SELF-PROPELLED BALER

Transcription

1 SELF-PROPELLED BALER OPERATOR'S MANUAL

2 I CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

3 CONTENTS II CONTENTS... II GENERAL OVERVIEW...IV GENERAL INFORMATION...V SAFETY...VI FIRE SAFETY...X SPECIFICATIONS...XII INSTRUMENTS AND CONTROLS Overhead Instruments and Controls Control Switch Colors Armrest Control Panel Hydrostatic Drive Control Handle Function Controls Baler Engage Switch Engine Speed Adjustment Switch Field/Road Switch In Cab Monitor (ICM) Corner Post Monitor Heater and Air Conditioning Windshield Wiper Switch Light Control Switches Start Switches Horn and Turn Signals Steering Adjustments Storage and Door Lock Emergency Exit Seat MACHINE BREAK-IN PRE STARTING CHECKS OPERATING ENGINE (check with engine Manufactures Operators Manual) OPERATING BALER Preparing For Field Operating Speed Starting Baler Engaging Baler Towing SETTINGS AND ADJUSTMENTS Tire and Wheels Steering Internal Park Brakes Final Drives Air Conditioning Needle Meter Trip Bar Knotter Clutch Knotter Brake Twine Needle Adjustment Twine Finger Adjustment

4 III TABLE OF CONTENTS CONTINUED Knotter Adjustment Feed Fork Feed Arm Feed Arm Safety Latch Plunger Plunger Safety Latch Plunger Knife Pinion and Bullgear Bullgear Luber Bale Length Pick Up Hay Saver Wheel Twine Routing FUEL,COOLANT AND LUBRICATIONS LUBRICATION AND MAINTENANCE Fuses TROUBLE SHOOTING Knotter ICM (In Cab Monitor) Air Conditioning Heater Drive System Hydraulics Electric Power Screen Steering Throttle Tires Park Brake Seat Display Radio

5 IV GENERAL OVERVIEW Your decision to buy a Freeman Baler was a wise decision. When it comes to Harvesting hay, Freeman is a solid investment. You will fi nd your new baler comes from a long history of top quality haying equipment. At Allied Systems Company, our goal is to provide you with the most rugged, highest capacity, longest lasting equipment available on the market. Freeman Self Propelled Balers, manufactured by Allied Systems Co., combine the best of Freeman and John Deere technologies. Combining Freeman and John Deere components has saved thousands of dollars in research and development costs, yet we have produced the best Self Propelled baler on the market today. The baler frame and all baling components are Freeman designed and built. The operators cab, engine, planetary drives, hydraulic pump and hydrostatic system are from John Deere (see Replacement Parts on next page). At Allied Systems Company, safety is not just a word, it is the Rule. Allied Systems Company prides itself on an outstanding safety record. This concern for safety is displayed in the equipment that we build. Special care has been taken while designing your Freeman baler to make it as safe as possible. We recommend that you carefully read the entire manual before operating your new baler. Becoming fully acquainted with its performance features, adjustments, controls and maintenance schedules will be repaid in a long, satisfactory life of the product.

6 V GENERAL INFORMATION The purpose of this manual is to assist the operator in maintaining and operating a Freeman Self Propelled Baler. Please read it carefully, as it provides important information and instructions that will help you achieve years of dependable equipment performance. NOTE: Reference to left-hand and right-hand usage throughout this manual refers to the position when seated in the operator s seat, facing forward. Replacement Parts: Only genuine Freeman and John Deere replacement parts should be used to service the baler. These parts are available from your authorized Freeman and John Deere dealer. To ensure prompt and effi cient service when ordering parts or requesting service repairs, remember to provide the dealer with the following information: 1. The correct part description or part number. 2. The model number of the baler. 3. The serial number of the baler. Use the Freeman and John Deere parts books you received with your baler for ordering parts. Serial number location: The serial number is very important in effectively transacting a parts order or service repair with the dealer. Use the serial number in all correspondence to ensure proper identification of your Freeman baler. The serial number is located on the baling chamber as shown. Serial Number Plate SERIAL NO. ASC-SP TO CURRENT AND 280S TO CURRENT Allied Systems Co. reserves the right to make changes to new equipment without incurring the obligation to make such changes to equipment previously manufactured.

7 VI SAFETY General The following pages contain general safety warnings which supplement specifi c warnings and cautions appearing elsewhere in this manual. All electrical and hydraulic equipment is potentially hazardous. You must thoroughly review and understand this Safety Section before attempting to operate, troubleshoot, maintain or service this baler. Time, money and effort have been invested in making your Baler a safe product. The dividend from this investment is YOUR PERSONAL SAFETY. However, it must be realized that no power-driven equipment can be any safer than the person behind the controls. If you don t operate and maintain your Freeman Baler safely, our efforts will have been in vain. The safety instructions and warnings, as documented in this manual and shipped with the machine, provide the most reliable procedures for the safe operation and maintenance of your Baler. It s your responsibility to see that they are carried out. Allied Systems Company cannot anticipate all worksite conditions, local regulations, etc. It is the responsibility of the end user to be aware of and obey any specifi c worksite, local, state, or national regulations or procedures that are applicable to operating this baler. NOTE: All possible safety hazards cannot be anticipated so as to be included in this manual. Therefore, you must always be alert to potential hazards that could endanger personnel and/or damage the equipment. Safety Symbols The following symbols/terms are used to emphasize safety precautions and notices in this manual: DANGER The DANGER symbol indicates a hazardous situation which, if not avoided, will result in death or serious injury. Carefully read the message that follows to prevent serious injury or death. WARNING The WARNING symbol indicates a hazardous situation which, if not avoided, could result in death or serious injury. Carefully read the message that follows to prevent serious injury or death. CAUTION The CAUTION symbol indicates a hazardous situation which, if not avoided, could result in minor or moderate injury, or equipment damage. Carefully read the message that follows to prevent minor or moderate injury. NOTICE The NOTICE symbol alerts to a situation that is not related to personal injury but may cause equipment damage. NOTE: The term NOTE highlights operating procedures or practices that may improve equipment reliability and/or personnel performance, or to emphasize a concept. Intended Use Statement: This baler is intended to gather and compress loose, fi brous material (i.e., hay) and form it into rectangular bales. Use in any other way is considered to be contrary to the intended use. If you are unsure of the material you intend to bale, consult the factory.

8 VII Operation Warnings WARNING Warning: Failure to observe the following safety rules may result in extreme personal injury, dismemberment or death. It is the operator s responsibility to understand the proper and safe use of this baler. Make sure that you read, understand, and obey all of the safety precautions and operating instructions in this Operator s Manual. Keep this Operator s Manual and the Safety Card (Allied form #89-028) with the baler at all times. Do not operate the baler unless you are authorized and trained to do so. If it has been some time since you last operated the baler, refamiliarize yourself with the baler before starting, then proceed slowly. Do not operate the baler if you are aware of any malfunctions, needed maintenance or repairs. Stop the baler immediately if any problems arise. Never allow others to ride on the baler. Never allow anyone within 10 ft of the baler while the baler is in operation. Never operate the baler without all safety shielding in place. Keep hands, feet, hair, jewelry and clothing away from moving parts, including but not limited to the pickup, knotter, and PTO shaft. Avoid wearing loose clothing which can easily be caught in moving parts. Use appropriate signs (i.e., Slow Moving Vehicle sign), signals or warning lights when transporting on highways. Always use lights when working at night or in low light conditions. Know your job-site rules. Some have site specifi c directions and procedures. The methods outlined in this manual provide a basis for safe operation of the baler. Because of special conditions, your company s baling procedures may be somewhat different from those shown in this manual. Do not start the tractor if the key had been marked with a DO NOT START or RED tag. Never operate any of the baler controls from anywhere other than the operator s seat. Alert personnel in the area before starting the engine, and make sure everyone is clear. Be sure that all controls are in neutral and the baler is disengaged before starting the engine. Each country has its own safety legislation. It is in the operator s own interest to be conversant with these regulations and to comply with them in full. This also applies to local bylaws and regulations in force on a particular worksite. Should the recommendations in this manual deviate from those in the user country, the national regulations should be followed. Never attempt to disconnect any of the safety devices built into the baler or tractor. Maintain proper clearance from energized equipment, energized power lines or other power sources. High voltage electricity can discharge to ground without direct contact with the baler s or tractor s structure. If the baler or tractor contacts energized equipment, or if electrical energy does discharge through the machine stay clear, and prevent anyone else from coming in contact with the baler or tractor. If you are on the tractor, stand fast, avoid contact with metal surfaces, and do not permit anyone to come into contact with the tractor or baler. Finally, Do not jump off. Hydraulic Hazards Be aware of the hazards of pressurized hydraulics:

9 VIII Wear personal protective equipment, such as gloves and safety glasses, whenever servicing or checking a hydraulic system. Assume that all hydraulic hoses and components are pressurized. Relieve all hydraulic pressure before disconnecting any hydraulic line. Never try to stop or check for a hydraulic leak with any part of your body; use a piece of cardboard to check for hydraulic leaks. Small hydraulic hose leaks are extremely dangerous, and can inject hydraulic oil under the skin, even through gloves. Infection and gangrene are possible when hydraulic oil penetrates the skin. See a doctor immediately to prevent loss of limb or death. Maintenance Safety Perform all routine maintenance outlined in this Operator s Manual in the time intervals indicated. Maintenance, lubrication and repair of this machine can be dangerous unless performed properly. In order to ensure safety, each person working on this baler must have the necessary skills, information, tools and equipment, and satisfy himself that his work method is safe, correct, and meets his own company s requirements. Do not attempt to make adjustments, or perform repairs unless you are authorized and qualifi ed to do so. Never attempt to service energized equipment alone. Someone capable of rendering aid in the event of accidental shock must be present. Do not rely on the hydraulic system to support any part of the baler during maintenance or lubrication. Never stand under a baler component that is supported only by the hydraulic system. Ensure components are resting on their mechanical stops or supported with appropriate safety stands during maintenance or lubrication. Never attempt servicing while the baler is moving. Shut off the tractor and secure power. Shut off tractor and baler engine, engage the parking brake, disengage the baler, and wait for all movement to stop before adjusting, lubricating, cleaning, or servicing the baler. Tag the key switch with a DO NOT START sign and/or remove the key. Always perform all maintenance and lubrication procedures with the baler on level ground, parked in a safe area. Block the tires to keep the machine from rolling. Any unauthorized modifi cations made to the baler by the customer or parties other than Allied Systems will relieve Allied Systems Company and your Freeman dealer of any liability for damage or injury. Replace any worn parts only with genuine Freeman parts. Call your dealer for assistance. Unless specifi ed in service procedures, never attempt maintenance or lubrication procedures while the baler is moving or the engine is running. Engine exhaust fumes can cause death. If it is necessary to run the engine in an enclosed space, remove the exhaust fumes from the area with an exhaust pipe extension. Use ventilation fans and open shop doors to provide adequate ventilation.

10 IX DO NOT remove the radiator cap when the engine is hot. The coolant will be under pressure and can fl ash to steam with explosive force, causing severe burns. To prevent burns, remove the radiator cap only when the engine is cool. Always use personal protective equipment (PPE) appropriate to the situation. This may include the use of hearing protection, eye protection, a respirator, a hard hat, leather gloves, steel toed boots, etc. Batteries contain sulfuric acid which can cause severe burns. Avoid contact with skin, eyes or clothing. Batteries produce explosive gases. Keep sparks, fl ame and cigarettes away. Ventilate when charging or servicing in an enclosed space. Always shield your eyes when working near batteries. When removing battery cables, disconnect the negative (-) cable fi rst. When installing a battery, always connect the positive (+) cable fi rst. This procedure will help to prevent a spark which could cause an explosion. Before making adjustments to the engine or chassis electrical system, disconnect the battery. An electrical spark could cause a fi re, explosion or severe burns. Safety Equipment Ensure test equipment is in good condition. If an instrument must be held while taking measurements, ground the case of the instrument before energizing equipment. Do not touch live equipment or personnel working on live equipment while holding a multimeter. Some types of measuring devices should not be grounded do not hold such devices while taking measurements. Prevent personal injury or equipment damage by using a lifting device with a lifting capacity greater than twice the weight of any equipment to be lifted. Electrical Hazards An electric shock could be fatal. Ensure power to the baler is OFF before opening electrical panels. All electrical cables and connectors must be in good condition (free of corrosion, damage, etc). Use caution in wet weather to avoid danger from electrical shock. Never attempt electrical testing or repair while standing in water. Do not wear electrically conductive jewelry, clothing, or other items while working on the electrical system. Hot Oil Hazards Burns from hot oil can be severe Always allow lubricating and hydraulic oil to cool before draining. Compressed Air Hazards When using compressed air to dry parts, pressure should not exceed 30 psi (200 kpa). Air pressure penetrating your skin can be fatal. Never direct compressed air at anyone.

11 X FIRE SAFETY WARNING WARNING: Diesel fuel and hydraulic oil are flammable. Never smoke while handling fuel or working on the fuel system. The fumes in an empty fuel container are explosive. Never cut or weld on or near fuel lines, tanks, or containers. Keep open flames and sparks away from the machine. Reduce the Risk of Fire Keep the baler free of oil, grease, hay, and trash accumulations. Regular cleaning is recommended for fire prevention and general safety. Use an approved solvent to clean machine parts. Never use gasoline or diesel fuel. Shut off the engine and electrical equipment while filling the fuel tank. Use extra caution when fueling a hot engine. Always ground the fuel nozzle against the fi ller neck to avoid sparks. Never overfi ll the fuel or hydraulic tanks. Any overfl ow could cause a fi re. Immediately repair any hydraulic or fuel leaks and clean up any spills. Handle all solvents and dry chemicals according to procedures identifi ed on manufacturer s containers. Work in a well-ventilated area. Make sure you know where fi re extinguishers are kept and how to use them. Avoid spilling fuel or other hazardous liquids. If a spill occurs, follow local or state regulations for clean-up. Contact your state s OSHA offi ce for details. Always ensure that excess grease and oil accumulation, including spillage, is cleaned up immediately. Inspect the baler daily for potential fi re hazards and make any necessary repairs immediately. Check all the electrical wiring and connections for defects, and repair or replace as necessary. Keep battery terminals clean and tight. Never perform welding operations until the entire machine has undergone a thorough cleaning. In addition, cover rubber hoses, disconnect the battery, XA2 (located to the rear of the Feeder House about centered under the cab) and MD3 (located inside the cab, 1/2 way up the right A pillar) modules. Failure to disconnect these items could result in permanent damage. Have at least a fi re extinguisher at hand. Hydraulic fl uid is fl ammable. Do not weld on or near pipes, tubes, or hoses that are fi lled with fl uid. Do not smoke when checking or fi lling the tank. Keep open fl ames and sparks away from the baler. Hay dust is combustible. Do not have an open fl ame or weld in dusty environments. Maintain the engine cooling system to avoid overheating. Remember, there is always a risk of fi re. Fire Fighting Equipment It is recommended to carry an ABC fi re extinguisher on the baler or in the pull vehicle at all times. Install it within easy reach of the operator in a position that protects it from damage. Use only a quick release type of mount. It is also recommended to carry a four gallon water container with a pump, or as required by local and state law. Keep your fi re extinguisher(s) fully charged and in good working order. Know how to use them. Read and understand the instructions printed on the canisters and learn how to operate them. Learn how to remove the canisters from their mounting brackets in the shortest amount of time. Service the extinguisher according to the manufacturer s specifications. Service after every use, no matter how short a time.

12 XI Fire Suppression Do not panic. At the first sign of trouble (burning smell, smoke, visible fl ame, etc), stop the tractor and turn off the engine in the clearest area available. If the fi re cannot be extinguished safely, immediately evacuate the area. DO NOT attempt to extinguish it. DO NOT risk personal injury. Contact your local fi re department. If you have determined that the fire may be safely extinguished, use the fire extinguisher according to the manufacturer s instructions, or use the water pump, aiming water at the base of the fi re. When the baler has fully cooled, thoroughly inspect, and make all necessary repairs to return the baler to normal operation. Recharge or replace the extinguishers before returning to work.

