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Operator’s Manual 31

Relay Board

(Version Date 05/08/01)

Front Computer Relay Board

Input#

Red LEDs

Output#

Green LEDs

1 bale 0

1 kicker

2 vertical swing

2 vertical swing

3 vertical plunger

3 vertical plunger

4 horizontal plunger

4 horizontal plunger, (green wire for manuel)

5 bale1 & bale 3

5 strap guide motor down

6 bale2

6 strap guide motor up

7 kicker (black #5 wire)

7 back floor, (white wire for manuel)

8 reset banding (black #6 wire)

8 strap out

9 reset bundle (green wire)

9 counter

10 photo1

10 elevator

11 photo2 (black #3 wire)

11 safety valve

12 photo3 (black #4 wire)

12 clutch

Banding Box Computer Relay Board

Input#

Red LEDs

Output#

Green LEDs

1 OPEN

1 back gate

2 left fetcher out

2 mid band out

3 right fetcher out

3 mid band in

4 left fetcher in

4 full band in

5 right fetcher in

5 full band out

6 left band full

6 fetcher out

7 right band full

7 fetcher in

8

8 fetcher swing

9

9 bander raise, (blue wire for manuel)

10

10 bander lower, (yellow wire for manuel)

11

11

12

12

The above spreadsheet indicates the location of each input and output on the relay boards.
There are two computers/relay boards on the machine. One computer/relay board is located in
the Front Relay box on the front of the machine. The other computer/relay board is located in the
Band Relay box inside of the Banding box. The computer/relay boards and software are identical
and therefore are interchangeable.

Program Options:

There are two program options available on the machine. The 18 bales/bundle option is
intended for the 16 inches x 18 inches small square bales. This program will bundle together 18
bales. The 21 bales/bundle option is intended for the 14 inches x 18 inches small square bales.
This program will bundle together 21 bales. In order to switch programs, first unplug the main
power cord, move the jumper to the desired program option. Plug the main power cord back
together. The Tractor Display will then indicate which option has been activated as soon as
power has been applied.

RED LEDs

When a red LED is on this indicates that that specific input is on. For example, if red LED #7 is
on, then the Kicker read switch has a magnet in front of it. The Photo eye LEDs work a little
different. The red LED inputs# 10, 11, 12 will be on when NO bale is present, but the yellow
LED located on the Photo eye itself will be off. And when a bale IS present, the red LED (in the
box) will go off and the yellow LED on the Photo eye will come on.

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Содержание GFC 100

Страница 1: ...Operator s Manual GFC God Family Country 34273210th Ave Pittsfield IL62363 217 285 6487 gfc balebandit com Website http www balebandit com Version1 08...

Страница 2: ......

Страница 3: ...Operator s Manual GFC God Family Country 34273210th Ave Pittsfield IL62363 217 285 6487 gfc balebandit com Website http www balebandit com Version1 08...

Страница 4: ......

Страница 5: ...n 17 Reset Bundle Button 18 Lubrication and Maintenance 19 Break in Period 19 Daily Maintenance 8 hours 21 Weekly Maintenance 40 hours 22 Monthly Maintenance 250 hours 24 Yearly Maintenance 24 Hydraul...

Страница 6: ...00 psi 172 3 bar GPM 25 gpm 94 6 l m System closed center Filter Element Replacement high pressure element 6 micron Tractor Horse Power 90 hp Steel Strapping Size 02 in x 5 in 0 5 mm x 12 5 mm Strengt...

Страница 7: ...one year or 40 000 bales which ever comes first Buyer of unit provides performs service Phone support during GFC or Bale Band It Sales Rep office hours Towing the Bale Band It beyond its designed use...

Страница 8: ...Operator s Manual 3 Serial Number Location...

Страница 9: ...no one is near moving parts Safety Maintenance Precautions If at any time the Safety Light Horn located on the machine does not work properly it must be replaced immediately Do not operate the machine...

Страница 10: ...Operator s Manual 5 Safety Decals...

Страница 11: ...Operator s Manual 6 Safety Decals...

Страница 12: ...Operator s Manual 7 Safety Decals...

Страница 13: ...Operator s Manual 8...

Страница 14: ...o hydraulic hoses that are to be attached onto the baler These hydraulic hoses go from the tractor to the Bale Band It and must be 1 inch 25 4 mm ID hoses Anything less than 1 inch 25 4 mm ID will not...

