove the accumulator 2. Look into the end of it. If there is a green plastic seal showing (A) and

cannot be pushed in, it can be assumed that it is ok. 3. If this cannot be seen or can be moved the accumulator should be re placed.

Cut and hold accumulators.

Conveyer accumulator.

A

Fig. 9A Fig. 9



7.10: Cradle lift hydraulic circuit The hydraulic circuit for the cradle lift is shown in Fig. 10. There are two Hydraulic cylinders on each cradle. The cylinders on the left hand side (drawbar side of machine) are the master and slave on the non drawbar side (Fig. 10B). The oil is pumped into the master cylinder to extend it and the oil from the small side of this cylinder is piped into the large side of the slave cylinder causing it to extend (Line A). This happens in reverse for the down stroke of the cylinders. Shown in fig. 10A is the system used in a master /slave system to ensure the same distance is moved by both cylinders. This will happen at the end of each stroke where the ball is lifted of its seat. (B in Fig. 10A) This system ensures that both cylinders travel the same distance. If the slave cylinders are not travelling as far as the master it is generally oil leaking through one of the two check valves in the master cylinder.

Line A

Fig. 10 Fig. 10A

B



Master cylinder Slave cylinder

Fig. 10B

McHale 998 drive systems section 8-1


Section 8

Drive System

Contents: 8.1: Pump gearbox 8.2: Conveyer drive line 8.3: Cradle roller drive 8.3.1: Chain adjustment 8.4: Dispenser gear drive 8.5: Top reduction drive 8..5.1: Dispenser gearbox oil level 8.5.2: Gearbox assembly 8.5.3: Dispenser drive assembly parts



8.1: Pump gearbox The hydraulic pump is fitted with a 1:3 step up gearbox. The level of oil in the gearbox needs to be checked daily which is easily accomplished through the level sight gauge on the side of the gearbox. It is recommended that the oil is changed after the first 50 hours of use and thereafter every year. The oil is changed as follows:

1) Ensure gearbox oil is warm to aid draining. 2) Place suitable container under the drain stud. 3) Remove filler/breather cap (A) 4) Remove the drain stud. (C) 5) Once drained replace drain stud (C) and dispose of oilsafely. 6) Fill gearbox with EP80 gearoil until oil can be seen on the sight gauge. (B) 7)Replace filler/breather cap (A) and run machine for 2-3 minutes. 8) Stop machine and allow oil to settle. Check oil level again and refill if necessary.

A

B

Fig. 1

C



3

46

8.2: Conveyer drive line The hydraulic motor marked A drives the main conveyer from the rear of the machine. This 625 cc motor to a sprocket and chain drive system that is tensioned as in Fig. 4. The drive from the rear shaft of the machine carried by the conveyer to the front shaft and from there to the front pick up chain drive. The means of tensioning the main conveyer chain is shown in Fig. 3. The pick chains can only be tensioned all together. Shaft and tension bolt, marked (A) will move to tension the chains. There is no individual tensioner so pick up chains will not always have the same tension.

A

Fig. 3

Fig. 4

Fig. 2

A



8.3: Cradle roller drive The drive to the cradle rollers from a 305 cc motor (Fig. 6) to a centre shaft as shown in Fig. 5 is to allow the rollers to oscillate and therefore both rollers will be in contact with the bale at all times. These chains should be checked, tensioned and lubricated every 1000 bales. At the other end of this centre shaft the drive is taken to each roller. There is a tensioner for each chain where the bearing is mounted and able to pivot. The plastic roller itself has the centre shaft going all the way through with support brackets 5 welded along inside it. The roller is also foam filled.

Fig. 7

Fig. 6

Fig. 5

8.3.1: Chain adjustment 1) Remove two (2) M8 setscrews holding on chain guard and remove guard. 2) Slightly loosen three (3) M10 nyloc nuts, holding on bearing. 3) Turn cam adjuster against bearing, using 17mm spanner on the two machined flats until there is 8-10mm sag in the chain. 4) Tighten the three (3) nyloc nuts on the bearing. 5) Replace chain guard and tighten the two (2) M8 setscrews.