13 XII SPECIFICATIONS General: For SN ASC-SP & ASC- For SN 280S SP Engine See: Engine Manufacturer's Operator's PowerTech E 4.5L 4045 Manual Overall Length 20 ft. 18 ft. Overall Width 12.9 ft ft. Overall Height 11 ft. 11 ft. Weight 14,800 lbs. 14,000 lbs. Pickup Width 73 inch. Fuel Tank 30 Gal. Feed System Adjustable Feed Arm, Swings on Tapered Bearings In Sealed Tube Bullgears On Tapered Roller Bearings Tires: Front Rear Max Road Speed / 30 psi / 28 psi. 15 mph Plunger: Plunger Speed Stroke Length Drive 84 Strokes Per Minute 30 in. Heavy Duty Bullgears Bale Chamber: Height 14,15,16 or 17 in. 14 in. Width 3 tie: 22 in. / 2 tie: 18 in. 18 in. Bale Length 30 to 46 in. 30 to 46 in. Bale Width 3 tie: 22 in. / 2 tie: 18 in. 18 in. Bale Weight 3 tie: 60 to 120 lbs. 2 tie: 50 to 100 lbs. Knotter System: Knotters Conventional Knotters Twine Storage Capacity 9 or 12 rolls 6 rolls Twine Type 200 to 280 knot strength

14 XIII Parts diagram below is for SP balers ASC-SP & ASC-SP Freeman Components John Deere Components

15 XIV Parts diagram below is for SP baler 280S Freeman Components John Deere Components

16 1-1 INSTRUMENTS AND CONTROLS Figure 1-1 Cab A. Seat Controls B. Corner Post Monitors C. Armrest Control Panel D. Steering Column Tilt Pedal E. Telescoping Steering Wheel Lock Knob F. Turn Signal Lever G. Turn Signal Indicators H. Start Switch I. Horn Button J. Hydrostatic Guide K. Engine Diagnostic Gauge (see your manufacturer's engine manual) L. Low Moisture Range Hay Tester (see your Baler mounted Low Moisture Range Operators Manual) (Optional) M. ICM (In Cab Monitor)

17 1-2 INSTRUMENTS AND CONTROLS Overhead Instrument and Controls Figure 1-2 Overhead Controls A. Light Switch Controls B. Temperature Control C. Blower Motor Speed D. Windshield Wiper Control E. AM-FM/Weather band Radio F. Optional 7" Flat Panel Color Observation Monitor ( see your monitor owner's manual) Control Switch Colors Before operating the self-propelled baler for the fi rst time, become familiar with the controls and switches. These controls and switches are color coded to help you quickly locate them when operating the self-propelled baler. ORANGE Ground Drive and Engine Speed. YELLOW Baler Drive Engagement. BLACK Operating Adjustment and Controls. Figure 1-3 Armrest Control Panel (2-Tie Shown)

18 1-3 INSTRUMENTS AND CONTROLS Armrest Control Panel A. Pickup Switch Control B. Plunger Slow Down Switch C. Hydrostatic Drive Control Lever D. Baler Drive Engage Switch E. Engine Speed Adjustment F. Accessory Switch (Not Used) G. Field/Road Speed Switch H. Beverage Holder I. Power Port Hydrostatic Drive Control Handle Function Controls The engine must be running to perform any of these functions. Rocker switch (A) allows the adjustment of the Pickup (see Figure 1-4). Handle (C) controls the Hydrostatic Drive (see Figure 1-4). Not Used Figure 1-5 Hydrostatic Drive A. Pickup Switch Control B. Plunger Slow Down Switch C. Hydrostatic Drive Control Lever IMPORTANT! If the hydrostatic charge pressure light (see Figure 1-24 on page 1-21) comes on in the warning display panel when the lever is moved, check hydrostatic/ hydraulic oil level or replace filter. If this doesn t correct the problem, see your John Deere dealer. Figure 1-4 Armrest Control Panel Move lever to the right and forward to go forward. Move lever to the right and rearward to go backward.

19 1-4 INSTRUMENTS AND CONTROLS To adjust handle angle (see Figure 1-6), turn handle (A) counterclockwise to loosen collar (B). Position handle, tighten collar with fi ngers, then turn handle clockwise to tighten collar firmly. If additional tightening of the handle is required, position hydrostatic handle approximately 20 degrees counterclockwise from the desired position. Tighten collar with fi ngers. Hold collar with fi ngers and turn handle clockwise to desired position. Do not use pliers on collar, tighten with fi ngers only. A. Handle B. Collar Baler Engage Switch NOTE: Operator must be in the seat to engage baler. Baler will disengage if operator leaves the seat after 5 seconds. Baler will disengage if engine is started with Baler switch engaged. To operate the Baler engage switch (see Figure 1-7), push down on the switch and push forward to engage baler. Pull switch back to the OFF position to disengage baler. See ENGAGING BALER in Operating Baler section on page 5-3. Figure 1-6 Adjusting Hydrostatic Drive Figure 1-7 Baler Drive Switch

20 1-5 INSTRUMENTS AND CONTROLS +/- Accessory Switch (Not Used) + Figure 1-8 Accessory Switch Engine Speed Adjustment Switch The engine speed adjust switch (see Figure 1-9) allows the increasing or decreasing of the unit s engine speed. This adjustment will affect the unit s ground speed and operating speed of the Baler. The high and slow engine speeds are preset. Depressing the TURTLE for slow (IDLE) engine speed, depressing the RABBIT for high (ROAD) engine speed and depressing the ADJ for baling speed (BALE) will cause engine to automatically go to selected speed. When the baler is started, it will go to previously selected engine speed. Figure 1-9 Engine Speed Switch

21 1-6 INSTRUMENTS AND CONTROLS Field/Road Switch CAUTION CAUTION: Always stop and shift to the slower (TURTLE) field operations speed when going down a steep slope. The ground speed adjust switch (see Figure 1-10) selects a higher (RABBIT) speed for transporting the baler, or the lower (TURTLE) speed for fi eld operations, without affecting engine speed. The unit can be shifted from the lower field operation speed to the higher transport speed while on the go. The baler fl ywheel will be disengaged and it will not rotate in Road position. However, when Ground Speed Switch is put back into the Field position, the baler fl ywheel will return to its previous state. If the Plunger Slow Down Switch was adjusted while in the Road position, it will remember the new position and adjust the speed accordingly. The unit must be stopped, and the hydrostatic control handle returned to the neutral park position, to shift from the higher transport speed to lower fi eld operations speed. Figure 1-10 Ground Speed Switch

22 1-7 IN CAB MONITOR Bale Screen Figure 1-11 ICM (In Cab Monitor) / Bale Screen The ICM (In Cab Monitor) Bale screen will display after the initial Freeman startup screen. The Bale Screen is the main display used by the operator for all baling and basic diagnostics. NOTE: When starting the machine, if the key is held in the "ON" position for more than 1 to 2 seconds before advancing to the "START" position, the ICM (In Cab Monitor) may have time to completely boot up. If this happens, then when the key is held in the "START" position, the ICM may measure voltage below 9 volts resulting in an informational message that must be cleared before further operating the baler. This message is considered normal when it appears immediately at start up. However, if this message appears after the machine has been started, with the engine running or while baling, it might indicate a possible problem with the battery or charging system. It is suggested that these systems be inspected for proper function. 1. F1 Button Press to prompt DEALER screen. The dealer screen consists of: Dealer Name, Baling Hours, Life Hours, Life Bales, Date and Time, Program, Screen Saver, Flake Goal, (See Page 1-12). 2. F2 Button Press to prompt MAINTENANCE screen. Here you can adjust or reset maintenance timers (See Page 1-13). Once a timer is triggered by hours or number of bales, it will keep appearing at start up until it is re set. 3. F3 Button Press to prompt FIELD screen. The field screen displays fields 1-10 and bale counts that can be adjusted or reset (See Page 1-17). 4. F4 Button Press to prompt TENSION SYSTEM screen. The tension system screen displays Electrical Current supplied to Tension Solenoid, Accumulator Charge Status, Tension Pressure, Accumulator Pressure, Tension Rails Open or Closed (See Page 1-14).

23 ARROW LEFT Button Press to access the previous screen. 6. MENU Button Press to prompt MAIN screen. The main screen displays: Adjust, Measure, Preferences and Info (See Page 1-10). 7. UP/DOWN Buttons Press to raise and lower the Command Pressure or Tension pressure when Tension Control is set to "Auto" or "Manual" ( see Page 1-14). If Tension Control is set to "Manual", Press OK button first to prompt the Manual Tension screen, then press UP/DOWN button to adjust manual tension. Press OK again to save the setting and exit the Manual Tension screen. 8. OK Button Press to execute choices or, If Tension Control is set to "Manual," access manual tension pressure (see page 1-15). If Tension Control is in "Automatic," access Command Pressure (see page 1-9). 9. BALE COUNT The bale count can be reset in the Field screen (See Page 1-17). 10. STROKES PER BALE of last bale. 11. VARIANCE FROM FLAKE GOAL The upper part of the indicator will display green when there are too many fl akes per bale and ground speed should be increased. The lower part of the indicator will display red when there are not enough fl akes and ground speed should be decreased. INSTRUMENTS AND CONTROLS 14. TENSION PRESSURE Adjust by pressing OK button to prompt the Manual Tension screen when Tension Control is set to "Manual" (see Page 1-15). Press UP/DOWN arrows to adjust and OK to save settings. When the cylinder pressure is increased, it increases the amount of force the tension rails apply to the bales. This increase in force raises the friction between the bale material and the tension rails, which requires more compacting force to move the bale through the chamber. The increase in compacting force increases the density of the bale by putting more material into the same volume. The maximum tension system pressure varies by model and is preset at the factory. Note: The type of material, moisture content and other factors will often change how the density setting affects the amount of compacting force required to push the bale through the chamber. Drier materials like Straw and some types of grasses may require more pressure than is possible at the highest density setting. If this is the case, chamber restrictor wedges can be installed. These wedges are designed to further compact the material without requiring an increase in the density setting. However, the installation of wedges may require the Operator to reduce the density setting to maintain the appropriate weight. Please contact your Freeman representative for more information on these and other products. 12. CLOCK The time can be adjusted by accessing MAIN screen/preferences/time (See Page 1-10). Also will flash Tension rails open if open. 13. STROKES (FLAKES) PER BALE The bar graph will fi ll as Flake Goal (See Page 1-18) is achieved. For optimum bale weight and shape, the baler should make a bale with 14 to 16 strokes per bale.

24 1-9 INSTRUMENTS AND CONTROLS Bale Screen cont ACCUMULATOR PRESSURE The accumulator is a pressurized hydraulic reservoir which is used to maintain the pressure in the hydraulic circuit while the baler is operating. The accumulator is partially fi lled with hydraulic oil from the hydraulic system pump, and partially with a high pressure gas (nitrogen). Its primary purpose is to minimize the variances in the operating pressure of the bale tension system during operation. If the pressure of the hydraulic system is reduced when an assembly is operated (tension, pickup, or drawbar), the accumulator will make up the difference in pressure. As the pressure in the accumulator is reduced, the hydraulic pump will re-charge the accumulator. If only the tension system is being used, the accumulator should re-charge every 7 to 10 minutes, but this may occur more frequently if other optional assemblies are activated ie. pickup. CAUTION If the pump is cycled too frequently when re-charging the accumulator, the hydraulic oil may overheat. If this happens, contact your dealer. 16. FIELD Displays current field (See Page 1-17 for adjusting fi eld settings). Also will fl ash Low RPM if below adjustable baling parameter of 70 RPM (See Page 1-19 for adjusting baling parameter). 17. ACCUMULATOR PRESSURE NEEDLE (red) The needle turns clockwise when there is an increase in pressure. 18. TENSION PRESSURE NEEDLE (green) The needle turns counterclockwise when there is an increase in pressure. 19. COMMAND PRESSURE The Command Pressure setting allows the operator to select the target tension pressure up to the factor set maximum. Adjust Command Pressure by pressing the UP/DOWN arrows when Tension Control is set to "AUTO" (see Page 1-14). Press OK button to save and exit out of Command Tension adjustment pop up screen. The nitrogen used for the pre-charge of the accumulator is highly affected by the ambient temperature. Refer to the Temperature/Pressure decal above the accumulator for proper charging.

25 1-10 INSTRUMENTS AND CONTROLS Main Screen Figure 1-12 Main Menu To reach the Main screen: press the Menu button from any of the four user screens (Dealer, Maintenance, Field, Tension System). The ICM Main screen is used to display module information and logs, set preferences, measure system I/O or adjust parameters. 1. F1 Button Press to access the Adjust screen (See Page 1-11). 2. F2 Button Press to access the Measure screen. Machine Sensors and Module Diagnostics can be viewed in Raw Value or Scaled Value. 3. F3 Button Press to access the Preferences screen where Display, Date/Time and Language is displayed. When in the Preferences screen: Use UP/ DOWN/OK for navigating and adjusting. Press F1 To adjust Display. Backlight and Screen saver can be adjusted here. Press F2 to access the Date/Time screen. Press F3 to access the Language screen. Not adjustable at this time. 4. F4 Button Press to access the INFO screen. Here the Modules and Log File can be accessed and may help with troubleshooting the ICM.

26 1-11 INSTRUMENTS AND CONTROLS Adjust Screen Figure 1-13 Adjust Screen To reach the Adjust screen: press F1 button from the Main screen (see page 1-10). The Adjust screen has a collection of adjustable values on the machine that can be changed from the ICM. These values are grouped into Adjust Groups based on their function. Use the UP/DOWN arrows to scroll through the options in the ADJUST screen and press OK to access. FIELD NAMES Change the name of the current fi eld. SERVICE TIMERS Set up custom timer and text, and change the other service counts. A WARNING will pop up in the screen when a pre-set timer has timed out. Follow recommended baler maintenance, then reset the timer(s) (see page 1-13 for reseting). DEALER Choose dealer, set idle time before screen saver turns on, and activate screen saver. CUSTOM DEALER INFO Set up a custom dealer. TENSION All adjustments should be made in the Bale (see page 1-7) or Tension System (see page 1-14) screens. Note: If "Tension Current ma" is accessed, the power to the ICM must be cycled off, then on, in order to reset the tension system and enable it to build pressure. BALE FLAKES Flake Goal, Turn on Rabbit, Turn on Turtle, Flake Window + or -, Rabbit & Turtle and Low Baling RPM Warning can be adjusted here (see page 1-18 for Flake Goal and Rabbit Turtle adjustments). MANUAL TENSION Charge Interval, Charge Time, Accumulator Pressure settings. These settings are only adjustable by a Freeman Service Representative. TENSION PID These are parameters for how the tension solenoid current responds to the tension pressure. These settings are only adjustable by a Freeman Service Representative. LIFETIME COUNTERS These settings are only adjustable by a Freeman Service Representative.

27 1-12 INSTRUMENTS AND CONTROLS Dealer Screen 1 2 Figure 1-14 Dealer Screen To reach the Dealer screen: press F1 button from the Bale screen (see page 1-7). The Dealer screen displays dealer contact information, program version number along with screen saver and fl ake goal adjustments. 1. F1 Button Press to adjust SCREEN SAVER settings. Use the UP/DOWN arrows to select ON or OFF then press OK when done. 2. F2 Button Press to adjust DESIRED FLAKES PER BALE settings in the fl akes goal screen. Use the UP/DOWN arrows to select to raise or lower fl ake count then press OK when done. Press F2 while in the fl ake goal screen to reset fl ake count to default of PROGRAM VERSION Contact Freeman Service Department for the latest ICM program version. 4. TIME, DATE and DAY Can be adjusted from the MAIN screen (See Page 1-10). 5. DEALER INFORMATION Press OK to change dealer. 6. BALING HOURS displays total hours over 20RPM. 7. LIFE HOURS Total hours with key ON. 8. LIFE BALES Total bales on machine. 9. FLAKE GOAL displays desired flake goal. Press F2 to adjust. 10. SCREEN SAVER displays ON or OFF. Press F1 to access, use UP/DOWN buttons to adjust and press OK to save.

28 1-13 INSTRUMENTS AND CONTROLS Maintenance Screen 1 Figure 1-15 Maintenance Screen To reach the Maintenance screen: press F2 button from the Bale screen (see page 1-7). The Maintenance screen displays important maintenance procedures. Each maintenance procedure has a timer with a message that will display when time has elapsed. The message will continue to display until the timer has been reset. To reset a timer, you must be in this maintenance screen. Press the DOWN ARROW (2) to display the astrisk. Scroll the astrisk to the desired timer using the arrow buttons. Press and hold F4 (1) untill the timer resets. Press the MENU button to return to the Bale screen. NOTE: See SETTINGS and ADJUSTMENTS starting on page 8-1 for settings and adjustment instructions. NOTE: see LUBRICATION AND MAINTE- NANCE starting on page 11-1 for complete maintenance schedule. 2. UP/DOWN ARROW Buttons Press to scroll up and down through the different timer groups. An asterisk will display to mark the selected group ,000 BALE TIMER Maintenance needs to be performed every 10,000 bales (see page 11-6) ,000 BALE TIMER Maintenance needs to be performed every 15,000 bales (see page 11-7). 5. EVERY 4 HOUR S TIMER Maintenance needs to be performed every 4 hour s (see page 11-5). 6. CUSTOM TIMER Setup your own custom timer. Note: Service Timers are adjustable from the Service Timer screen: Press menu button from the Maintenance screen, press F1 button (Adjust), scroll to Service Timers using the UP and DOWN arrow buttons and then press OK button. Here you can adjust all the timers. You can also push F2 (Reset) to have the Timer selected reset to the factory default setting. 1. F4 Button Press and hold to RESET a timer.