Страница 15: ...rn line CANNOT be connected directly to the remote or ran through a return kit It must be connected directly to the tank of the tractor or through the fill cap WITHOUT restriction Mount hoses on baler...

Страница 16: ...s the end of the strap must come off of the top of the roll 2 Thread the strap between the 12 5 mm rod and the spring loaded strap guide attached to the banding drum brake arm The strap should be unde...

Страница 17: ...earing starting from the bottom of the bearing For easier threading bend an upward radius in the strapping This will allow the strapping to flow easily around the bearing 6 Thread the strapping inside...

Страница 18: ...round the bearing 10 Thread the strapping under the roller and in the channel of the Strap Guide Arms For easier threading straighten the strapping before threading under the roller This will allow th...

Страница 19: ...30 0 75 m of strapping from the Strap Guide Arm Finger 14 Remove safety clamp by loosening plastic knob Release the tension on the red handled clamp by pulling the handle back 15 Pull back on the spr...

Страница 20: ...to the inside of the machine Slightly tighten the plastic knob Do not over tighten Note The amount of tension on the red handled clamp can be adjusted by adjusting the bolt mounted in the end of the...

Страница 21: ...tion 3 a Horizontal plunger pushes the 3 bales in stacking chamber rearward into the main chamber b Back floor drops lowering the previously made bundle of 21 small square bales to the ground The bund...

Страница 22: ...square bale with the edge up into the Horizontal Plunger chamber the same direction as all the other bales y Close all side doors and properly fasten them y Hold down PLUNGER button until Horizontal P...

Страница 23: ...he elevator chamber and front chamber from the side doors before resetting the bundle This will allow the Strap Guide Arms to go up without trying to raise bales up with it Anytime the Reset Bundle ha...

Страница 24: ...erials are cleared daily Break in Period Wheels Lugs Torque 85 100 ft lb 115 24 135 58 N m After First 4 hours of operation Tighten lugs on wheels After First 8 hours of operation Tighten lugs on whee...

Страница 25: ...the locking upper nut Tighten the tightening lower nut and check the spacing between the chains until you reach the correct dimension After adjusted properly retighten the locking upper nut Repeat pro...

Страница 26: ...tive way to remove trash Clean the three photo eye sensors making sure all oil and grease is removed Fasteners Check for loose bolts and fasteners If bolt nut is loose or removed replace with Loctite...

Страница 27: ...a bale count of 1 4 7 10 13 16 or 19 Refer to Break in Period for complete procedure Horizontal Elevator Chain It is recommended to have a raised chain dimension between inch 1 inch 12 5 mm 25 0 mm R...

Страница 28: ...Operator s Manual 23 Lubrication Lubrication Location Time Frame hours of Zerts Back gates 40 4 Banders 40 8 Back floor 40 2...

Страница 29: ...ue to viscosity breakdown change hydraulic oil once a year Vertical Plunger gear rack clearance Check Gear and rack clearance needs to be between 0 020 inch 0 51 mm min 1 16 inch 1 6 mm max If gear an...

Страница 30: ...074 inch 1 88 mm Shim 1 M 0147 is 20 ga 0 0375 inch 0 95 mm These shims allow you to loosen the rack bolts and slide them in from the side How to put the vertical plunger in time if is out of time Put...

Страница 31: ...Operator s Manual 26 Hydraulic Manifold Layout Front Manifold...

Страница 32: ...Operator s Manual 27 Inside Banding Box Manifold...

Страница 33: ...Operator s Manual 28 Outside Banding Box Manifold...

Страница 34: ...Operator s Manual 29 Electrical Layout Front Relay Box located behind banding drums...

Страница 35: ...Operator s Manual 30 Band Relay Box located in Banding Box...

Страница 36: ...machine One computer relay board is located in the Front Relay box on the front of the machine The other computer relay board is located in the Band Relay box inside of the Banding box The computer re...

Страница 37: ...nergized State Vertical Swing Cylinder is Extended see Hydraulic Manifold Layout Amp Description Amp Description 2 Power to Inputs 12 terminals 7 5 Output 7 10 Main Power 7 5 Output 8 10 Main Power 7...

Страница 38: ...been put onto the machine the Reset Strapping button must be pressed in order for Bale Band It to keep an accurate Strapping count Busted Bale The Bale Band It can help notify the operator of a possib...

Страница 39: ...und in the following pages The following pages also give different scenarios to further help in any troubleshooting instances Before inspecting the machine turn off hydraulic power supply by disengagi...