12 3



8.4: Dispenser drive gears The dispenser drive gears (Fig. 9) are situated on top of each of the two aluminium stretch rollers. Depending on the stretch required the no. of teeth on each gear will vary. 55% stretch : 58 teeth 37 teeth 64% stretch : 59 teeth 36 teeth 70% stretch :60 teeth 35 teeth It is important that these gears are kept greased to ensure free running of the aluminium rollers. Any restriction will cause the plastic to over stretch or tear. If the gears mesh to tightly it can cause one tight spot when rotating the rollers, this will also cause the plastic to tear.

Fig. 9



8.5: Top reduction The top reduction drive from the motor unit (A) through the brake unit (B) and into the gearbox (C) to drive the satellite arms is shown in Fig. 8.

Fig. 8

C

B

A

8.5.1: Dispenser gearbox oil level 1. Check oil level in dispenser gearbox using sight glass on side of gearbox housing. 2. If there is no oil level showing in the sight glass then top up oil level by undoing the breather cap shown. 3. Fill until oil level is half way up the sight glass.



8.5.2: Gearbox assembly



8.5.3: Dispenser drive assembly parts

Note: 1. For machines with serial no.’s ranging from 250235 to 250160 use part number ADP00097 when ordering a replacement motor or valve block (this kit re-places both motor and valve block as motor CMT00005 is no longer available). 2. For machines with serial no.’s ranging from 250159 and below, kit ADP00118 is required.

McHale 998 Machine maintenance section 10-1


Section 10

Machine maintenance and storage

Contents: 10.1: Machine maintenance

10.2: Maintenance intervals

10.3: Dispenser gearbox

10.4: Recommended lubricants

10.5: Tightening torque values



10.1: Machine Maintenance To maintain the machine in good working order it is necessary to carry out preventative maintenance from time to time. The following section gives details of how this may be carried out and how often it is required. It is vitally important to observe health and safety rules where necessary to avoid unnecessary enviromental damage or danger to anybody near the machine. This especially applies to disposal of oil, filters etc. Items such as chain adjustments are to be carried out when necessary (ie. when chains become loose etc). 1) Maintenance intervals. 2) Hydraulic oil level/replacement. 3) Hydraulic oil filter replacement. 4) PTO shaft. 5) Pump gearbox. 6) Cut & hold knife changing. 7) Spare film roll holder. 8) Dispenser gearbox oil level. 9) Dispenser brake oil level. 10) Dispenser pivot points.



10.2: Maintenance Intervals The following intervals should be adhered to, to ensure long and efficient life of the machine. They assume constant working during the wrapping season. 1) First 50 working hours 1) Change oil filter 2) Change pump gearbox oil 3) Change dispenser drive gearbox oil 2) Every day 1) Check hydraulic oil level 2) Check pump gearbox oil level 3) Grease PTO shaft joints (2) 4) Grease front conveyor sprockets (5) 5) Check wheelnuts 6) Check dispenser drive gearbox oil level 7) Check all guards and safety related components 8) Check for any oil leaks and damaged pipes 3) Every week 1) Grease drawbar front horizontal pivot (1) 2) Grease drawbar front vertical pivot (1) 3) Grease drawbar rear vertical pivot (1) 4) Grease drawbar hydraulic cylinder ends (2) 5) Grease lifting hydraulic cylinders ends (8) 6) Grease roller cradle pivots (4) 7) Grease cut and hold plunger (2) 8) Grease rear of front conveyor bearings (2) 9) Grease front of main conveyor bearings (3) 10) Grease rear of main conveyor bearings(4) 11) Grease rear unloading roller bearings (2) 12) Grease PTO cover (2) 13) Grease PTO shaft tube profiles 14) Check tyre pressure ( 26 PSI,1.75 bar) 15) Grease slotted links