29 INSTRUMENTS AND CONTROLS Tension System Screen Figure 1-16 Tension System Screen To reach the Tension System screen: press F4 button from the Bale screen (see page 1-7). The Tension System screen is used to control and monitor the Tension System. The screen incorporates displays for the condition of the Accumulator charge and the operating pressure and settings for the Tension System. 1. F1 Button Press to change Accumulator to: Drained drains accumulator and prevents charging. Its always good to drain the accumulator before performing any maintenance on the baler. The Accumulator drains automatically when the ignition is turned off. 5. ADJUST COMMAND PRESSURE buttons Press to raise and lower the Command Pressure, press OK to save. 6. ADJUST MANUAL TENSION Only adjustable by a Freeman Service Representative. 7. COMMAND PRESSURE The Command Pressure setting allows the operator to select the target tension pressure. Adjust Command Pressure by pressing the UP/DOWN arrows. Press OK button to save and exit out of Command Tension adjustment pop up screen. The maximum pressure is set at the factory and varies by baler. 8. ELECTRICAL CURRENT supplied to tension solenoid. Pressurized normal automatic operation. 2. F2 Button Press to access Manual Tension Control screen (See Page 1-15). 3. F3 Button Press to access Transducer Calibration screen (See Page 1-16). 4. F4 Button Press to change Tension Rails to Opened (opens tension rails) or Closed (normal operation). 9. ACCUMULATOR CHARGE STATUS True: Charging, red needle on gauge should be moving when accumulator is charging. False: No Charging, red needle shouldn t move. 10. CHARGE ON PRESSURE Pressure at which accumulator starts charging. Only adjustable by a Freeman Service Representative. 11. CHARGE OFF PRESSURE Pressure at which the accumulator stops charging. Only adjustable by a Freeman Service Representative.

30 1-15 INSTRUMENTS AND CONTROLS Manual Tension Control Screen To reach the Manual Tension Control screen: press F4 button from the Bale screen (see page 1-7), then press F2 from the Tension System screen. The Manual Tension Control screen allows adjustment to Tension Control and Charge Accumulator. 1. F1 Button Press to change Tension Control to Auto or Manual Figure 1-17 Manual Tension Control Screen 2. F2 Button Press to change Charge Accumulator to As Needed or By Timer. By Timer : Disables the accumulator from turning on and off automatically and will charge the Accumulator for adjustable Charge Time over adjustable intervals of Charge Interval. Press F3 to adjust the charge time. Press F4 to adjust the charge interval (these are only adjustable by a Freeman Service Representative). This is designed as a backup if the accumulator pressure transducer fails. Manual Tension Control overrides Command Tension and allows direct control of the tension solenoid current. Auto : Command pressure is the operators desired tension pressure. When Tension Control is in Auto, the tension pressure is adjusted automatically and attempts to maintain the command pressure. The ICM constantly monitors the tension pressure transducer. If the tension pressure rises above the command pressure, it will decrease the current to the tension valve and if the tension pressure drops below the command pressure, it will increase the tension valve current. As Needed : Turns on and off accumulator pressure automatically. The pressure may be adjusted in the Transducer Calibration screen (see page 1-16). 3. F3 Button Only adjustable by a Freeman Service Representative. With the Manual Charge Accumulator set to True, this is used to set the charge time of the accumulator. 4. F4 Button Only adjustable by a Freeman Service Representative. With the Manual Charge Accumulator set to True, this is used to set the time interval between cycling charge to the accumulator. Note: the Charge Interval must be longer than the Charge Time.

31 1-16 INSTRUMENTS AND CONTROLS Figure 1-18 Transducer Calibration Screen Transducer Calibration Screen To reach the Transducer Calibration screen: press F4 button from the Bale screen (see page 1-7), then press F3 from the Tension System screen. The Transducer Calibration Screen allows adjustment to Accumulator and Tension Transducers. NOTE: To calibrate a pressure transducer, fi rst connect a manual gauge with tee fi tting to a pressure transducer port. 1. F1 Button Press to calibrate the accumulator transducer. If the calibrated value dips to zero, it will display a low voltage warning. These warnings may be avoided by leaving a slight buffer, so that true 0 psi will register as a positive value (e.g. 1-5 psi). The same method may be used for the tension transducer. Use UP/DOWN/OK for adjusting. 3. F3 Button Press to set the low accumulator pressure that signals the system to begin charging the accumulator. To hold tension pressure, this must be greater than the tension command pressure. Use UP/DOWN/OK for adjusting. 4. F4 Button Press to set the high accumulator pressure that signals shutting off the charge. This must be set below hydraulic pump system pressure or it will attempt to charge continuously. Use UP/ DOWN/OK for adjusting. 2. F2 Button Press to calibrate the tension transducer. Use UP/DOWN/OK for adjusting.

32 1-17 INSTRUMENTS AND CONTROLS Field Screen 1 2 Figure 1-19 Field Screen To reach the Field screen: press F3 button from the Bale screen (see page 1-7). The Field Counts screen is used to record and display the number of bales made per fi eld (up to 10). Controls are provided that allow the operator to reset the count, and adjust the current field count. NOTE: Field names may be changed from the Adjust screen (see Page 1-11). 3. UP/DOWN ARROW Press to scroll through the fi elds and adjust bale counts. 4. CURRENT FIELD Displays the unique identification created for a fi eld. 5. LIST OF FIELDS Displays the Life Bales count when the Field Count for the selected fi eld was last reset. This value can be used to estimate a bale count if a Field Count for a fi eld was not reset when baling was started. 1. F3 Button Press and hold down while pressing the UP or DOWN arrows to move bale count up or down in each fi eld. 2. F4 Button Press and hold down to reset the fi eld to 0.

33 1-18 INSTRUMENTS AND CONTROLS Bale Flakes Screen Figure 1-20 Bale Flake Screen To reach the Bale Flake screen: press Menu button from the Bale screen, scroll to Bale Flakes and press OK button (see page 1-7). The Bale Flake screen has a collection of adjustable values on the machine that can be changed from the ICM. These values are grouped into Adjust Groups based on their function. Use the UP/DOWN arrows to scroll through the options in the ADJUST screen and press OK to access. FLAKE GOAL Sets the desired number of fl akes per bale (max = 40). Use the UP/DOWN arrow keys to select the desired mode, and OK to accept the value. Press F2 to reset to factory default, and F1 to return to the Main Screen. TURN ON RABBIT Sets the value for when the RABBIT symbol will be illuminated (see Figure 1-21). If the fl ake count is more than the value of the FLAKE GOAL + RABBIT VALUE, RABBIT will be illuminated to indicate ground speed is too slow and should be increased. For this feature to work the RABBIT AND TURTLE mode needs to be activated (see Rabbit and Turtle on page 1-18). TURN ON TURTLE Sets the value for when the TURTLE symbol will be illuminated. If the fl ake count is less than the value FLAKE GOAL + TURTLE VALUE, the TURTLE will be illuminated to indicate ground speed is too fast and should be reduced. For this feature to work the RABBIT AND TURTLE mode needs to be activated (see Rabbit and Turtle on page 1-18). FLAKE WINDOW + or - Sets the number of fl akes that the upper and lower bars represent in the Flake Variance Bar on the Bale Screen (max = 30) (see Figure 1-21). The lowest setting window is a variance of 1 fl ake. Setting the Flake Window to 1 is the strictest monitoring setting providing most accurate results (see Flake Window chart example on page 1-20). Use the UP/DOWN arrow keys to change the value, and OK to accept the value. Press F2 to reset to factory default, and F1 to return to the Main Screen.

34 1-19 INSTRUMENTS AND CONTROLS RABBIT AND TURTLE Sets the RABBIT/TURTLE feature mode to ON or OFF. When ON the Rabbit will illuminate when there are too many fl akes per bale and ground speed should be increased. When the TURTLE is illuminated there are not enough fl akes per bale and ground speed should be decreased (see Figure 1-21). Use the UP/DOWN arrow keys to select the desired mode, and OK to accept the value. Press F2 to reset to factory default, and F1 to return to the Main Screen. too many fl akes, suggesting the need to increase ground speed. If the bar is below center (and red), there are fewer fl akes than the goal, suggesting the need to slow down. LOW BALING RPM WARNING Adjusts the value for when the Baling RPM Alarm will be activated (max = 100). When the Baling RPM is below the set value, the alarm will be activated to indicate the RPM of the baler should be increased. Use the UP/DOWN arrow keys to change the value, and OK to accept the value. Press F2 to reset to factory default, and F1 to return to the Main Screen. Flakes Per Bale And Flake Variance Bar Flakes Per Bale Flakes Varience Bar Rabbit Turtle Figure 1-21 Bale Screen With Rabbit Displayed To set up the fl akes per bale and fl ake variance bar in the Bale screen (see Figure 1-21), fi rst choose a flake goal in the Dealer screen (see Page 1-11). The fl akes/bale bar in the Bale screen adjusts its scale so that the fl ake goal is the mid-point. After a bale is tied, the fl akes/bale bar resets and the variance bar represents the number of fl akes from the goal. If the bar is above center (and green), there are

35 FLAKE WINDOW CHART The chart below illustrates what the Flake Variance Bar will display at different ground speeds. Flake Goal: 14 and Flake Window: 3 are used for example only (see page 1-18 for setting Flake Goal and Flake Window). FLAKE WINDOW CHART Bale Shape Settings: Flake Goal: 14 Flake Window: 3 Not enough fl akes per bale. Ground speed should be decreased. Bale should have tied here Last Bale tied off here +14 (28 Strokes) +13 (27 Strokes) +12 (26 Strokes) +11 (25 Strokes) +10 (24 Strokes) +9 (23 Strokes) +8 (22 Strokes) +7 (21 Strokes) +6 (20 Strokes) +5 (19 Strokes) +4 (18 Strokes) +3 (17 Strokes) +2 (16 Strokes) +1 (15 Strokes) 0 (14 Strokes) -1 (13 Strokes) -2 (12 Strokes) -3 (11 Strokes) -4 (10 Strokes) -5 (9 Strokes) -6 (8 Strokes) -7 (7 Strokes) -8 (6 Strokes) -9 (5 Strokes) -10 (4 Strokes) -11 (3 Strokes) -12 (2 Strokes) -13 (1 Strokes) Flake Window Flake Variance Bar 1-20 Bale Shape Settings: Flake Goal: 14 Flake Window: 3 Too many flakes per bale. Ground speed should be increased. Last Bale tied off here Bale should have tied here +14 (28 Strokes) +13 (27 Strokes) +12 (26 Strokes) +11 (25 Strokes) +10 (24 Strokes) +9 (23 Strokes) +8 (22 Strokes) +7 (21 Strokes) +6 (20 Strokes) +5 (19 Strokes) +4 (18 Strokes) +3 (17 Strokes) +2 (16 Strokes) +1 (15 Strokes) 0 (14 Strokes) -1 (13 Strokes) -2 (12 Strokes) -3 (11 Strokes) -4 (10 Strokes) -5 (9 Strokes) -6 (8 Strokes) -7 (7 Strokes) -8 (6 Strokes) -9 (5 Strokes) -10 (4 Strokes) -11 (3 Strokes) -12 (2 Strokes) -13 (1 Strokes) Flake Window Bale Shape Settings: Flake Goal: 14 Flake Window: 3 Flake Goal achieved. Ground speed perfect. Last Bale tied off here +14 (28 Strokes) +13 (27 Strokes) +12 (26 Strokes) +11 (25 Strokes) +10 (24 Strokes) +9 (23 Strokes) +8 (22 Strokes) +7 (21 Strokes) +6 (20 Strokes) +5 (19 Strokes) +4 (18 Strokes) +3 (17 Strokes) +2 (16 Strokes) +1 (15 Strokes) 0 (14 Strokes) -1 (13 Strokes) -2 (12 Strokes) -3 (11 Strokes) -4 (10 Strokes) -5 (9 Strokes) -6 (8 Strokes) -7 (7 Strokes) -8 (6 Strokes) -9 (5 Strokes) -10 (4 Strokes) -11 (3 Strokes) -12 (2 Strokes) -13 (1 Strokes) Flake Window Figure 1-22 Bale Flake Screen

36 1-21 INSTRUMENTS AND CONTROLS Corner Post Monitors (see Figure 1-23) A. Warning Lamp Display 12 displays with colors indicating existing condition and an audible alarm for when a serious condition exists. (See WARNING DISPLAY PANEL in this section.) B. Fuel Gauge Indicates fuel level. (See FUEL GAUGE in this section.) C. Engine Temperature Gauge Indicates engine coolant temperature. (See ENGINE COOLANT TEMPERATURE GAUGE in this section.) D. Digital Display Indicates rpm, mph, psi or hours depending on function selected. Display is a dual display showing any combination of two functions at the same time. (See DUAL DIGITAL DISPLAY in this section.) Note: On balers with Teir III Engines, only the Ground Speed function is capabile of be displayed. RPM can be found on the Engine Diagnostic Gauge (see Figure 1-1 (K) on Page 1-1). E. Function Select Selects the desired function to be displayed. Operator can select which function to display in the upper digital display or the lower digital display. (See OPERATING THE DUAL DIGITAL DISPLAY in this section.) Figure 1-23 Corner Post Monitors

37 1-22 INSTRUMENTS AND CONTROLS Warning Display Panel (see Figure 1-24) NOTE: To perform a bulb check, see CHECKING WARNING LIGHTS in Operating Engine section. The display shows a red, yellow or blue light and may sound an audible alarm for the specific condition RED LIGHT Stop engine at once and correct problem YELLOW LIGHT Service or correct problem. Stop engine as required. BLUE LIGHT Be aware of condition. Listed below is the keyed designation of the warning lamp color displayed and if an audible alarm is present. NOTE: Decal on the inside storage lid of the right-hand armrest identifi es symbols used on the panel (see Figure 1-42 page 1-30). Figure 1-24 Warning Display Panel KEY FUNCTION COLOR ALARM (A) Engine Temperature Red Yes (B) Engine Oil Pressure Red Yes (C) Engine Air Filter Yellow No (D) Hydrostatic Charge Pressure Red Yes (E) Hydrostatic Oil Filter Yellow No (F) Operator Presence Yellow No (G) Low Fuel Yellow No (H) Road Shift Engage Blue No (I) Park Brake Applied Blue No (J)* Tension Red Yes (K) Alternator Red Yes (L) Hydrostatic Oil Temperature Red Yes * Not applicable to S/N 280S14-003

38 1-23 INSTRUMENTS AND CONTROLS Fuel Gauge With key on, fuel gauge needle (see Figure 1-25) will move to the right showing amount of fuel in tank. Red/orange color shows low fuel. Green color shows fuel tank 1/4 full or more. The needle may be in any position with the key off. Fuel tank capacity is 113 L (30 U.S. gal). Dual Digital Display The dual digital display (see Figure 1-27) will display one function in the upper display (H) and another function in the lower display (K) simultaneously. Note: On balers with Teir III Engines, only the Ground Speed function is capabile of be displayed. The dual digital display tachometer displays four different functions on the digital displays (H) and (K). Engine hours (B) and Baler hours (G) are also available for display. The tachometer is accurate within ± 10 rpm in displaying both rpm functions. If ground speed drops below 3/4 km/h (1/2 mph) digital display shows 0.0. Figure 1-25 Fuel Gauge Engine Coolant Temperature Gauge Needle should be in the black zone during operation. If the engine temperature red light on the WARN- ING DISPLAY PANEL turns on and the audible alarm sounds, turn off engine and check problem immediately. The engine and Baler hour meters are accurate to ± one hour. Only full hours are shown, but the computer memory is updated in quarter hours. The dual digital displays (H) and (K) will dim by 50% when the headlights are on. See OPERATING THE DUAL DIGITAL DISPLAY on page Figure 1-26 Temperature Gauge Figure 1-27 Dual Digital Display Panel

