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Section 7 - Troubleshooting

7.0

TROUBLESHOOTING

Symptom

Problem

Solution

Bale lifting problems

Forks do not raise

Check hydraulic
connections and lines

Bale tips off back of forks

Narrow forks for a better lift
on bale

Bale hung up on forks - not
going into the tub

Cycle feed rollers left to right
to pull bale into tub

Plugging in discharge area

Snow and ice on bales
causes blockage in tub

Have flail drum rotating
while loading bale to clear
out discharge area

Trying to “lift” thrown
material too much

Reduce the lower discharge
door height

Material builds up on one
side of bale in tub

Bale unwrapping in tub

Reverse direction of feed
rollers to consume material
buildup

Difficult to rotate bale in tub

Feed rollers not fully
engaging bale

Increase aggression of flails
to help rotate bale

Roll bale into the direction of
the discharge area

Bale on forks contacting
bale in tub

Lower the bale on the forks

Bale Not Rotating

Feed rollers not engaged

Slowly engage the feed
rollers to get the bale
rotating

Grooves cutting into bale

Slowly engage the feed
rollers. Slow down the
rotating speed of the rollers

PTO and flail drum not
turning

Flail drum lock engaged

Disengage drum lock

Driveline shear bolt

Replace shear bolt on drive
line

Page 7-1

Содержание Bale Pro CFR650

Страница 1: ...O p e r a t o r s M a n u a l E9813V1 Bale Pro Complete Feed Ration CFR650 ...

Страница 2: ...Manufacturing Ltd All rights reserved The content of this manual was based on the most current information available as of the date of copyright It is the policy of Highline Manufacturing Limited to improve and develop our products continually We reserve the right to make changes or add improvements at any time without incurring any obligation to make changes or improvements on machines previously...

Страница 3: ...ration of your Complete Feed Ration 650 CFR 650 In the manual you will find safety procedures maintenance routines and detailed operational instructions If you find that you require information not covered in this manual please feel free to consult your local dealer Your dealer is always able to contact Highline for this technical information HighlineManufacturing Ltd thanksandcongratulates you fo...

Страница 4: ...the lower discharge deflector 3 Adjust the bale loader forks for the width of bale 4 Inspect all hydraulic motors cylinders and hoses 5 Inspect the wheels and tires 5 Check that the axle u bolts are tight 6 Remove twine built up around axle spindle and hub 6 Ensure the driveline shields are lowered 6 Remove the flail drum lock 7 Remove the fork lock from the hydraulic cylinder 7 Remove lock pin on...

Страница 5: ...d 2 Raise the discharge deflector door 2 Install the discharge deflector door transport lock 2 Place the jack onto the hitch 3 Remove the driveline from the tractor PTO shaft 3 Disconnect the safety chain from the tractor 3 Disconnect the hitch from the tractor 3 Disconnect hydraulic hoses 3 Disconnect the electrical connection 3 Secure the hydraulic hoses and electrical connector 4 Change the oil...

Страница 6: ...processed material to be laid down into a feed bunk or spread to different distances The Complete Feed Ration 650 has an option of adding a Feed Chopper for additional processing of the feed materials There is also the option of adding a Grain Tank to add feed grains in a measured amount to the feed mix to achieve the feed ration needed for the animals The operator of the CFR 650 is located in the...

Страница 7: ...This Page Left Blank ...

Страница 8: ... 1 attached to the Complete Feed Ration 650 on the top left hand side of the front tub wall It is important to record the serial number for proof of ownership and for any service or maintenance assistance Serial Number Owner Model Date of Purchase Serial Plate Location 215068C Page 1 1 ...

Страница 9: ... Safety Operating and Maintenance information presented in this manual Do not operate or allow someone to operate this equipment until this information has been reviewed This information should be reviewed by all operators before the season start up This sign off sheet is provided for record keeping to indicate that the person working with the equipment has read and understood the information in t...