Страница 40: ...chine is waiting for If the Kicker cylinder is fully extended Loosen nuts on Kicker reed switch and hold the switch away from any magnets or metal for approximately 10 seconds Check tractor box displa...

Страница 41: ...e suggested range then the reed switch needs to be replaced If the Kicker cylinder is partially extended Check that a bale or foreign object is not preventing the Kicker from extending Hydraulic power...

Страница 42: ...free up the stuck switch The switch may need to be replaced if this problem continues If the Horizontal Plunger cylinder is partially retracted Check that a bale or foreign object is not preventing t...

Страница 43: ...d engage hydraulic power 009 Waiting for Horizontal Plunger reed switch to be on Note After the machine has retracted the Horizontal Plunger cylinder the Horizontal Plunger reed switch should be lined...

Страница 44: ...it until the sensor bar switch is off before continuing the operation The switch is located at the top of the sensor bar at the white mark If Vertical Plunger Swing cylinder is retracted Check that hy...

Страница 45: ...h and the magnet The distance should be a maximum of 3 8 inch 9mm If it is within the suggested range then the sensor bar needs to be replaced If the Vertical Plunger Swing cylinder is partially retra...

Страница 46: ...the Strap Guide Arms not being in the proper position The return line CANNOT be connected directly to the remote or ran through a return kit It must be connected directly to the tank of the tractor or...

Страница 47: ...at return line is still connected Check that a bale or foreign object is not preventing the Strap Guide Arms from moving Check that the directional valve is not stuck 014 Waiting for Strap Guide Arms...

Страница 48: ...d This switch within the sensor bar is located approximately 23 inches 584 mm down from the bottom of the Vertical Plunger plate and will be marked with a blue colored pen Since the Strap Guide Arms a...

Страница 49: ...itch the machine stops the motor The machine is waiting for the magnet to reach the Bale Position 3 sensor bar switch The switch is located near the bottom of the sensor bar at the yellow mark Check p...

Страница 50: ...hes are wiring together Therefore placing the south pole of the magnet at Bale Position 1 green mark will trip the switch at Bale Position 3 Engage hydraulic power the machine should continue to opera...

Страница 51: ...ber by opening the side doors Once the bales are out press the Reset Bundle button 017 Waiting for Vertical Plunger Down sensor bar switch to be on Note After the machine has retracted the Vertical Pl...

Страница 52: ...Operator s Manual 47 If the Vertical Plunger cylinder is fully retracted...

Страница 53: ...ot stuck 018 Waiting for Kicker reed switch to be off Note Before the machine retracts the Kicker cylinder the Kicker reed switch is in front of the first magnet mounted in the round plastic When the...

Страница 54: ...Check that the directional valve is not stuck 019 Waiting for Horizontal Plunger reed switch to be off Note Before the machine extends the Horizontal Plunger cylinder the Horizontal Plunger reed switc...

Страница 55: ...is still retracted Check that hydraulic power is still on to the machine and that return line is still connected Check that a bale or foreign object is not preventing the Horizontal Plunger from exte...

Страница 56: ...k that a bale or foreign object is not preventing the Horizontal Plunger cylinder from extending Check that the directional valve is not stuck 022 Vertical Plunger Up sensor bar switch is stuck on Not...

Страница 57: ...m of 3 8 inch 9 mm If it is within the suggested range then the sensor bar needs to be replaced If the Vertical Plunger cylinder is partially extended Check that a bale or foreign object is not preven...

Страница 58: ...unplug the two 10 amp fuses Reconnect main electrical power only Wait approximately 10 seconds and then reinstall the two 10 amp fuses at the same time Recheck number on Line 3 after the dash it shoul...

Страница 59: ...th each other They should be the same height If their heights vary inch 12 5 mm or greater then they are at least one gear tooth out of time A quick way to check their heights is to compare the distan...

Страница 60: ...is waiting for the magnet to reach the Bale Position 0 sensor bar The switch is located upper mid way of the sensor bar at the brown mark Check that Strap Guide Arms are in time with each other They s...

Страница 61: ...out of time keep their chains tight Check that hydraulic power is still on to the machine and that return line is still connected Check that a bale excess hay or foreign object is not preventing the...

Страница 62: ...Guide Arms motor and sent them up When the Strap Guide Arms magnet reaches the Bale Position 0 sensor bar switch the machine stops the motor The machine is waiting for the magnet to reach the Bale Pos...