39 1-24 INSTRUMENTS AND CONTROLS Operating Dual Digital Display When the key is turned on, the dual digital display (see Figure 1-28) will show the functions selected the last time the baler was operated. NOTE: Any combination of functions may be displayed in the upper (H) and lower (K) displays. Tension (F) could be shown in the upper display and Baler hours shown in the lower display. The digital indicator (J) arrows shows on which display the function selected will be shown. Press and hold display selector (I) until display indicator (J) arrow is pointing at either the upper display (H) or lower display (K). Select function to be displayed and press symbol. Square (A) will move to show the function displayed. Press and hold display selector (I) until display indicator (J) arrow is pointing at the other display. Select function to be displayed and press symbol. Square will move to show the function displayed. Pressing ground speed (C) and engine speed (D) at the same time will display the engine hours. Note: On balers with Teir III Engines, only the Ground Speed function is capabile of be displayed. RPM can be found on the Engine Diagnostic Gauge (see Figure 1-1 (K) on Page 1-1). Figure 1-28 Dual Digital Display Panel A. Function Selected B. Engine Hours C. Ground Speed D. Engine Speed E. N/A F. Tension G. Platform Hours H. Upper Digital Display I. Display Selector J. Display Indicator K. Lower Digital Display

40 1-25 INSTRUMENTS AND CONTROLS Heater and Air Conditioning Controls The recirculating fan controls air fl ow through the louvers (see Figure 1-30). Knob B (see Figure 1-29) selects one of three recirculating fan speeds or the off position. Knob (B) also turns on the A/C compressor in all positions except for off position. A. Temperature Control Knob B. Fan Speed Knob Temperature Control Rotate the temperature control knob (A) to control the air temperature. Heater To increase air temperature move knob 3 mm (1/8 in.) into the red. Wait 3 to 4 minutes, allowing the air temperature to stabilize, before repeating the procedure if needed. Figure 1-29 Heater and Air Conditioning Controls Air Conditioning If maximum cooling is needed, turn temperature control knob (A) to the maximum position in the blue area and turn fan control knob (B) to the fastest fan position. Lower the fan speed to medium as the cab cools, then lower the fan speed to low if necessary. Wait 3 to 4 minutes between adjustments, allowing the air temperature to stabilize. Move fan control knob (B) to the off position to turn off the air conditioning. Defogging To defog the windshield, turn fan control knob (B) on and adjust temperature with temperature control knob (A). If the cab is still too cool, turn temperature control knob 3 mm (1/8 in.) toward the red. Wait 3 to 4 minutes, allowing the air temperature to stabilize, before repeating the procedure if needed. If the A/C compressor stays off 3 to 4 minutes and the air smells musty, move temperature control knob (A) slightly toward the red and increase fan speed one position.

41 1-26 INSTRUMENTS AND CONTROLS Heater and Air Conditioning Controls Adjust air louvers (see Figure 1-30) with tabs (A) to prevent damage to louvers. A. Tabs Windshield Wiper Switch To operate the wiper, depress the switch (see Figure 1-32) to the ON position (A). The windshield wiper will stop on the left-hand side of the machine, when the switch is returned to the OFF position (B). A. ON Position B. OFF Position Figure 1-30 Air Louvers Figure 1-31 Wiper Figure 1-32 Windshield Wiper Control Switch

42 1-27 INSTRUMENTS AND CONTROLS Light Control Switches (see Figure 1-33) A. HAZARD Flashing Ambers in Front and Flashing Amber/Red in Rear of Machine. B. ROAD Four Headlights and Tail Lights/Red and Amber Rear Flashing. C. FIELD Six Headlights and Tail Lights/Red and Amber Rear. D. WORK First Position Left back Work Light. Second Position Right/Left Rear Field Lights. Start Switch CAUTION CAUTION: Sound horn before starting engine to clear people away from the baler. Start switch (E) is located on right side of steering column (see Figure 1-35). NOTE: To perform a bulb check, see CHECK- ING WARNING LIGHTS in the Operating Engine section. NOTE: When starting the machine, if the key is held in the "ON" position for more than 1 to 2 seconds before advancing to the "START" position, the ICM (In Cab Monitor) may have time to completely boot up. If this happens, then when the key is held in the "START" position, the ICM may measure voltage below 9 volts resulting in an informational message that must be cleared before further operating the baler. Figure 1-33 Light Control Switches Cab Interior Lights (see Figure 1-34) A. Front Console and Armrest Console Light B. Dome Light C. Dome Light Switch This message is considered normal when it appears immediately at start up. However, if this message appears after the machine has been started, with the engine running or while baling, it might indicate a possible problem with the battery or charging system. It is suggested that these systems be inspected for proper function. Figure 1-34 Interior Lights

43 1-28 INSTRUMENTS AND CONTROLS Turn key (F) from off position (A) to position (D) to start. When released, it will return to run position (C). Horn Press button (A) to sound horn (see Figure 1-36). If engine will not crank, check for: Hydrostatic Lever in Neutral Park Steering Wheel Centered and Locked If accessories are to be operated, turn key to accessories position (B). A. Off B. Accessories C. Accessories and Run D. Start E. Switch F. Key Turn Signals Figure 1-36 Horn NOTE: The turn signals are not self cancelling. Right and left turn indicator lights (A) glow steadily in direction of indicated turn. Turn signals (see Figure 1-37) are operable whenever ignition key is in ACCESSORIES or ACCES- SORIES AND RUN position. When operating the baler on the road or highway, use the turn signals when turning the baler. Figure 1-35 Key Switch Amber lights in front, and amber and red lights at rear of machine, will fl ash at 90 fl ashes a minute in direction of indicated turn. Corresponding lights on the opposite side of the machine will burn steady. A. Turn Indicator Lights Figure 1-37 Tying Holder Bolt

44 1-29 INSTRUMENTS AND CONTROLS Steering Wheel Height Adjust CAUTION CAUTION: To prevent loss of control, adjust steering wheel only when baler is stopped. NOTE: Only a slight tightening of the hub (A) is needed to hold steering wheel in position. Loosen hub (A). Push or pull wheel to position. Tighten hub to lock (see Figure 1-38). A. Hub Steering Column Tilt Adjust CAUTION CAUTION: To prevent loss of control, adjust steering wheel only when baler is stopped. Column is spring loaded to the upward position. Do not step on pedal without holding the steering wheel in both hands. Press pedal (A) to release lock on steering column. Put column in desired position. Column locks when pedal is released (see Figure 1-39). A. Pedal Figure 1-38 Steering Wheel Figure 1-39 Steering Wheel Tilt Adjust Pedal

45 1-30 INSTRUMENTS AND CONTROLS Storage Tray/Cab Air Filter A tray is located in left rear corner of cab. Remove tray for access to the cab recirculating air fi lter (see Figure 1-40). Cab Storage Box The decal (A) shows the following information (see Figure 1-42): Identifi es function of lights in warning display panel. Tachometer service interval reset procedure. A. Decal Figure 1-40 Storage/Cab Air Filter Manual Storage Keep your manuals in the holder (A) at rear of cab (see Figure 1-41). A. Holder Figure 1-42 Storage Cab Door Lock This lock uses the ignition key (see Figure 1-43). Figure 1-41 Manual Storage Figure Door Lock

46 1-31 INSTRUMENTS AND CONTROLS Emergency Exit (Right-Hand Cab Window) Pull tab (A) to begin removal of rubber rope (B). Continue to pull until rope (see Figure 1-44) is removed from around right-hand cab window. The window can now be pushed out and allowed to fall free. See your John Deere dealer for window replacement. A. Tab B. Rope COMFORTCOMMAND Operator's Seat The COMFORTCOMMAND operator s seat (see Figure 1-45) has an air suspension system for added operator comfort. The seat has a self-contained electric compressor to adjust the seat suspension to match the operator s height and weight. Seat adjustments are as follows: Vertical Shock Dampener Height Adjustment Fore/Aft Adjustment Fore/Aft Attenuator Lock-Out Seat Bottom Tilt Seat Bottom Fore/Aft Adjustment Seat Back Tilt Seat Back Lumbar Support Left Hand Armrest Height Left Hand Armrest Tension Figure Emergency Exit Figure Operator's Seat

47 1-32 INSTRUMENTS AND CONTROLS Checking Operator Presence System IMPORTANT! If the operator presence fails to function properly, see your John Deere dealer. To check the function of the operator presence (see Figure 1-46), start baler and engage baler switch. With baler operating, proceed as follows: Raise up out of the seat for 3 seconds, then sit down again. The baler should continue to operate normally. Raise up out of the seat for 5 6 seconds. The baler should stop operating. If baler stops, operator presence is functioning properly. If the baler does not stop, see your John Deere dealer. Seat Suspension and Forward and Rearward Adjustment Vertical shock dampener handle (A) allows the operator to limit the amount of upward motion the seat suspension provides (see Figure 1-47). Push the control forward for the softest ride. Move the handle back for the fi rmest ride. Between these two positions is the medium fi rmness position. Height adjustment is made with handle (B). To raise the seat, pull up on the handle. To lower the seat, push down on the handle. NOTE: The suspension can be adjusted to reach limits in the minimum and maximum heights which, in effect, locks out the suspension system, making it rigid. The suspension height control will also hit the limits if adjusted too close to the extremes. The forward/rearward adjustment handle (C) allows the seat to slide forward or rearward for best working position. Figure 1-46 Operator's Seat Seat bottom tilt control handle (D), allows the front of the seat cushion to be raised or lowered for the best working position. Attenuator lockout lever (E) locks out or releases the forward or rearward movement. Pull up on the handle to lock; push down on the handle to release. The forward/rearward adjustment handle (F) allows the seat bottom to slide forward or rearward for the best working position. NOTE: If the seat does not fl oat or pump up, see your John Deere dealer.

48 1-33 INSTRUMENTS AND CONTROLS The air seat also has the operator s presence system. Figure 1-48 Armrest Figure 1-47 Operator's Seat A. Vertical Shock Dampener Control B. Height Adjustment Knob C. Forward/Rearward Adjustment Handle D. Seat Bottom Tilt Control Handle E. Forward/Rearward Attenuator Lock-Out Lever F. Seat Bottom Forward/Rearward Adjustment Handle To adjust the left-hand armrest (see Figure 1-48) up or down, use knob (A). Rotate the knob clockwise to lower and counterclockwise to raise. Pull up on handle (B) to adjust seat back angle. Release handle when seat back is in desired position. Turn knob (C) clockwise or counterclockwise to adjust lumbar back support. Turn knob (D) clockwise or counterclockwise to adjust left-hand armrest tension. Seat Belts Seat belts are standard equipment on both the operator and instructional seats. The lap type seat belts have push button quick release and automatic belt retraction to allow unrestricted exiting and entering of the seats (see Figure 1-49). CAUTION CAUTION: Inspect the seat belt and mounting hardware on your machine at least once a year. If the seat belt system, including the mounting hardware, buckle, belt or retractor, shows any sign of damage such as cuts, fraying, extreme or unusual wear, discoloration or abrasion, the entire seat belt system should be replaced immediately. For your safety, replace the belt system only with replacement parts approved for your machine. See your John Deere Dealer. A. Left-Hand Armrest Height Adjustment Knob B. Seat Back Angle Adjustment Handle C. Lumbar Back Support Adjustment Knob D. Left-Hand Armrest Tension Adjust Knob Figure 1-49 Seat Belt

49 2-1 MACHINE BREAK-IN The engine is ready for normal operation. However, you should use extra care during the fi rst 100 hours of operation. A. Dipstick IMPORTANT! Do not let fuel tank run dry. Check fuel gauge frequently. During the first 20 hours, avoid sustained maximum load operation. 1. Promote good ring seating and prevent cylinder wall glazing, put the engine to work as soon as possible. Avoid unnecessary idling. Turn off engine if baler must be idled longer than 5 minutes. 2. Watch coolant temperature gauge (see Figure 2-1) closely. If gauge goes into the RED zone, slow ground speed to reduce load. Figure 2-2 Engine Oil Dip Stick IMPORTANT! Check engine oil and coolant levels frequently. After starting the engine, do not accelerate or apply load until the engine oil pressure warning light is out. Turn off engine by idling at least 1 3 minutes before stopping engine. Refer to Fuel, Coolant and Lubricants section in your Engine Manufacturer's Operator's Manual for types of fluids and oils to use. 3. This engine is factory-fi lled with John Deere engine break-in oil. Operate the engine at heavy loads with minimal idling during the break-in period. Figure 2-1 Fuel and Temperature Gauge IMPORTANT! DO NOT add additional oil until the oil level is BELOW the ADD mark on the dipstick. John Deere Engine Break-In Oil (TY22041) should be used to make up any oil consumed during the break-in period. DO NOT use PLUS-50 engine oil during the break-in period of a new engine or engine that has had a major overhaul. PLUS-50 oil will not allow a new or overhauled engine to properly wear during the break-in period. DO NOT fill above the cross hatch pattern on the dipstick. Oil levels anywhere within the cross hatch are considered in the acceptable operating range.

50 2-2 MACHINE BREAK-IN B. Coolant Overfl ow Tank 8. Check hydraulic oil level (see Figure 2-4) in sight tube (A). Investigate cause for any loss of hydraulic fl uid. 9. Follow fl uid recommendations in Fuel, Coolant, and Lubricants section very closely in your Engine Manufacturer's Operator's Manual. A. Sight Tube Figure 2-3 Coolant Overflow Tank (tank may vary between models) NOTE: Some increase in oil consumption may be expected when low viscosity oils are used. Check oil levels more frequently. 4. Check engine oil level (see Figure 2-2 page 2-1) with dipstick (A) more frequently during engine break-in period. If oil must be added during this period, John Deere Engine Break-In Oil is preferred. (See ENGINE BREAK-IN OIL in Fuel, Coolant, and Lubricants section of Engine Manufacturer's Operator's Manual.) Figure 2-4 Hydraulic Oil Site Gauge (tank may vary between models) 5. After the fi rst 100 hours (maximum), change engine oil and replace the oil fi lter. (See CHANGING OIL FILTER in Engine Manufactures Operators Manual.) Fill crankcase with seasonal viscosity grade oil. (See DIESEL ENGINE OIL in Fuel, Coolant, and Lubricants section of your Engine Manufacturer's Operator's Manual.) 6. Check coolant level (see Figure 2-3) in reservoir (B). Level must be between the HOT and COLD marks. 7. Follow fl uid recommendations in Fuel, Coolant, and Lubricants section very closely.

51 2-3 MACHINE BREAK-IN After One Hour of Operation IMPORTANT! Check torque on front wheel nuts (see Figure 2-5) and rear wheel cap screws. Tighten after first hour of operation. Check and tighten every 4 hours of operation thereafter until the specified torque level is maintained. 1. Drain gear oil from the fi nal drives (see Figure 2-6) and refi ll. (See CHECKING, DRAINING AND FILLING FINAL DRIVES in Wheels, Steering, Brakes, and Rear Axle section.) A. Screws Check torque after every 50 hours of operation. Specifi cation Front Wheel Nuts Torque 163 N m (120 lb-ft) Rear Wheel Cap Screws Torque 150 N m(110 lb-ft) Figure 2-6 Tighten Screws 2. Tighten screws (A) to specification. Tighten screws starting at twelve o clock then six o clock, one o clock then seven o clock, etc. Specifi cation Final Drive Screws Torque 75 N m (55 lb-ft) Figure 2-5 Wheel Nuts After 50 Hours of Operation IMPORTANT! See the EVERY 50 HOURS service requirements in the Lubrication and Maintenance section on page Perform all maintenance required at this service interval. After 100 Hours of Operation Change engine oil and filter. IMPORTANT! See the EVERY 100 HOURS service requirements in the Lubrication and Maintenance section for required service intervals. Perform all maintenance required at each of the specified service intervals when due.

52 3-1 PRE STARTING CHECKS A. Dipstick A. Coolant Reservoir Figure 3-1 Engine Oil Dip Stick 1. Before starting the engine check the engine oil level (see Figure 3-1). Do not operate the engine when oil level is below the low mark on dipstick (A). IMPORTANT! Do not operate the engine when coolant level is below the COLD mark on the overflow tank. Figure 3-2 Coolant Overflow Tank (tank may vary between models) 2. Check coolant level (B). It must be visible on the overfl ow tank between the HOT and COLD marks (see Figure 3-2). 3. Be sure baler has plenty of fuel. Do not allow a diesel engine to run out of fuel. Figure Fuel Gauge 4. Check air pre cleaner fl apper valve (A) for debris. Clean if necessary (see Figure 3-4).