4) Every month 1) Grease dispenser top roll holder shaft (2) 2) Grease bale position arm bearings (2) 3) Check all chain tensions 4) Check oil level in brake unit 5) Every year 1) Clean and lubricate dispenser gears. 2) Change hydraulic oil filter. 3) Remove front conveyor chains, clean and soak in oil. 4) Change pump gearbox oil. 5) Change brake unit oil. 6) Change dispenser drive gearbox oil. 6) Every two years 1) Change hydraulic oil. It may become necessary from time to time to clean the dispenser rollers as they pick up the “tack” from the plastic film. At the end of the wrapping season the machine should be washed and cleaned. Any damaged paintwork should be touched up. Any maintenance or repairs should be carried out at this stage. The electronic control box is not waterproof so must always be stored in a dry environment.



10.3: Dispenser gearbox

1. Check oil level in dispenser gearbox using sight glass on side of gearbox housing. 2. If there is no oil level showing in the sight glass then top up oil level by undoing the breather cap shown. 3. Fill until oil level is half way up the sight glass.

1

2

1

2

Always ensure tractor is stopped, handbrake applied, engine stopped and ignition key removed before working on machine.



10.4: Recommended lubricants The following lubricants are recommended for use on the 998 square bale wrapper Hydraulic oil ISO HV 46 or higher Pump gearbox oil EP 80 gear oil Grease Multi purpose grease Dispenser gears Open gear grease PTO shaft tubes Graphited grease Rotation Arm Gearbox EP 80 gear oil



10.5: Tightening torque values It is important that the correct torques for fasteners and fittings are adhered to.Below are tables of recommended torques for these. These are to be used unless torques are otherwise specified. These values are for general use only. Check tightness of all fasteners periodically. All torques are in Nm (Newton metres).

Nuts and bolts Black, Phosphatised or Galvanized

Grade marking 8.8 10.9 12.9

Dimensions Metric standard thread

Hex. bolts Din 931 Din 933 Socket head cap screws Din 912 Hex. nuts Din 934

M4 2.7 3.8 4.6 M5 5.5 8 9.5 M6 10 14 16 M8 23 33 40

M10 45 63 75 M12 78 110 130 M14 122 175 210 M16 195 270 325 M18 260 370 440 M20 370 525 630 M22 510 720 870 M24 640 900 1080 M27 980 1400 1650 M30 1260 1800 2160

Dimensions Metric fine thread

Hex. bolts Din 960, Din 961 Hex. nuts Din 934

M8 X 1 25 35 42 M10 X1.25 48 67 80 M12 X 1.25 88 125 150 M12 X 1.5 82 113 140 M14 X 1.5 135 190 225 M16 X 1.5 210 290 345 M18 X 1.5 300 415 505 M20 X 1.5 415 585 700 M22 X 1.5 560 785 945 M24 X 2 720 1000 1200 M27 X 2 1050 1500 1800 M30 X 2 1450 2050 2500

NOTE: For cadmiated or copper plated bolts and nuts a torque value must be used that is 25% lower than the value stated above.



McHale 998 Technical specification section 11-1


Section 11 Technical specifications

Contents: 11.1: Technical specifications



11.1: Technical specifications Transport length 7.30m (24’) Transport width 2.99m ( 9’ 10”) Transport height 3.5m (11’ 6”) (at lowest machine height) Weight (unladen) 3875 kg (8680 lbs.) Tyre dimensions 16.0/70-20 12 ply Attachment to tractor Cat 2 lower linkage SAE 6 spline PTO shaft PTO speed 600-800 RPM Hydraulics Self contained load sensing Hydraulic requirements 1 single acting spool valve (Front conveyor lift) 1 double acting spool valve (Drawbar) Hydraulic tank capacity 130 litres (approx) Film stretch 64% (55% optional) Film layers 2,4,6,8,10 or 12 Electrics 12Volt DC

Options: 1) Remote control kit for static machine operation. 2) Round bale kit.



Section 12

Notes



11.1: Notes

998 Square bale wrapper - showmeshortline.com...McHale 998 main component reference section 02-2 Issue 1: 0108 McHale 998 square bale wrapper technical service manual 2.1: Designated

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