Страница 63: ...the switch to free up the stuck switch The switch may need to be replaced if this problem continues If the Vertical Plunger Swing cylinder is partially extended Check that a bale or foreign object is...

Страница 64: ...agnet The distance should be a maximum of 3 8 inch 9 mm If it is within the suggested range then the sensor bar needs to be replaced If the Vertical Plunger Swing cylinder is partially retracted Check...

Страница 65: ...If it is it will wait until the reed switch is off before continuing the operation Loosen nuts on Left Band Full reed switch and hold the switch away from any magnets or metal for approximately 10 se...

Страница 66: ...gage hydraulic power and unplug main power cord Wait for approximately 10 seconds plug back in and engage hydraulic power On Line 3 of Display Monitor if the number after the dash is 0 then disconnect...

Страница 67: ...r approximately 10 seconds Check tractor box display to see if it is still displays 040 If it does lightly tap the switch on something to free up the stuck switch The switch may need to be replaced if...

Страница 68: ...ximately 10 seconds plug back in and engage hydraulic power On Line 3 of Display Monitor if the number after the dash is 0 then disconnect main electrical and hydraulic power Open the plastic computer...

Страница 69: ...ve in and it spring back then the check valve needs to be replaced If the Left Fetcher cylinder is still retracted Check that hydraulic power is still on to the machine and that return line is still c...

Страница 70: ...aulic power or hydraulic return has been disconnected or shut off from machine Remove and observe the Fetcher check valve If the snap ring in the bottom of the check valve is missing then the check va...

Страница 71: ...for approximately 10 seconds plug back in and engage hydraulic power On Line 3 of Display Monitor if the number after the dash is 0 then disconnect main electrical and hydraulic power Open the plastic...

Страница 72: ...e Strap Guide Arms are in time with each other They should be the same height If their heights vary inch 12 5 mm or greater then they are at least one gear tooth out of time A quick way to check their...

Страница 73: ...r to prevent the Strap Guide arms from getting out of time keep their chains tight Electric power or hydraulic power or hydraulic return has been disconnected or shut off from machine If the Right Fet...

Страница 74: ...their heights vary inch 12 5 mm or greater then they are at least one gear tooth out of time A quick way to check their heights is to compare the distance between the Vertical Plunger plates to the St...

Страница 75: ...of time keep their chains tight Electric power or hydraulic power or hydraulic return has been disconnected or shut off from machine If the Right Fetcher Swing cylinder is still extended Check that hy...

Страница 76: ...Right Fetcher In reed switch It checks to see if the reed switch is stuck on If it is it will wait until the reed switch is off before continuing the operation Loosen nuts on Right Fetcher In reed sw...

Страница 77: ...um of 1 8 inch 3 mm If it is within the suggested range then the reed switch needs to be replaced If the Left Fetcher cylinder is partially retracted Check that a foreign object is not preventing the...

Страница 78: ...e Right Fetcher cylinder is fully retracted Check the air gap distance between the Right Fetcher In reed switch and the magnet The distance should be a maximum of 1 8 inch 3 mm If it is within the sug...

Страница 79: ...r is still extended Check that hydraulic power is still on to the machine and that return line is still connected Check that a foreign object is not preventing the Right Fetcher cylinder from retracti...

Страница 80: ...amp fuses at the same time Recheck number on Line 3 after the dash it should then be 1 Apply hydraulics 063 Communication from Band Computer Disengage hydraulic power and unplug main power cord Wait f...

Страница 81: ...he machine and that return line is still connected Check that a foreign object is not preventing the Left Band Full cylinder from extending Remove and observe all 4 Band Position check valves If the s...

Страница 82: ...the snap ring in the bottom of the check valve is missing then the check valve needs to be replaced If you are unable to push the plunger from the end of the check valve in and it spring back then th...

Страница 83: ...gn object is not preventing the Left Bander cylinder from retracting Electric power or hydraulic power or hydraulic return has been disconnected or shut off from machine If the Left Bander cylinder is...

Страница 84: ...main power cord Wait for approximately 10 seconds plug back in and engage hydraulic power 071 Communication from Band Computer Disengage hydraulic power and unplug main power cord Wait for approximate...

Страница 85: ...l valve is not stuck 073 Waiting for Right Band Out reed switch to be on Note After the machine has raised the Right Left Bander cylinders the Right Band Out reed switch should be lined up with the Ri...

Страница 86: ...approximately 10 seconds and then reinstall the two 10 amp fuses at the same time Recheck number on Line 3 after the dash it should then be 1 Apply hydraulics 076 Communication from Band Computer Dise...