53 3-2 PRE STARTING CHECKS A. Pre cleaner Flapper Valve NOTE: Check hydraulic oil level with baler on level ground and the pickup on the ground. 6. Check the hydraulic oil level at location (A). Oil level should be between the low and high mark (see Figure 3-6). A. Sight Tube Figure 3-4 Clean Flapper Valve 5. Check pre cleaner bowl (A) A. Pre cleaner Bowl Figure 3-6 Hydraulic Oil Site Gauge (tank may vary between models) Figure 3-5 Pre cleaner Bowl

54 3-3 PRE STARTING CHECKS 7. Perform bulb check to insure all warning lights and audible alarm are functioning. (See CHECKING WARNING LIGHTS in the Operating Engine section on page 4-1.) 9. Move engine speed switch to low speed position (see Figure 3-9). Figure 3-9 Engine Speed 10. Disengage baler engage switch (see Figure 3-10). Figure 3-7 Warning Display Panel 8. Move fi eld/road switch (see Figure 3-8) out of road position. 11. Place hydrostatic lever in neutral park position (see Figure 4-1 on page 4-1). 12. Make sure steering wheel is locked in centered position. Figure 3-10 Plunger Drive Engage Switch Figure 3-8 Road / Field Switch

55 4-1 OPERATING ENGINE Checking Warning Lights (see Figure 4-2) NOTICE Failure to replace a failed light bulb could lead to serious machine failure. Replace any failed light bulbs before starting the engine. NOTE: The warning light check is only checking the operation of the light bulbs in the warning display panel. Figure 4-1 Arm Rest Control Panel A. Hydrostatic Control Lever B. Neutral Start Switch C. Engine Air Filter D. Hydrostatic Charge E. Hydrostatic Oil Filter F. Operator Presence G. Low Fuel H. Engine Oil Pressure I. Engine Coolant Temperature J. Hydrostatic Oil Temperature K. Alternator L. Tension Pressure Low M. Park Brake Applied N. Road Shift Engaged Road Shift Engaged (N) will only light if the Field/ Road switch is in the road position. Park Brake Applied (M) will only light when the neutral start switch (B) is activated. The Road Shift Engaged and Park Brake Applied lights (blue) are informational only, not indicating a hazard when on. Check Warning Lights: 1. With hydrostatic control lever (A) in neutral park position (see Figure 4-1), move lever to the right to release neutral start switch (B). 2. Turn ignition switch to the START position. 3. Warning lights (C L) should light. Return ignition switch to OFF position and allow hydrostatic control lever to move into park position. Engine Warm-Up Period Do not run engine at top rpm or place baler under full load until engine is properly warmed up. To warm up the engine, set engine speed at mid range until operating temperature has been reached. Figure 4-2 Warning Display Panel

56 4-2 OPERATING ENGINE Starting Engine WARNING Avoid possible injury or death from machinery runaway. Do not start engine by shorting across starter or starter solenoid terminals. Machine will start and move with hydrostatic drive control lever in forward or reverse drive position, or with the steering wheel not centered, if normal starting circuitry is bypassed. ONLY start the from the operator s seat, with the hydrostatic drive control lever (see Figure 4-3) in neutral park position and baler drive switch disengaged. Before starting engine, be sure area is well ventilated. NOTE: The hydrostatic ground drive lever must be at rest to the left in the neutral park position. This will trip the neutral switch (E), allowing the unit to start. NOTE: When starting the machine, if the key is held in the "ON" position for more than 1 to 2 seconds before advancing to the "START" position, the ICM (In Cab Monitor) may have time to completely boot up. If this happens, then when the key is held in the "START" position, the ICM may measure voltage below 9 volts resulting in an informational message that must be cleared before further operating the baler. This message is considered normal when it appears immediately at start up. However, if this message appears after the machine has been started, with the engine running or while baling, it might indicate a possible problem with the battery or charging system. It is suggested that these systems be inspected for proper function. 1. Read Entire Manual Before Operating. 2. Move hydrostatic drive control lever (A) to neutral park. 3. Move engine speed switch (B) to low speed. 4. Move fi eld/road switch (C) to fi eld position. 5. Disengage baler drive (D). 6. Make sure steering wheel is locked in center position. IMPORTANT! Do not operate starter more than 30 seconds at a time. If engine does not start, wait at least two minutes before trying again. If engine does not start in four attempts, refer to engine manufactures engine Troubleshooting section. 7. Turn ignition switch to the start position until engine starts. Release switch. Figure 4-3 Arm Rest Control Panel A. Hydrostatic Drive Control Lever B. Engine Speed Switch C. Field/Road Switch D. Baler Drive E. Neutral Switch

57 4-3 OPERATING ENGINE After Engine Starts 1. Check engine oil pressure lamp (A) as soon as engine starts. If warning lamp is on, stop the engine and determine the cause. IMPORTANT! Avoid prolonged idling. Prolonged operation at low rpm may cause the engine coolant temperature to fall below the normal operating temperature. This will cause an accumulation of engine sludge and unburned fuel in the exhaust system. 2. Increase engine speed to BALE (see Figure 3-9 page 3-3). 3. Check hydrostatic pressure lamp (B) and alternator lamp (C). If warning lamps are on, stop the engine and determine the cause. 4. Leave engine speed at mid-range, allowing the engine to warm up. 5. Check all warning lamps with engine running. If any lamp is on or if the audible alarm is on, turn off the engine and determine the cause. Stopping engine NOTE: The hydrostatic ground drive lever must be at rest to the left in the neutral park position. This will engage the neutral switch (E). The steering is locked and the park brake is hydraulically applied while the neutral switch is engaged. 1. Move hydrostatic drive control lever (A) to neutral park. 2. Move fi eld/road switch (C) to fi eld position. 3. Disengage baler drive (D). 4. Move engine speed switch (B) to IDLE. Allow the engine to operate at low rpm for 1 3 minutes. 5. Lower pickup to the ground. IMPORTANT! After engine has stopped, remove the key to prevent unauthorized operation or tampering. Key cannot be removed unless switch is in OFF position, preventing accidental battery discharge. 6. Turn OFF engine and remove the key. Figure 4-4 Warning Display Panel A. Oil Pressure Lamp B. Hydrostatic Pressure Lamp C. Alternator Lamp Figure 4-5 Arm Rest Control Panel A. Hydrostatic Drive Control Lever B. Engine Speed Switch C. Field/Road Switch D. Baler Drive E. Neutral Switch

58 4-4 OPERATING ENGINE Starting Fluid CAUTION CAUTION: Ether starting fluid is highly flammable. Do not use near fire, sparks, or flames. Read cautionary information on the container. Either starting fluid may be used in the engine air pre cleaner above the hood. Inject ether only while engine is cranking, since a large concentration into the engine can cause engine damage. Hot Weather Operation IMPORTANT! Liquid Coolant Conditioner is NOT an antifreeze or a cooling system sealer. Protect the engine cooling system against corrosive action by using 50% antifreeze (ethylene-glycol type without a stop-leak additive) and 50% clean, soft water. DO NOT use a high silicate automotive grade antifreeze. Refer to Fuel, Coolant, and Lubricants section on page 10-1 for additional information.

59 5-1 Preparing For The Field OPERATING BALER Starting Baler 1. Load and route twine (see Loading and Routing Twine in section 9-1). 2. Lube bullgears (See page 8-11). 3. Adjust pickup height (See page 8-12). 4. Set bale length (See page 8-12). 5. Set Tension to 300 lbs initially, then raise as needed. Pressing the UP/DOWN button in the bale screen to lower or raise tension pressure (see page 1-5). 6. Seat is adjusted and comfortable. (See page 1-31). 7. Steering column tilt and height are adjusted and in a comfortable position (See page 1-29). Operating Speed The baler is designed for operation at or near maximum ca pacity. This requires the feeder house to be full at all times. To achieve this, advance ground speed and reduce baler speed when the hay volume is low. Reduce ground speed and advance baler speed when hay volume is high. 1. Read Entire Manual Before Operating. IMPORTANT! When the hydrostatic drive control lever and steering are locked out, to prevent damage to the linkage and mechanism, do not try to move them or apply any force against them. NOTE: The hydrostatic ground drive lever (A) must be at rest to the left in the neutral park position, engaging the neutral switch (B), allowing the unit to start. 2. Start the engine. (See page 4-2). When the unit is running, the steering wheel is locked and the parking brake is applied when the hydrostatic drive lever is at rest in the neutral park position. When the unit is running, moving the hydrostatic drive control lever to the right, still in neutral position, will release the steering and brakes. Turning the steering wheel at this time will cause the baler to pivot (spin turn) between the drive wheels. Moving the drive lever forward while turning, will increase the turning radius. The baler should be operated so that the plunger speed is 84 strokes per minute. Adjust speed with engine speed switch (see Figure 1-9 page 1-5). The ground travel speed should be regulated according to the volume and condition of the hay. To check this, count the number of plunger strokes in each bale. There should be 12 to 16 plunger strokes in each bale under normal con ditions. The plunger strokes are counted between each time the knotter ties a bale. The baler should not be run at high speeds when it is empty. A quality bale can be produced by adhering to the above in structions. Consistent bale length is of great importance when using any automatic stacking system. Consistent bale length will occur as a result of following the above in structions. For easy, effi cient stacking and hauling, set and maintain the bale length at 46 inches (see Figure 8-32 page 8-12). Figure 5-1 Arm Rest Control Panel A. Hydrostatic Drive Control Lever B. Neutral Switch 3. Raise pick-up. (See page 5-2).

60 5-2 OPERATING BALER Note: Steps 4-7 are for Balers equiped with Tier I and II Engines only. Balers with Tier III Engines can only display Ground Speed (C). 4. Press display selector (H) positioning display indicator arrow on upper (B) or lower display (see Figure 5-2). 5. Press symbol of function (C), (D), (E) or (F) to be displayed, function display (A) will move to indicate the function being shown in the upper (B) or lower display (see Figure 5-2). 6. Press display selector (H) positioning display indicator arrow on other display. 7. Press another symbol of function (C), (D), (E) or (F) to be displayed. (See OPERATING DUAL DIGI- TAL DISPLAY on page 1-24). NOTE: Steering is accomplished by turning the wheel right or left, except when backing. Steering is reversed when backing the machine. Place hand on bottom half of steering wheel and rotate in direction of desired turn. 8. Move hydrostatic drive lever forward for forward travel and rearward for reverse travel. Figure 5-2 Dual Digital Display A. Function Display B. Digital Display C. Ground Speed mph D. Engine Speed rpm E. N/A F. Tension psi H. Display Select Raising And Lowering Pick-up A. Hydrostatic Drive Control Lever B. Plunger Slow Down Switch C. Pickup Switch Control Figure 5-3 Pickup Switch Pressing up and down on (A) Pickup switch raises and lowers the Pickup.

61 5-3 OPERATING BALER Engaging Baler The baler will not engage if BALER engage switch is on when engine is started. Cycle switch to OFF/ ON position to engage baler. Figure 5-4 Baler Engage Switch NOTE: Operator presence and resetting Baler information is on the decal (A) under the lid of the right-hand armrest (see Figure 5-5). If the operator is not present in the seat, the Baler will engage but will disengage after 5 seconds. If the operator leaves the seat for more than 5 seconds, the Baler will disengage. Cycle the BALER engage switch to the off position to reset. To engage the Baler, push down and forward on the yellow switch. Towing Baler CAUTION CAUTION: Baler is free to move when the final drive hubs are disengaged. The parking brakes are inoperative. Do not exceed a maximum speed of 25 km/h (16mph) while towing the baler. IMPORTANT! If it is necessary to tow the baler, the front final drive wheel hubs MUST be disengaged. 1. Park the baler on fl at, level ground. 2. Block drive wheels (block in the front and in the rear of wheels). IMPORTANT! Do not allow any debris to enter the final drive. 3. Thoroughly clean the face of the fi nal drive (see Figure 5-6). 4. Remove two cap screws (A) and cover (B). A. Cap Screws B. Cover Pull back to disengage the Baler. Figure 5-5 Storage Figure 5-6 Final Drive IMPORTANT! The pin is spring loaded, and the lobe on the cover will push the pin in. Pin spring is very stiff, so tighten cap screws (B) evenly (see Figure 5-8), until cover is installed. Binding can cause severe damage.

62 5-4 OPERATING BALER NOTE: Pin (A) disengages the input shaft from the sungear in the fi nal drive. If pin is in a bind and hard to move, it may be necessary to push (rock) the drive wheel to free pin (A) (see Figure 5-7). 9. Turn off engine and remove blocks. A. Pin B. Cap Screws C. Cover 5. Install cover (C) with lobe facing inward. 6. Repeat Steps 3 5 on opposite side. CAUTION CAUTION: The drive wheels are now disengaged and parking brakes are inoperative. Pin (A) is spring loaded and may be ejected unexpectedly when cover (C) is removed. Figure 5-7 Final Drive 7. After towing, block the front and rear of drive wheels. Remove the cover and install with the lobe facing outward on both wheels. NOTE: The slight movement of the hydrostatic drive motor will cause the spring loaded pin to move in position. 8. Start baler, set engine speed at low rpm, barely move hydrostatic control lever forward and then rearward. Figure 5-8 Final Drive

63 6-1 SETTINGS AND ADJUSTMENTS Service Tires Safely WARNING WARNING: Explosive separation of a tire and rim parts can cause serious injury or death. Only attempt to mount a tire if you have the proper equipment and experience to perform the job. Otherwise, have it done by your John Deere dealer or a qualified repair service. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Inspect tires and wheels daily. Do not operate with low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. Tire Inflation Pressures IMPORTANT! Never operate baler with tires at shipping pressure. Keep valve caps screwed down finger tight on valve stems to prevent foreign material from accumulating in the valve core. Check tire pressure with cold tires before operating baler. Check tire pressure frequently and inflate or deflate, both front and rear tires, to obtain proper pressure. Item Inflation Pressure Front: kpa (2.07 bar) (30 psi) Rear: kpa (1.93 bar) (28 psi) IMPORTANT! The baler is calibrated with the size tire that came with the baler. The baler will not function correctly if wrong size tires are used. Only use Front: , Rear: See inflation pressure above.

64 6-2 SETTINGS AND ADJUSTMENTS Checking Wheels IMPORTANT! Maintain proper torque on wheel hardware according to specifications. Whenever a wheel is removed, check torque after one hour of operation. Check cap screws or nuts every 4 hours until the torque is maintained. Thereafter, check torque every 50 hours. Steering, Hydrostatic Controls and Linkage Steering and hydrostatic controls are located behind cowling (A) below front of cab (see Figure 6-2). A. Cowling Specification Front Wheel Nuts - Torque 163 N m (120 lb-ft) Rear Wheel Cap Screws - Torque 150 N m (110 lb-ft) Figure 6-2 Cab Steering controls are combined with forward and reverse hydrostatic ground drive controls and use a common linkage (D) (see Figure 6-3 on page 6-3). Figure 6-1 Tire IMPORTANT! Any attempt to move the steering wheel or ground drive lever while locked will result in damage to the controls and linkage. Ground drive cable (A) is connected to the ground drive control lever in the cab. Index link (B) keeps the steering and ground drive synchronized. This allows decreasing or increasing ground speed without turning the machine. It also prevents the unit from speeding up or slowing down when making a turn. Hydraulic cylinder (C) releases the locking device when the engine is started and the ground drive lever is moved out of the neutral park position. The locking device locks out the steering wheel and the ground drive control lever.

65 6-3 SETTINGS AND ADJUSTMENTS Steering/hydrostatic linkages (D) are used to move the control levers on the hydraulic pumps supplying oil to the left-hand and right-hand hydraulic motors on the ground drive. The index link (B) controls the movement of the common linkage. Centering cables (E) will return steering wheel and steering controls to center position when steering wheel is released (see Figure 6-3). A. Ground Drive Cable B. Index Link C. Hydraulic Cylinder D. Steering/Hydrostatic Linkages E. Centering Cables F. Dampener Dampener (F) prevents accidental quick movement of ground drive control lever causing jack rabbit starts or loss of control from stopping too quickly. For steering or ground drive neutral adjustments, see your John Deere dealer. Internal Park Brakes The internal park brakes (A) are located inside the fi nal drives and are applied when there is a drop in hydraulic pressure when one of the following occurs (see Figure 6-4): The engine is turned off. Loss of hydraulic pressure. Ground drive control lever is in neutral park. When baler is started and ground drive control lever is moved out of neutral park, hydraulic pressure releases the internal park brakes. A. Internal Park Brake Figure 6-3 Steering/Hydrostatic Linkages CAUTION CAUTION: To prevent bodily injury and machine damage, do not remove dampener (F) or fail to replace the dampener if not functioning properly. Figure 6-4 Internal Park Brakes NOTE: Dampener (F) will allow the unit to be safely stopped in a very short distance. There is no need to try and over-power the dampener (see Figure 6-3).