Страница 10: ...tuation that if not avoided WILL result in DEATH OR SERIOUS INJURY The color is Red with White lettering Indicates a potentially hazardous situation that if not avoided COULD result in DEATH OR SERIOUS INJURY and includes hazards that are exposed when guards are removed or unsafe practices The color is Orange with Black lettering Indicates a potentially hazardous situation that if not avoided MAY ...

Страница 11: ...ss concern prudence and proper training of personnel involved in the operation transport maintenance and storage of the machine 3 The CFR 650 shall not be operated without all the guards in place SAFETY DECALS 1 Keep decals and signs clean and legible at all times 2 Replace decals and signs that are damaged missing or have become illegible 3 Replaced parts that displayed a decal should also displa...

Страница 12: ...area and processor tub when the flail drum is rotating Always disengage power takeoff set park brake lower loader forks to the ground shut off tractor engine remove key and wait for PTO to stop turning before unplugging by hand or servicing Stay out of the processor tub when the PTO is connected to the tractor Keep guards in place and in good condition DO NOT ENTER TUB WHILE PARTS ARE ROTATING Wit...

Страница 13: ...al or objects leaving the discharge area can cause serious injury or death Do not operate within 100 ft 30m of any person Keep all shields and guards in place ENSURE SLOW MOVING VEHICLE SIGN IS IN PLACE Ensure the Slow Moving Vehicle sign is in place clean and easily visible Ensure the reflectors are in place clean and easily visible DO NOT RIDE ON MACHINE Falling from the moving machine can cause...

Страница 14: ...ls attached to the machine could result in serious injury or death Keep all safety and instruction decals in good condition Replace any missing or damaged decals SHUT DOWN THE TRACTOR BEFORE DISMOUNTING TRACTOR Shut down the tractor and remove the key before repairing servicing lubricating or cleaning the machine Relieve all hydraulic pressure in the hoses before going near the machine Leave the h...

Страница 15: ...ood or cardboard instead of hands Keep all components in good repair IMPLEMENT IS DESIGNED FOR OFF ROAD USE ONLY Do not transport with bales in the processor tub Do not transport with a bale loaded on the forks DO NOT EXCEED PTO SPEED Do not operate at excess speeds or damage to the machine may result DO NOT EXCEED 80F TURNS IN OPERATION Do not operate the Constant Velocity CV driveline at greater...

Страница 16: ...rame if the u bolts are loose Tighten u bolts after first 5 hours of use and then annually Do not extend the axles further than 14 SHUTDOWN PROCEDURE For your safety and the safety of others this shutdown procedure must be followed before dismounting from the tractor for inspecting repairing servicing cleaning or lubricating the machine Step 1 Reduce the engine speed to idle Step 2 Disengage tract...

Страница 17: ...Section 1 Safety 650DecalIso2 SAFETY DECAL LOCATIONS Page 1 10 ...

Страница 18: ...ransport on public roads with a bale loaded on the forks Check with local traffic regulations to transport on public roads Stay away from overhead power lines when transporting equipment Electrocution can occur without contacting power lines Do not allow any person to ride on the tractor or CFR 650 Falling off can result in serious injury or death Keep the Axle U Bolts Tight Injury could result if...

Страница 19: ...t attempt to operate the CFR 650 at a different PTO speed Note Do not use PTO adapters PTO adapters will cause a driveline failure and possible tractor damage Your CFR 650 warranty will also be invalid 3 Adjust the tractor drawbar length Set the drawbar length to 16 406 mm for a 1 3 8 21 spline PTO This length is measured from the tip of the PTO shaft end to the center of the drawbar hole Refer to...

Страница 20: ...with the jack 1 The hitch is heavy Do not attempt to lift it without using the jack 5 Connect the hitch to the tractor clevis drawbar Use a 1 25 mm pin Secure with a hitch pin clip Lift Hitch with the Jack 201192 Connect Hitch to Tractor Clevis Drawbar 201193 Page 2 3 ...