Страница 87: ...er only Wait approximately 10 seconds and then reinstall the two 10 amp fuses at the same time Recheck number on Line 3 after the dash it should then be 1 Apply hydraulics 081 Communication from Band...

Страница 88: ...cylinder is partially extended Check that a foreign object is not preventing the Left Fetcher cylinder from extending Electric power or hydraulic power or hydraulic return has been disconnected or sh...

Страница 89: ...cylinder from extending Electric power or hydraulic power or hydraulic return has been disconnected or shut off from machine Remove and observe the Fetcher check valve If the snap ring in the bottom o...

Страница 90: ...t The distance should be a maximum of 1 8 inch 3 mm If it is within the suggested range then the reed switch needs to be replaced If the Left Fetcher cylinder is partially retracted Check that a forei...

Страница 91: ...etracting Electric power or hydraulic power or hydraulic return has been disconnected or shut off from machine Remove and observe the Fetcher check valve If the snap ring in the bottom of the check va...

Страница 92: ...of 3 8 inch 9 mm If it is within the suggested range then the reed switch needs to be replaced If the Kicker cylinder is partially retracted Check that a bale or foreign object is not preventing the...

Страница 93: ...h 9 mm If it is within the suggested range then the reed switch needs to be replaced If the Horizontal Plunger cylinder is partially extended Check that a bale or foreign object is not preventing the...

Страница 94: ...magnet reaches the Bale Position 0 sensor bar switch the machine stops the motor The machine is waiting for the magnet to reach the Bale Position 0 sensor bar switch The switch is located upper mid w...

Страница 95: ...n the plastic computer box in the banding box and unplug the two 10 amp fuses Reconnect main electrical power only Wait approximately 10 seconds and then reinstall the two 10 amp fuses at the same tim...

Страница 96: ...r 095 Bale Position 1 sensor bar switch stuck on Note Before the machine will lower the Strap Guide Arms it does a safety check on the Bale Position 1 sensor bar switch It checks to see if the sensor...

Страница 97: ...the blue mark Tap on Bale Position 2 sensor bar switch until display number changes or replace the sensor bar 097 Bale Position 3 sensor bar switch stuck on Note Before the machine will lower the Stra...

Страница 98: ...2 rolls of strapping In order for the machine to continue operating the Reset Banding button needs to be pressed which is located in the Banding box By pressing the Reset Banding button the computer...

Страница 99: ...r will both be running but nothing needs to be done to fix this As soon as the next bale enters the machine it will clear out the false reading at Photo 1 This will not affect the bale count in any wa...

Страница 100: ...rtical elevator will be off Things that could cause a false trip A lens that was at one time wet with dew or hydraulic oil and collected dust A piece of chaff being continuously in front of the lens 4...

Страница 101: ...t the elevator motor Adjust the stop on the pressure plate to give more distance from pressure plate to elevator chain If elevator chain is tearing through the bale Tighten the spring tension on the p...

Страница 102: ...Display Monitor if the number after the dash is 0 then disconnect main electrical and hydraulic power Open the plastic computer box in the banding box and unplug the two 10 amp fuses Reconnect main e...

Страница 103: ...ect alignment Bale Band It begins to operate slowly y Check hydraulic supply level and temperature y Check that hydraulic pressure line hose is connected to primary remote on tractor y Check that hydr...

Страница 104: ...witches on the Horizontal Plunger need to have an air gap of 3 8 9 mm Read switches on the Kicker and all Banding box switches need an air gap of 1 8 3 mm Display indicates that a photo eye is not on...

Страница 105: ...ng Clean Area 1 Clean Area 1 Clean Area 1 Clean Area 3 Clean Area 2 There is hay obstruction that is not allowing banders to go full stroke Area s are indicated that must be cleaned daily Most people...

Страница 106: ...ends of the failed strapping and refer to the possible options below Problem 2 Seal not centered on strapping Possible Cause Obstruction in groove Correction Take two 10 24 X 1 2 counter sunk bolts o...

Страница 107: ...extends Option 3 Check to see if knurled weldment is bent Overview There are three things that must happen before the fetchers can hold the strapping 1 There must be adequate force applied to knurled...

Страница 108: ...g down when fetchers are retracting Correction Option 1 Lubricate and remove any excess paint at pivoit bushing Lubricate and remove any excess paint at the surface contact between the knurled weldmen...

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