66 6-4 SETTINGS AND ADJUSTMENTS Checking, Draining and Filling Final Drives NOTE: Replace oil after fi rst 50 hours of use. Check oil level every 100 hours. Replace oil every 800 hours or each season. Check and Fill (Every 100 Hours) 1. Park machine on a fl at level surface with wheel positioned such that fi ll/drain plug (A) is on top and second fi ll/drain plug (B) is on horizontal line (C) (see Figure 6-5). 2. Turn off engine and remove key. Figure 6-5 Final Drive 3. Remove and inspect magnetic plug (B) for metallic particles. Oil level should be at same level as bottom of hole. 4. If necessary, remove fi ll/drain plug (A) and add oil. (See FINAL DRIVE OIL in Fuel, Coolant, and Lubricants section for recommended oil.) IMPORTANT! Inspect plug O-rings and replace if damaged. 5. Clean and install plugs. Tighten to specifi cation. Specification Final Drive Plugs Torque 25 N m (18 lb-ft) 6. Repeat Steps 1 5 on opposite fi nal drive. A. Fill/Drain Plug B. Fill/Drain Plug C. Horizontal Line

67 6-5 SETTINGS AND ADJUSTMENTS Replace Oil (After first 50 hours of use and then every 800 hours or each season) 1. Park machine on a fl at level surface with wheel positioned such that fi ll/drain plug (A) is on bottom and hole (B) is on horizontal line (C) (see Figure 6-6). A. Fill/Drain Plug B. Fill/Drain Plug C. Horizontal Line 2. Turn off engine and remove key. NOTE: Final drive oil capacity is approximately 1.8 L (3.8 U.S. pt). 3. Remove plugs (A and B) and drain oil. Inspect magnetic plugs for metallic particles. IMPORTANT! Inspect plug O-rings and replace if damaged. 4. Clean and install plug (A). Tighten to specification. Specification Figure 6-6 Final Drive Final Drive Plug Torque 25 N m (18 lb-ft) 5. Fill fi nal drive with clean oil until oil level is at same level as bottom of fill plug hole (B). (See FINAL DRIVE OIL in Fuel, Coolant, and Lubricants section for recommended oil.) IMPORTANT! Inspect plug O-rings and replace if damaged. 6. Clean and install plug (B). Tighten to specification. Specification Final Drive Plug Torque 25 N m (18 lb-ft) 7. Repeat Steps 1 6 on opposite fi nal drive.

68 7-1 SETTINGS AND ADJUSTMENTS Air Conditioning and Heating System Air is drawn into the cab through air intake vents (A). This air flows down air duct (B) and into the pressurizer fan (C). The air is then pushed through the pre cleaner (D) where the majority of dirt and a small amount of air is discharged out through the cab floor. Be certain this opening is clear (see Figure 7-1). This cleaned air then passes through fresh air fi lter (E) into the evaporator compartment. The air is now mixed with air from inside the cab, being drawn into the evaporator compartment through the recirculating fi lter (F) and the evaporator fi lter. The air is then drawn through the evaporator / heater core (I). Treated air (heated or cooled) is now drawn into the recirculator blower (G) and discharged into the cab through air vents (H). Air conditioning system low pressure switch (J) is located left of the evaporator compartment. Figure Air Conditioning

69 7-2 SETTINGS AND ADJUSTMENTS Observe Air Conditioning/Heating Precautions IMPORTANT! Do not over tighten knob (A). 6. Install fi lter and tray in reverse order as removed. A. Knob B. Dirt Tray C. Wing Nut D. Fresh Air Filter Figure 7-2 See Your John Deere Dealer CAUTION: Refrigerant (R134a) is under pressure. Improper servicing may cause refrigerant to penetrate eyes and skin or cause burns. Special equipment and procedures are required to service air conditioning system. (See your John Deere dealer.) Removing Fresh Air Filter and Tray (see Figure 7-3) Figure 7-3 Fresh Air Filter IMPORTANT! In dusty conditions, check every day. Normal service is 50 hours. 1. Loosen knob (A) and remove cover. 2. Lift out and dump dirt tray (B) attached to cover. 3. Remove wing nut (C) and fresh air fi lter (D). 4. Clean fresh air filter. (See CLEANING FRESH AIR AND RECIRCULATING FILTERS in this section.) 5. Remove and clean pre cleaner. (See REMOVING PRE CLEANER in this section.)

70 7-3 SETTINGS AND ADJUSTMENTS Removing Pre Cleaner Whenever the fresh air fi lter is serviced, clean the pre cleaner as follows: 4. Install fi lter in reverse order as removed. When replacing fi lter, it should drop easily into place. Do not force it. Be certain fi lter is installed as shown on the fi lter. 1. Remove fresh air fi lter and tray. (See REMOVING FRESH AIR FILTER AND TRAY in this section.) 2. Push down on pre cleaner (A) and pull it out from the top. Hole in fl oor under pre cleaner must be kept open (see Figure 7-4). 3. Wash and dry pre cleaner. 4. Install pre cleaner in reverse order as removed. A. Pre cleaner Figure 7-5 Storage Tray Cleaning Fresh Air and Recirculating Filters Clean fi lter by one of the following methods: Tap gently on fl at surface, dirty side down. Do not tap on a tire. Blow compressed air through filter in opposite direction of arrows on fi lter. Figure 7-4 Pre cleaner Removing Recirculating Filter IMPORTANT! In dusty conditions, check this filter often and service as required. Normal recommended service is 200 hours. 1. Remove storage tray in left rear corner of cab (see Figure 7-5). 2. Reach in opening and pull out fi lter. 3. Clean recirculating air fi lter. (See CLEANING FRESH AIR AND RECIRCULATING FILTERS in this section.)

71 7-4 SETTINGS AND ADJUSTMENTS Removing Evaporator Filter Clean this filter only if other service does not provide enough cooling. The evaporator fi lter (A) can be inspected from outside the cab after removing the fresh air fi lter (see Figure 7-6). (See REMOVING FRESH AIR FILTER AND TRAY in this section.) If it looks clean, do not remove and clean it. A. Filter If filter is dirty: 1. Remove fi ve screws (A) in seat console. 2. Remove six screws (B) and evaporator cover. 3. Remove evaporator fi lter (C). 4. Clean as you would the other filters. (See CLEAN- ING FRESH AIR AND RECIRCULATING FILTERS in this section.) 5. Install fi lter in reverse order as removed. A. Screw (5 used) B. Screw (6 used) C. Filter Figure 7-6 Evaporator Filter Figure 7-7 Evaporator Cover

72 7-5 SETTINGS AND ADJUSTMENTS Cleaning Air Intake Panel Clean this panel only when it looks plugged (see Figure 7-8). Air is brought in through the left-hand side panel only. The right-hand side panel does not provide cab air. 1. Remove six screws (A) and remove panel (B). 2. Clean with compressed air or water. 3. Install panel and screws. A. Screw (6 used) B. Panel Cleaning Condenser See CLEANING SCREEN, CONDENSER/OIL COOLER AND RADIATOR in Engine Manufactures Operators Manual. Checking Compressor and Drive Belt WARNING WARNING: To prevent injury, never service baler while it is running. Engine must be off and key removed. 1. Turn off engine and remove key. 2. Inspect serpentine drive belt. If worn, see RE- MOVING AND INSTALLING SERPENTINE BELT in Engine Manufactures Operators Manual. CAUTION CAUTION: Do not start engine. Figure 7-8 Air Intake Panel 3. Turn ignition switch to RUN, turn cab fan switch on and place temperature knob to coldest setting. 4. Check compressor pulley (A) for magnetism by placing a metallic object next to it. If area is not magnetic see your John Deere Dealer. 5. Turn ignition switch to OFF position and remove key. A. Pulley

73 7-6 SETTINGS AND ADJUSTMENTS 6. Start engine and turn on air conditioning. If switch shuts off compressor again, see your John Deere dealer. A. Switch Figure 7-9 Compressor High Pressure Switch A high pressure condition can result from insufficient air fl ow across the condenser. When this happens, switch (A) shuts off the compressor (see Figure 7-10). 1. Turn off engine and remove key. 2. Clean condenser and cab air fi lters. 3. Check recirculating blower. 4. Check for a worn or broken serpentine engine belt. 5. Check compressor clutch and magnetism at compressor pulley with air conditioning switch on. Figure 7-10 High Pressure Switch Low Pressure Switch Switch (A) (located under passenger seat) protects the compressor if refrigerant is lost. The switch can also activate if there is insuffi cient air fl ow across the evaporator. It can also cause the compressor to cycle on cool days or if there is a slow leak in the system (see Figure 7-11). 1. Clean condenser and cab air fi lters. 2. Check recirculating blower. 3. Check for a worn or broken serpentine engine belt. 4. If the compressor cycles excessively, or if there is no cooling, see your John Deere dealer. A. Switch Figure 7-11 Low Pressure Switch

74 8-1 KNOTTER SETTINGS Knotter Settings The following instructions will help you understand the Twine Knotter and the adjustments necessary to maintain and keep the system tying at the optimum level of performance. Periodic checks of these adjustments will help alleviate tying problems and reduce the risk of equipment damage. NOTE: Adjustments may vary for different crops. Needle Timing Adjustment If the needles are late, retard the knotter drive chain on the knotter sprocket one link. If the needles are early ad vance the chain one link. Replace the chain on the sprocket and connect it. Be sure that the clutch pawl (see Figure 8-2) roller is seated in the notch in the clutch and that the chain is connected on the idle side and on top of the idler sprockets (see Figure 8-3). Needle NOTE: Before timing the needles, be sure the needles are in adjustment. For adjusting the needles see page 8-4. To Check Needle Timing: Trip the knotter clutch (see Figure 8-2) by raising the trip bar (see Figure 8-4 page 8-2) until the notch is positioned over the knurl, and turn the flywheel counterclockwise until the tips of the needles are even with he bottom of the bale chamber (see Figure 8-1). Figure 8-2 Knotter Clutch Plunger Face Gussets Needle Figure 8-1 Needle and Plunger The leading edge of the gussets on the plunger must be 1/4" to 4" past the tips of the needles when the plunger is on the compression stroke. The needles are late if the leading edge of the plunger gussets are more than 3" past the tips of the needles and the needles are early if they are less than 1/4" past the leading edge of the plunger gussets. Con sult the decal on the left-hand side of the baler. Figure 8-3 Knotter Drive Chain Trip the knotter clutch and turn the fl ywheel counterclockwise and recheck the timing. Repeat the above procedures until adjustment is correct. NOTE: Always shut off baler and tractor when inspecting, adjusting, lubricating, or servicing baler.

75 8-2 SETTINGS AND ADJUSTMENTS Meter Trip Bar NOTE: Before timing the needles, be sure the needles are in adjustment. For adjusting the needles see pages 8-4. B 1/4 to 1/2 A Trip the knotter clutch by raising the trip bar (see Figure 8-4) until the notch is positioned over the knurl, then turn the fl ywheel counterclockwise until the needles are near top dead center (see Figure 9-13 page 9-4). The meter trip bar should have 1/8" clearance from the knurl, (A) (see Figure 8-4), when it is in the resting position. Adjustment is made by loosening the bolts on the bearing support, (B) and moving fore or aft as needed. The trip bar should not bind on guide washers when in the tripped position. C Figure 8-5 Needles In Home Position 2. Loosen clamp bolt A, (see Figure 8-8) to position stop bolt B, (see Figure 8-7) square to the face of clutch pawl A, (see Figure 8-7). Figure 8-4 Meter Trip Bar Knotter Clutch NOTE: Before timing the needles, be sure the needles are in adjustment. For adjusting the needles see page 8-4. Also be sure the meter trip bar is properly adjusted (see page 8-2). Figure 8-6 Saddle Roller 1. With needles in the home position, set the needle yoke drive bolt (A) 1/4" to 1/2" past center between (B) and (C) (see Figure 8-5). To obtain this setting, adjust saddle roller (A) on the opposite side of the knotter (see Figure 8-6).

76 8-3 SETTINGS AND ADJUSTMENTS 3. The clutch pawl (A) must have approximately 1/2" clearance at (C ) when depressed. The clutch pawl roller should have 1/8" clearance at (D) when the notch in the clutch disc is not near the clutch pawl roller. Adjust with bolt (B) (see Figure 8-7). Knotter Brake Adjust the brake shoe tension springs so that the springs are fully depressed, (A) (see Figure 8-9). Figure 8-8 Tying Holder Bolt Figure 8-7 Clutch Pawl 4. Trip the knotter clutch and rotate the clutch. The clutch pawl must have 1/8" clearance from the stop lever at (B). Adjust with stop bolt (G) (see Figure 8-8). Figure 8-9 Saddle Lever Spring The saddle spring is adjusted properly when roller (B) is in the notch and there is 1/2" of adjusted tension on the sad dle lever spring (see Figure 8-9).

77 8-4 SETTINGS AND ADJUSTMENTS Twine Needle Adjustment 1. Trip the knotter clutch and swing the needles up through the bale chamber by turning the fl ywheel coun terclockwise by hand. The needles should be adjusted left or right so that there is 0 to 1/32" clearance between the nee dle and the knotter bill hook pinion, (see Figure 8-10). Adjust by sliding the needle left or right on the needle yoke. Freeman Self Propelled balers have a needle yoke drive rod on each side. Be sure both are adjusted for equal load on each rod at top dead center. 4½ Figure 8-12 Needle Eye To The Twine Disc Figure 8-10 Knotter 2. The needles should clear the twine disc cleaner 1/8". To increase the distance between the needle and the twine disc cleaner, loosen the front and tighten the rear needle anchor bolts (A), Figure To decrease the clearance re verse the procedure. TDC (top dead center). TDC is when the needles are at the highest point of travel. At this time the Needle Yoke Drive Rod is in the 11 o clock position (see Figure 8-13). 11 o clock Position Needle Needle Yoke Drive Rod Clutch A Figure 8-11 Needle Anchor Bolts Figure 8-13 Needles at TDC, left-hand view 3. Trip the knotter and turn the fl ywheel counterclockwise, by hand, until the needles are in the uppermost position. The distance from the bottom of the needle eye to the twine disc should be 4-1/2" (see Figure 8-12). 4. Adjust needle height by loosening the lock nuts on the needle yoke drive rod (see Figure 8-13). Turn the rod to the right or left for desired setting. All of the

78 8-5 SETTINGS AND ADJUSTMENTS Twine Finger Adjustment 1. Trip the knotter and turn the fl ywheel counterclockwise until the point of the twine fi nger is just passing the inside edge of the needle. The point of the twine finger should clear the needle by 1/8", (see Figure 8-14). 5 1/2" Needle Needle Twine Finger Figure 8-15 Adjusting Twine Fingers B 1/8" A Minumum 1/8" Max 3/16" Twine Finger Figure 8-14 Needles In Home Position This adjustment is made by loosening the twine fi nger an chor bolts and sliding them to the front or back in the slotted holes in the bale chamber top (A) (see Figure 8-14). 2. Continue to turn the fl ywheel counterclockwise until the twine fi ngers reach the far point of their travel. Measure the distance from the tip of the twine fi ngers back to the knotter support angle (see Figure 8-15). This measurement should be 6-1/2" on the model 2 tie and 5-1/2" on 3 tie balers. This ad justment is made by lengthening or shortening the twine fi nger drive rods (B) (see Figure 8-14). Needle Slot Twine Finger Figure 8-16 Twine Guide and Twine Finger Extended Adjust the position of the twine fi ngers at the needle slots with the stop bolt (see Figure 8-17). WARNING WARNING: Always shut off baler and tractor when in specting, adjusting, lubricating, or servicing baler. After adjusting the twine fi ngers, turn the fl ywheel coun terclockwise until the twine fi ngers are in the returned posi tion. Check to see that there is 1/8" from the tips of the twine fi ngers to the edge of the needle slots (see Figure 8-16).