Страница 21: ...han the gross weight of the CFR 650 Route the safety chain around the lower safety chain bolt 1 Attach the chain to a secure location on the tractor Fasten the chain hook with the hook lock 2 7 Route the hydraulic hoses and wiring harness through the hose support arm Connect Safety Chain 201194C Hoses and Electrical in Support Arm 211217 Page 2 4 ...

Страница 22: ...opes easily and that the shields are in good condition and rotate freely Lift the tractor PTO shield Support the driveline pull back on the yoke collar align the splines by rotating the CFR 650 driveline and push the driveline into the tractor PTO shaft until the collar snaps into place Push and pull the yoke several times to ensure the driveline is locked Do not pull on the collar as this will re...

Страница 23: ... user preference Route the hoses so they do not interfere with moving parts 10 Connect the lights Connect the light plug into the appropriate tractor receptacle Ensure the light cable does not interfere with or contact moving parts 11 Place the hitch jack in the storage location Attach Hydraulics and Electrical 108008 Hitch Jack in Storage Location 201200 Page 2 6 ...

Страница 24: ... bolts 1 that hold the axle tubes in place Slide the axle to achieve the desired wheel stance setting Note Maximum axle extension is 14 355 mm Axles may bend if extended beyond this amount Tighten the u bolts 1 that hold the axle tubes in place to 250 lb ft 339 Nm 13 Check the condition of the tires Ensure that the lug nuts have the cone side of the lug nut against the wheel rim Torque the lug nut...

Страница 25: ...er may be linked to the feed roller hydraulic circuit through an optional electric solenoid Place the rubber panel into the tabs 1 and fasten with a washer and nut 2 to prevent the wind from blowing the rubber panel from the tabs during transport 17 Install the discharge deflector door transport lock Rotate the short link 1 toward the cylinder Join the flats by inserting the pin of the short flat ...

Страница 26: ...le SMV sign is clean and visible 19 Transport Do not transport on public roads with bales in the processor tub Do not transport on public roads with a bale loaded on the forks Do not transport on public roads with the forks in the lowered position 20 Transport Speed Do not exceed 25 mph 40 km h Page 2 9 ...

Страница 27: ...Section 2 Transporting the CFR 650 This Page Left Blank Page 2 10 ...

Страница 28: ...sign is clean and visible 4 Check the condition of the flail drum Shut down the tractor completely and set the parking brake Disconnect the PTO from the tractor before doing any work near the flail drum Do not place hands in the CFR 650 when it is rotating Contact with exposed rotating flails will cause serious injury or death 5 Clean debris and material buildup from the flail drum area and the pr...

Страница 29: ...on Replace the flails in pairs Replace on opposite sides of the drum to maintain drum balance Check the condition of the flail mounting bolts Ensure the mounting bolts are tight 7 Remove twine netwrap or other materials wrapped around the flail drum or drum bearings Note Remove the netwrap or twine from the flail drum every 25 bales Premature bearing failure can occur if twine is allowed to build ...

Страница 30: ... Fasten the tongue in place and torque the bolts to 210 ft lbs 285 Nm 9 Set the level of the lower discharge deflector To adjust the bottom deflector stand in front of the machine pull the lower handle and raise or lower the door as required To increase the height of discharge raise the door to the one of the upper slots To lessen the height discharge position the door to one of the lower slots Ad...

Страница 31: ...u bolts against the brace 1 For bales 5 feet 1 5 m in diameter Place both fork outer u bolts against the inside of the brace 2 For bales 4 feet 1 2 m in diameter Place both outer u bolts 3 6 152 mm from the edge of the vertical frame post Fork Width 6 Foot 1 8m Bales 201209C Fork Width 4 Foot 1 2m Bales 201211C Fork Width 5 Foot 1 5m Bales 201210C Page 3 4 ...