79 8-6 SETTINGS AND ADJUSTMENTS Knotter Adjustment: 1. Twine Holder: The twine holder holds the twine in the twine disc while the bale is being made and tied. The pressure is regulated by bolt (C) (see Figure 8-18). Adjust the twine holder only as tight as necessary to pre vent the twine from pulling from the disc and/ or producing bow knots. 2. Twine Disc: Be certain the twine disc cleaner is free. Adjust the twine disc notch so the left-hand side of the notch is even with the cleaner (D) (see Figure 8-18). Do this by loosening nut (A) several turns. Tap the nut end of the shaft to loosen the worm. After the disc is set turn the worm against the spacer washers (B) see Figure 8-18, and tighten the nut. After the knotter has com pleted one cycle check the notch setting again. 3. Knife Arm: Stop Bolt The knife arm cuts the twine and strips it off of the bill hook during the tying process of the knotter. The stripper fl ange on the knife arm should just touch the bill hook with fi rm pressure as the stripper fl ange advances the knot past the end of the bill hook (see Figure 8-19). Figure 8-17 Stop Bolt Bill Hook D C B Stripper Flange Figure 8-19 Knotter The knife arm should be 1/4" to 3/4" past the end of the bill hook when the knife arm is in the most extreme position (see Figure 8-20). Correct the adjustment of the knife arm by replac ing it. A Figure 8-18 Knotter 1/4"- 3/8" Make adjustments on bolt (C) in 1/6 of one turn increments. Proper adjustment is achieved when the knot ter is producing a clean and smooth knot. Figure 8-20 Knotter

80 8-7 SETTINGS AND ADJUSTMENTS 4. Cam Gear Adjustment: Both flat surfaces of the knotter hook and worm gear pinions must be held fl at with 0 to.005 interference on the smooth face of the cam gears (see Figure 8-21). This adjustment is made with shims between the cam gears and knotter frames. Shimming must be done be tween the cam gears and the knotter frames any time a knotter is assembled. Excess space between the cam gears and the knotter frames is taken out by adjusting nut A) (see Figure 8-22). Tighten nut until knotters will just hold their own weight when rotated up to horizontal. Feed Fork The two forward tines on the feed fork are adjustable. The tines can be fastened to the feed fork in position (A,B or C) (Figure 8-23). The normal position is (B). Figure 8-23 Feed Fork If the bales are not uniform and more hay is needed on the left-hand side of the bale chamber, move both tines to posi tion (B). If more hay is needed on the right-hand side of the bale chamber, move both tines to position (A). Some ex perimenting may be required to properly adjust the tines. After adjusting the feed fork tines, run the feed arm through one complete cycle by turning the fl ywheel counterclock wise to insure it does not interfere with any other parts. Figure 8-21 Knotter Additional adjustment can be done with the feed arm. Feed Arm A Figure 8-22 Adjusting Nut The normal position of the arm is parallel to the bale chamber when fully extended. The travel of the feed fork into the bale chamber can be adjusted so that the distance is retarded or advanced. The adjustment of the feed arm can affect the shape of the bales. By retarding the feed arm, you put more hay to the right-hand side of the bale chamber. By advancing the feed arm, you put more hay to the left-hand side of the bale chamber.

81 8-8 SETTINGS AND ADJUSTMENTS Loosen bolt (A), and rotate rod (B) to give desired position of the feed fork (see Figure 8-24). There should be no end play in rod at (C). The feed arm connecting rod swivel adjustment is done by loosening jam nut (C). Rotate the swivel nut clockwise until tight. Then loosen the swivel nut in a counterclockwise rotation 1/12" of a turn. To secure, hold the swivel nut in position and retighten the 2" jam nut (see Figure 8-24). WARNING WARNING: Always shut off baler when inspecting, adjusting, lubricating, or servicing baler. Figure 8-24 Feed Arm Feed Arm Safety Latch Your Freeman Baler is designed so that under extreme conditions of overfeeding the pickup, the feed fork will automatically release from the feed arm. When this hap pens the feed fork locks into the feed fork catch (A) (see Figure 8-25). Figure 8-25 Feed Fork Catch After removing any excess hay or foreign material from the feeder house, unlatch the feed fork from the feed fork catch, and attach it back to the latch on the feed arm (B). The feed arm latch should be adjusted to break away at 120 lbs.-ft. torque. This adjustment should be measured with a torque wrench applied to the end of the latch, (B). The torque is raised by increasing the amount of washers on the trip spring rod (C) and is lowered by de creasing the amount of washers.

82 8-9 SETTINGS AND ADJUSTMENTS Plunger The plunger can be adjusted to remove both side and up/down play. It is important to keep the plunger in adjustment to avoid unnecessary wear. To adjust the up/down play, be sure the top plunger roller is up to the top rail angle. Adjust the roller by loosening nut (A). Move the roller and shaft up or down as needed (see Figure 8-26). Lock it with nut (A). Plunger side play may be removed by adjusting the top and bottom hard slide mounting angles on the left-hand side of the plunger. Complete the following steps ( see Figure 8-27): 1. Loosen the eight hold-down bolts (A). 2. Slide the plunger over to the right-hand side of the bale chamber. Use a leverage bar to do this. 3. Adjust the four set screws, (B) (two top and two bottom), until there is 1/32" (the width of a thin knife shim) between the hard slides and slide rails, (C) 4. Tighten the eight hold-down bolts. 5. Remember the plunger must travel free. Run the plunger back and forth by hand to insure it is not binding. WARNING WARNING: Always shut off baler when inspecting, adjusting, lubricating, or servicing baler. Figure 8-26 Top Plunger Roller Nut Figure 8-27 Plunger

83 8-10 SETTINGS AND ADJUSTMENTS Plunger Safety Latch CAUTION CAUTION: Always check the needle timing with the plunger before adjusting the safety latch. Plunger Knife WARNING WARNING: Always shut off baler and tractor when in specting, adjusting, lubricating, or servicing baler. If the needles are obstructed by foreign material in the nee dle slots, foreign material in the chamber, or if the needles prematurely enter the chamber because of early timing, needle breakage can occur. The plunger safety latch (A), helps protect the needles against breakage (see Figure 8-28). If for any reason the needles re main in the bale chamber while baling, the plunger is stopped by the plunger stop dog and the fl ywheel shear bolt is sheared. Before replacing the fl ywheel shear bolt, always pull the stop dog out of the bale chamber. Do this by pulling the needle yoke back to the home position. The safety latch is adjusted by lengthening or shortening the latch rod at (B). As the needles are leaving the bale chamber and the tips of the needles are even with the bottom of the bale chamber, adjust the length of the latch rod so that the plunger stop dog (A) is just leaving the chamber and is fl ush with the inside of the dog plate. The baler should have sharp knives at all times. When re placing the knives with new or re-sharpened knives, be cer tain the adjustments of the knives are as described below to avoid serious equipment damage. Before adjusting the knife, adjust the plunger as described in the Plunger Adjustment section on page 8-9. After adjusting the plunger, shim the stationary knife (see Figure 8-29), (D), so that the two knives clear by 1/16" at the top, (E). Do not attempt to shim the plunger knife. Rotate the fl ywheel until the knives are even. Then with the use of a leverage bar slide the plunger over to the right side. Adjust the bottom of the knives so that they have 1/32" clearance at (A). Do this by loosening bolt (B), and adjusting set screw (C) which is under the stationary knife bolts, and set screw (F) which is about six inches forward under the feeder house. If adjustment cannot be achieved with bolts (C) and (F) re move or install shims behind the stationary knife. It is im portant to feather shim. After adjusting the bottom of the knives, adjust the top until there is 1/16" clearance between the two knives. The top of the knives can only be adjusted with shims. Figure 8-28 Plunger Safety Latch

84 8-11 SETTINGS AND ADJUSTMENTS Figure 8-29 Plunger Knife Check these adjustments closely and run the plunger back and forth by hand to insure the knives are properly ad justed. Using a bar force the plunger to the right side of the chamber with great pressure to insure the knives do not lock up. Pinion And Bullgear The fl ywheel (see Figure 8-30) should be parallel to the frame plus or minus 1/8", with pinions meshing evenly with the bullgear teeth (A). The lash of the pinion gears should have between 1/8" and 3/8" of free play on the rim of the fl ywheel at (B). Measure this when the connecting rod is fully extended and blocked to prevent bullgear movement. To correct excessive free play adjust set screws (C). Be certain both sides are adjusted evenly to avoid serious equipment damage. WARNING WARNING: Always shut off baler when inspecting, adjusting, lubricating, or servicing baler. Bullgear Luber Figure 8-30 Pinion Gears The bullgear luber (see Figure 8-31), distributes bullgear grease onto the bullgears through a manifold under the bullgear hood. Prior to initial baler operation, the bullgears require a complete coating of lubricant (Freeman bullgear grease, F , only). Allow 4 hours before fi rst using the baler, after completely covering the bullgears with grease. During the next 48 hours of bailing, grease bullgears every 30 minutes, and again at the end of the shift. Greasing at the end of the shift gives the bullgear grease an opportunity to set up and adhere to the bullgears. Once you have established a good coverage of grease on the bullgears, greasing every four hours thereafter is usually adequate; and always grease at the end of the shift. While turning the fl ywheel, operate the lube pump handle to apply a coating of bullgear grease to the gears. This typically will require about 5 revolutions of the bullgears to get a full fi lm of lube covering the working surfaces of the gear teeth. This process should only be done by turning the fl ywheel by hand and not by running the baler with the engine or tractor. Subsequent lubrication should be done at the end of the baling shift to allow the lube time to set up and minimize the fl inging off of the product.

85 8-12 SETTINGS AND ADJUSTMENTS WARNING WARNING: Always stop the baler engine and wait for all motion to cease before servicing or adjusting the machine. Pickup When the pickup is in the baling position, be sure the pick up fingers clear the ground by at least 1. Do not rotivate the ground with the pickup fi ngers. The pickup height may be adjusted by the pickup lift link (see Figure 8-33). Turn adjusting nuts until pickup teeth are 1" off the ground. Tighten adjusting nuts. Figure 8-31 Bullgear Luber Tank Bale Length Pickup Lift Link Adjusting Nuts The operating speed of the baler has a direct effect on the bale length. To help maintain a consistent bale length adhere to baler OPERATING SPEEDS, on page 5-1. Bale length is adjusted by changing the height of the trip bar stop bolt (see Figure 8-32). Raising the bolt decreases bale length and lowering the bolt increases bale length. If no more adjustment is available with the trip bar stop bolt, change the height of the meter trip bar stop. Use the holes provided to adjust the meter trip bar stop. If the meter trip bar stop is moved, the meter trip bar bolt will need adjustment. FRONT Figure 8-33 Pickup Lift Link Adjust the balance springs (see Figure 8-34) located behind the pickup under the baler so that the pickup may be lifted with one hand or approximately a 35 lb. with the hay saver wheel in the baling position (see Figure 8-36). FRONT Adjusting Nuts Figure 8-34 Balance Springs Figure 8-32 Bale Length

86 8-13 SETTINGS AND ADJUSTMENTS Hay Saver Wheel The Hay Saver Wheel should be in the raised position when transporting the baler (see Figure 8-35). Once the baler is in the hay fi eld change the Hay Savor Wheel to the baling position (see Figure 8-36). Hay Saver Wheel FRONT Figure 8-35 Road Position Hay Saver Wheel FRONT Figure 8-36 Baling Position

87 9-1 Twine Routing (3 tie baler displayed) 1. Load twine into twine box. TWINE ROUTING Twine Tensioners Figure 9-1 Twine 2. Feed twine through twine guides. Figure 9-3 Twine Tensioner 3. Feed twine through twine tension assemblies. Twine Guide Figure 9-4 Twine Tensioner Figure 9-2 Twine Guide

88 9-2 SETTINGS AND ADJUSTMENTS 4. Feed twine through guides on lower chamber. 6. Feed twine through the twine guides on the back of the needles. Lower Twine Guide Figure 9-5 Lower Chamber Twine Guide Figure 9-7 Needle Twine Guides 5. Route twine through the lower twine box guides to lower chamber guides (see Figure 9-6). 7. Route twine so it glides on top of the roll pins that are in the twine needles. Each Needle has 3 roll pins. Roll Pins Figure 9-8 Needles 8. Route Twine through eye of needle. Lower Twine Box Guides Figure 9-6 Slack Puller Lower Chamber Guides Figure 9-9 Twine Needle Eye 9. Tie twine to needle yoke.

89 9-3 SETTINGS AND ADJUSTMENTS Figure 9-10 Tie Off Twine

90 10-1 FUEL, COOLANT AND LUBRICATION Please refer to your Engine Manufacturer's Operator's Manual for all engine information. For Diesel Fuel, Lubricity of Diesel Fuel, Diesel Engine Coolant, Diesel Engine Oil, Oil Filters, Diesel Engine Break-In Oil, Engine Filters, see your Engine Manufacturer's Operator's Manual. The fuel tank is vented at the cap. Fill fuel tank at the end of each day. This prevents condensation in the tank as moist air cools. IMPORTANT! Do not mix used diesel engine oil or any other type of lubricating oil with diesel fuel. IMPORTANT! Improper fuel additive usage may cause damage on fuel injection equipment of diesel engines. Filling Fuel Tank CAUTION CAUTION: Handle fuel with care: It is highly flammable. Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine. Fill fuel tank outdoors. Prevent fires by keeping machine clean of accumulated trash, grease, and debris. Always clean up spilled fuel. Do not overfill fuel tank. Fuel level should not be closer than 25 mm (1 in.) to the top of the fuel tank. Bodily injury can result from fuel splash back. Leakage can result from expansion of fuel. If the tank is filled too full, then left in direct sunlight or if temperature gets too hot, the tank will overflow. Hydraulic Pump Drive Gear Case, Hydrostatic Drive and Main Hydraulic Systems Oil IMPORTANT! Do not mix hydraulic oils. Using only specified oil is recommended. DO NOT use low viscosity oil. The baler comes from the factory with J20CHY- GARD oil. Use only J20C HY-GARD oil. NOTE: Baler 28014S-003 Does not have Hydraulic Pump Drive Gear Case.

91 10-2 SETTINGS AND ADJUSTMENTS Final Drive Oil John Deere SAE 85W-140 API-GL5 Gear Lubricant is recommended. If other oils are used, they must meet requirements of: API Service Classification GL-5 Military Specifi cation MIL-L-2105B Military Specifi cation MIL-L-2105C Depending on the expected prevailing temperature for the fi ll period, use oil of viscosity as shown in the chart. Product Number Description Quantity TY W/140 GL5 Gear Lube 18.9 L (5 gal) TY W/140 GL5 Gear Lube 3.8 L (1 gal) In Canada use: Product Number Description Quantity TY W/140 GL5 Gear Lube 20 L pail Grease Use grease based on NLGI consistency numbers and the expected air temperature range during the service interval. The following grease is preferred: John Deere SD POLYUREA GREASE The following greases are also recommended: John Deere HD MOLY GREASE John Deere HD LITHIUM COMPLEX GREASE Other greases may be used if they meet the following: NLGI Performance Classifi cation GC-LB IMPORTANT! Some types of grease thickener are not compatible with others. Consult your grease supplier before mixing different types of grease. Figure 10-1 Gear Lubricant Figure 10-2 Perform Grease Lubrication and Maintenance

92 11-1 LUBRICATION AND MAINTENANCE CAUTION CAUTION: To prevent injury, never lubricate or service baler or engine while it is running. Engine must be off and key removed. IMPORTANT! The service times are for average conditions. Service more often if baler is used in extreme conditions. Perform each lubrication and service illustrated in this section both at the beginning of the season, and at the end of the season. STC Fitting Tools Supplied With Baler NOTE: Not all SP balers use STC Fittings. The STC release tools (see Figure 11-2) are located on the backside of the baler between the cab and engine. 1. There are two tools, sizes 6/8 and 10/12. Tools (A). 2. Remove tools by loosening wing nut and sliding upward, pull bolt head through hole. Clean grease fittings before using grease gun. Replace any lost or broken fi ttings immediately. If a new fi tting fails to take grease, remove and check for failure of adjoining parts. Observe Lubrication Symbols Follow hourly (C) intervals on lubrication symbols (A) and (B) LUBRICATION SYMBOL (A) Lubricate with John Deere High Temp EP grease or equivalent SAE multipurpose grease (unless otherwise specifi ed). OIL SYMBOL (B) Lubricate with SAE 30 or heavier oil. Figure 11-2 STC Fitting Tools IMPORTANT! DO NOT pry against release sleeve (C) or damage to fitting may result. DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off when hose is disconnected. If this happens and fitting is connected without release sleeve installed, fitting will not be able to be disconnected again. Figure 11-1 Lubricant Symbols Figure 11-3 STC Fitting Tools

93 11-2 LUBRICATION AND MAINTENANCE 3. Disconnect STC type hoses: a. Clean area around connection, especially around release sleeve (C). b. While keeping special tool perpendicular to connection, insert tool between release sleeve (C) and shoulder (I). c. Gently push, DO NOT PRY, release sleeve (C) away from shoulder (I) to disconnect hose. d. Slightly twist hose connection (H) while pulling outward to disconnect. 4. Inspect STC connectors: a. Check seal mating surfaces for nicks, scratches, or fl at spots. Figure 11-4 STC Fitting Tools A. STC Tool (2 each) B. STC Tool C. Release Sleeve D. Retaining Ring E. Backup Ring F. O-Ring G. STC Port H. STC Hose Connection I. Shoulder

94 11-3 LUBRICATION AND MAINTENANCE Service Interval Display For Balers equiped with Tier I & II Engines: Use operating hours display as a guide when performing the required service interval on the baler. A. Upper Display B. Lower Display C. Ground Speed and Engine rpm Buttons D. Tension and lower right button Every 50 hours of engine operation, the characters SEV 1 will appear on the lower tachometer display (B) indicating service is needed (see Figure 12-5). Both engine and baler hours can be displayed at the same time. With the display indicator on the upper display (A), pressing both the GROUND SPEED and ENGINE RPM buttons (C) simultaneously will display the engine hours. Move the display indicator to the lower display (B), pressing both the TENSION and lower right button (D) simultaneously will display the baler hours. NOTE: For resetting the tachometer after service completion, see the decal on the inside of the armrest compartment cover (see Figure 1-42 page 1-30). After completing the service, reset the tachometer by pressing the ENGINE RPM and TENSION PRES- SURE switches simultaneously and turning the key to ON (third position). The service interval timer can also be reset if service is performed between 45 and 50 hours but not prior to 45 hours. If service SEV 1 appears, pressing any of the four switches will suppress the message until the next time the ignition switch is turned on. For Balers Equiped with Tier III Engines: Maintenance messages will be displayed on the ICM (In Cab Monitor). See Maintenance Screen, page 1-13 for more information on viewing and reseting these messages. Figure 11-5 Service Interval Display

95 Maintenance diagram below is for SP balers ASC-SP & ASC-SP LUBRICATION AND MAINTENANCE Maintenance diagram below is for SP baler 280S14-003

96 11-5 LUBRICATION AND MAINTENANCE ITEM ITEM DESCRIPTION POINTS DESCRIPTION APPROVED MATERIAL Break-In *Engine, See Engine Manufacturer's Operator's Manual 3 Final Drives 2 Replace Oil (Only after fi rst 50 hours) SAE 85W-140 API-GL5 3 Final Drive Cover Cap Screws 24 Tighten to 75 N m (55 lb-ft) (Only after fi rst 50 hours) 3 Front Wheel Nuts 24 Tighten after fi rst hour and then every 4 hours until tight 8 Rear Wheel Cap Screws 12 Tighten after fi rst hour and then every 4 hours until tight 14 Engine* Oil and Filters 2 Replace oil and filter (Only after first 100 hours) As Required *Engine, See Engine Manufacturer's Operator's Manual 1 Fuel Tank 1 Drain water and sediment 9 Oil Cooler A/C Condenser 1 Clean debris from fi ns 11 Radiator 1 Clean debris from fi ns 16, 17 Engine* Air Screen or Primary Air Filter 17 Engine* Air Filters 2 Replace 20 Cab Fresh Air Filter 1 Replace 20 Cab Pre-Cleaner 1 Replace 23 Cab Recirculating Filter 1 Replace Every 3 To 4 Hours 2 Clean screen or primary fi lter when warning light comes on 2 Pickup Clutch 1 Grease / 1 pump Multi-purpose grease 5 Needle Yoke Drive Rod 4 Grease Ends 6 Plunger Rollers 4 Grease 10 Plunger Stop Dog 1 Grease / Make sure Stop Dog moves freely when greasing. 13 Con Rod / Plunger Side 1 Grease 22 Hay Saver Wheel 1 Grease 25 Torque Shaft Bearing 1 Grease Housing 35 Bullgears 2 see Bullgear Luber in Settings and Adjustments Freeman bullgear grease, F only.

97 11-6 LUBRICATION AND MAINTENANCE ITEM ITEM DESCRIPTION POINTS DESCRIPTION APPROVED MATERIAL Every 10 Hours *Engine, See Engine Manufacturer's Operator's Manual Check for loose bolts all Check Needle Timing Look in Knotter Section Check Knife Adjustments 2 Plunger Knife / Stationary Knife Check Knife Sharpness 2 Plunger Knife / Stationary Knife 11 Engine* Coolant 1 Check level at overfl ow tank 12 Alternator 1 Clean debris off screen 14 Engine* Oil 1 Check oil level on dipstick 16 Engine* Air Pre-Cleaners 3 Check dust bowl, screen and dust valve (Clean if needed) 18 Hydrostatic Oil 1 Check level at tank sight tube 36 Knotter Shaft 1 Grease 37 Knotter Luber Tank 1 Check level at tank sight tube SAE 30 SE, SF, or CD motor oil Every 40 Hours or 10,000 bales *Engine, See Engine Manufacturer's Operator's Manual 3 Front Wheel Nuts 24 Tighten to 163 N m (120 lb-ft) 7 Caster Fork Pivot 2 Grease 13 Plunger 1 Check Plunger Knife for sharpness and Plunger Adjustment 15 Engine* Fuel Filter 1 Check for water and sediment 20 Cab Fresh Air Filter/Pre 2 Clean cleaner 27 Con Rod, Bullgear Side 1 Grease/Bullgear & Pinion Gear Adjustment 28 Knotter Trip Lever 1 Grease 29 Feed Arm Latch 1 Grease 30 Feed Arm Bearing Housing Grease 31 Side Plate Bearing 2 Grease 33 Feed Arm Yoke's 6 Grease 34 Saddle Lever 1 Grease 39 Stationary Knife 1 Check for sharpness and adjustment 40 Bullgear and Pinion Gears 3 Check for adjustment Sealed Bearings ALL Grease

98 11-7 LUBRICATION AND MAINTENANCE ITEM ITEM DESCRIPTION POINTS DESCRIPTION APPROVED MATERIAL Every 50 Hours or *Engine, See Engine Manufacturer's Operator's Manual 15,000 bales 3 Front Wheel Nuts 24 Tighten to 163 N m (120 lb-ft) 7 Caster Fork Pivot 2 Grease 15 Engine* Fuel Filter 1 Check for water and sediment. 20 Cab Fresh Air Filter/Pre 2 Clean cleaner 27 Con Rod, Bullgear Side 1 Grease 28 Knotter Trip Lever 1 Grease 29 Feed Arm Latch 1 Grease 30 Feed Arm Bearing Grease Housing 31 Side Plate Bearing 2 Grease 32 Pinion Shaft Bearings 1 Grease 33 Feed Arm Yoke's 6 Grease 34 Saddle Lever 1 Grease Every 100 Hours 3 Final Drives 2 Check oil level SAE 85W-140 API-GL5 8 Rear Wheel Hub 2 Check bearings, grease hub 21 Tires 3 Check pressure Front ( ) 2.07 Bars - 30 PSI Rear ( ) Bars- 28 PSI Every 200 Hours 4 Battery 1 Check Water Level 23 Cab Recirculating Filter 1 Clean Every 300 Hours Or Each Season *Engine, See Engine Manufacturer's Operator's Manual 14 Engine* Oil and Filter a 2 Replace oil and fi lter a If John Deere PLUS-50 oil is used along with a John Deere oil fi lter, the oil change interval may be extended by 100 hours. Every 400 Hours Or Each Season 19 Hydrostatic Filters 2 Replace Filter AH128449

99 11-8 LUBRICATION AND MAINTENANCE ITEM ITEM DESCRIPTION POINTS DESCRIPTION APPROVED MATERIAL Every 600 Hours Or *Engine, See Engine Manufacturer's Operator's Manual Each Season 11 Engine* Coolant 1 Check system and do coolant solution analysis. Add supplemental coolant additives as required. 15 Engine* Fuel Filter 1 Replace 15 Engine* Crank Case 1 Clean Vent Tube 16,17 Air Intake System 1 Check hoses and connections 38 Engine* Fan Belt 1 Check tensioner and belt wear Every 800 Hours Or Each Season 3 Final Drives 2 Replace oil SAE 85W-140 API-GL5 Each Season *Engine, See Engine Manufacturer's Operator's Manual Operator Presence Check Operator Presence Switch Switch 9 Oil Cooler A/C Condenser 1 Clean debris from fi ns 11 Radiator 1 Clean debris from fi ns 17 Engine* Air Filters 1 Replace 24 Seat Belts 2 Inspect seat belt components for excessive wear 25 Torque Shaft Bearing 1 Grease Housing 26 Steering Components 6 Grease 31 Side Plate Bearings 2 Grease Every 2000 Hours *Engine, See Engine Manufacturer's Operator's Manual 14 Engine* Valve Clearance Every 2000 Hours or Every Other Season 1 Check and adjust. (See your John Deere dealer.) *Engine, See Engine Manufacturer's Operator's Manual 11 Engine* Coolant 1 Pressure test, flush cooling system and replace coolant. 18 Hydrostatic 1 Replace oil. Clean fi ll cap and strainer. J20C HY-GARD a If John Deere COOL-GARD Pre diluted Coolant is used, the fl ushing interval may be extended to 3000 hours or 36 months, whichever comes fi rst.

100 11-9 FUSE CHART (ASC-SP & ASC-SP38-702) Figure 11-6 Fuse Chart

101 11-10 FUSE CHART (280S14-003) ROAD LIGHTS ROTATING WAND REEL SPEED (-) LOWER FLOODS (UPPER FLOODS) ( ) REEL SPEED (+) HEATER RUNNING POWER BLANK NEUTRAL START HEADER FLOAT LATCH TACH OUTPUT F18 10 AMP 15 AMP F22 20 AMP F21 10 AMP F20 10 AMP F19 10 AMP F8 30 AMP F6 10 AMP F11 15 AMP Figure 11-6 Fuse Chart

102 12-1 TROUBLE SHOOTING If you are experiencing problems with the twine knotter, or missing a knot on one twine or another, it is important to determine which twine is not tying prop er ly. The TOP twine is the twine that is being held in the knotter while the bale is being formed. The BOTTOM twine is the twine that the needle de liv ers to the knotter to tie the bale. When a miss tie occurs you must locate the problem twine and determine: 1. Is the knot missing in the TOP or BOTTOM twine? 2. Is the end of the untied twine frayed, or squared cut? 3. Is there any damage to the twine? Frayed along the length, frayed beyond the knot? 4. Is the twine long enough to wrap around the bale? 5. Are there any scraps longer than one inch in or around the knotter? 6. Is twine tangled in the knotter? In the majority of cases, the miss tie is caused external of the knotter frame. Some things to always check before condemning the knotter are: 1. Check twine delivery from the twine box. Twine boxes are correctly tied together and not obstructing free feeding. 2. Twine is properly routed to the needle. 3. Twine guides and/or needles have no sharp worn edges. 4. Twine tensioners are properly adjusted so that twine has approximately 4 pounds of pull, while the knotter is tying. 5. Check hay dogs for proper operation, and/or broken or missing springs. Hay dogs will wear and are very important. If unable to correct a twine fi nger miss tie, it is possible that the hay dogs have worn and are not properly holding the end of the bale. 6. Check bale weight/density. Too light of a bale may cause the knot to hang on the bill hook, and to heavy of bale can cause several different miss ties (see chart). 7. Are all the necessary components in proper adjustments? Remember, any time you replace or adjust a needle, the twine fi nger must be checked and prob a bly adjusted at the same time. 8. Next to the hay dogs, the twine fi ngers are important to keep in good operating condition. They cannot have excessive play in the pivot, and they must be free of any nicks or burrs that may damage the twine. Following are a few examples of failed knots with possible causes for, and possible rem e dies. Problem Possible Cause Possible Remedy Twine fi ngers did not pickup needle twine. Alternatively, did not fully load the bill Hook. Adjust twine fi ngers closer to the needle, adjust full travel, adjust needle to twine disc clearance. Check twine tension. Hay dogs not properly holding end of bale Check hay dog springs and free operation. Hay dogs worn replace. Figure 12-1 Knot In Top Twine Only

103 12-2 TROUBLE SHOOTING KNOTTER Problem Possible Cause Possible Remedy Extreme tension on twine around bill Hook during tying cycle causes twine to shear or pull apart. Loosen twine disc holder spring. Smooth off all rough edges on bill Hook. Figure 12-2 Twine Broken In Knot Dull twine knife. Replace twine knife or sharpen cutting edge. Figure 12-3 Twine Ends Frayed Worn or damaged bill hook tongue. Replace bill hook. Bale density to low. Increase bale density tension. Excessive twine holder pressure. Loosen twine holder spring. Figure 12-4 Knot Too Loose Improper adjustment of twine disc. Adjust, time twine disc. Insuffi cient tension on twine holder. Tighten twine holder spring. Dull or chipped knife. Replace twine knife, or sharpen cutting edge. Figure 12-5 Twine Ends Uneven Figure 12-6 No Knot In Either Twine Twine sheared in twine disc. Bill Hook not rotating. Bill Hook tongue fails to open. can also be a result of a bow knot that has come apart. Loosen twine holder or remove all sharp edges and burrs on twine holder and twine disc. Check for sheared roll pin in bill Hook pinion. Check for lost trigger roller, or cam face worn. Check twine fi nger travel.

104 12-3 TROUBLE SHOOTING KNOTTER Problem Possible Cause Possible Remedy Figure 12-7 Knot In Bottom (Needle) Twine Top twine over bale pulled out or sheared out of the twine holder. This twine will be too short to wrap around the bale. If the top twine is squared cut, it pulled out of twine holder. If it is ragged and drastically frayed, it sheared out of the twine disc or over bill Hook. Bill Hook is closing on top of twine. Tighten twine holder spring pressure. Decrease bale density tension. Decrease twine holder spring pressure. Decrease bale density tension. Move knife arm so grove in knife arm will hold twine over bill Hook tongue farther to the right. Adjust twine disc timing. Figure 12-8 Strands On One Twine Doubled Back Through Knot Figure Double Bow Knot Insuffi cient travel of knife arm past Bill Hook. Bill Hook roller cam pressure too loose. Twine fi nger full travel not going far enough, knot is being formed to far to the left on the bill Hook. Insuffi cient travel of knife arm past bill Hook. Move knife arm to obtain more travel past bill Hook. Check for wear on cam lobe. Tighten bill Hook roller cam springs. Check twine fi nger full travel adjustment. Move knife arm to obtain more travel past bill Hook. Check for wear on cam lobe. Figure Single Bow Knot Bill Hook roller cam pressure too loose. Tighten bill Hook roller cam springs As bill Hook rotates, twine is pinched between bill Hook and knife arm and twine is damaged below knot. Rough knife arm cuts twine. Bend knife arm so bill Hook turns freely. Make certain wiper ledge on knife arm contacts back side of bill Hook. Smooth rough edge in twine notch on knife arm, or replace knife arm. Figure Twine Cut Or Frayed Behind Knot Extreme high top twine tension. Reduce bale density tension, or check twine tensioners.

105 12-4 NOTES

106 13-1 TROUBLE SHOOTING ICM SYSTEM ICM - MESSAGES MESSAGE MEANING Requires attention as soon as possible. ICM may inhibit further machine operation to prevent damage. For information on machine setup.

107 13-2 WARNING / SYMPTOM CAUSE REMEDY Low Voltage Battery is below 9.0 V 10,000 Bale Service See Manual for complete maintenance schedule. The low battery voltage warning will display if any of the ICM modules are supplied with less than 9.0 V. The message screen will appear when the battery voltage to the MD3 module is less than 9.0 volts. The 10,000 Bale Service message will display when 10,000 bales have exited the baler. Individual module voltages may be viewed in the Main menu / Info / Modules. Low voltage could be caused by a poor charging system, weak battery, or faulty connection (If this Warning appears imediately upon start up see Note under Start Switch on page 1-27). See Every 40 Hours or 10,000 bales in the Lubrication and Maintenance section on page ,000 Bale Service The 15,000 Bale Service message will display when 15,000 bales have exited the baler. See Every 50 Hours or 15,000 bales in the Lubrication and Maintenance section on page See Manual for complete maintenance schedule. 4 Hour Service See Manual for complete maintenance schedule. The 4 Hour Service message will display every 4 hours baling operation. See Every 3 To 4 Hours in the Lubrication and Maintenance section on page Custom Timer Custom Timer Text. The custom timer will display when your custom time has elapsed. A Custom Timer can be made from Custom Timer Text and Custom Time screens. Access the Service Timers screen by pressing the Menu button, Press F1 "Adjust", select Service Timers and press OK Making a custom timer: 1. Select custom timer text and press OK. Use UP/DOWN and OK buttons to make your custom text. 2. Select custom time in the Service Timers Screen and press OK. Use UP/DOWN and OK buttons to make your custom text.