Страница 32: ...sure on the hydraulic system before repairing adjusting or disconnecting Visually inspect all the hydraulic hoses and fittings See Section 5 Maintaining the CFR 650 for conditions indicating that replacement is needed Ensure the proper size cylinder pins are in place and secured 12 Inspect the wheels and tires for damage or foreign objects Repair or replace as necessary Check All Hydraulics 214086...

Страница 33: ...indle plate 14 Remove any twine that is built up around the axle spindle and hub Be careful to not damage the bearing grease seal while removing twine 15 Ensure the driveline shields are lowered into place and are in good repair to prevent injuries The CFR 650 shall not be operated without the driveline shields in place Remove Twine from the Spindle and Hub 212021 Check That Axle U bolts Are Tight...

Страница 34: ...7 Remove the fork lock from the hydraulic cylinder and store on the storage tab Note The forks may need to be raised with the hydraulics to remove the weight from the lock 18 Remove the lock pin on the discharge deflector door to allow the door to be operated by the hydraulic cylinder Note The cylinder may need to be moved with the hydraulics to remove the weight from the lock Remove the Flail Dru...

Страница 35: ... deflector is going to be used in processing material remove the rubber panel from the tabs 1 on the deflector door 21 Lubricate all grease fittings and check the fluid level in all gear boxes See the Maintenance Section 22 Ensure all fasteners are tightened Remove Rubber Panel Fasteners 201198C Page 3 8 ...

Страница 36: ...down the tractor completely and set the parking brake Disconnect the PTO from the tractor before doing any work near the flail drum Do not place hands in the CFR 650 when it is rotating Contact with exposed rotating flails will cause serious injury or death 1 Raise the forks to fully raised position 2 Install the cylinder locks onto the fork cylinders Install and secure the cylinder locks before g...

Страница 37: ... the flail drum lock Turn the lock pin to release the roll pin from the slot Allow the spring to push the lock pin into the processing chamber Manually rotate the driveline until the lock pin snaps into place locking the flail drum 6 Move flails blocking the knife path Failure to do so will result in damage to the twine cutter blade Move Flail Guard Rod Lever to less than 5 214087 2 Engage Flail D...

Страница 38: ...cutter into the guide at the back of the processor tub 9 Cut through the netwrap or twine Use a saw like action along the entire length of the drum 10 Place the twine cutter back into the storage position Ensure the handle is facing down and is locked into the key hole slot Remove Twine Cutter from Storage Position 201231 Insert Twine Cutter with Blade Up 201232 Replace Twine Cutter Into Storage P...

Страница 39: ...e to lock in the disengaged position Failure to unlock the flail drum will result in damage to the machine during start up 12 Remove the cut netwrap or twine from the flail drum 13 Remove the fork lock from the hydraulic cylinder and place in the storage location Remove the Flail Drum Lock 201213 Remove Netwrap Twine 214083 Remove Fork Lock 201228 Page 3 12 ...

Страница 40: ... flail drum will cause serious injury or death Note Use caution if entering the tub with a bale in it even after all rotation has stopped The bale is unstable Stay back from an operating machine which can discharge objects several feet Thrown material or objects leaving the discharge area can cause serious injury or death Do not operate within 100 ft 30m of any person 1 Unlock the flail drum 1 Pul...

Страница 41: ... rod setting There are five guard rod settings Pull the upper handle out of the handle lock Raise or lower the handle to the desired discharge setting Lock the handle in the notch To Increase the discharge rate Raise the handle to a higher number To Decrease the discharge rate Lower the handle to a lower number If the Hydraulic Aggression Control Option is installed Activate the hydraulic cylinder...

Страница 42: ... a slower discharge of material 3 Set the upper deflector door Raise or lower the upper deflector door to adjust the amount of spreading of material Use the hydraulic cylinder to adjust the door Lowered the material will be left in a windrow or directed into a feed bunk Allow the rubber deflector to hang down Midway deflector door will control the height and distance of discharged material Place t...

Страница 43: ...er of the processor Lower the forks completely Slowly back up to the bale until the forks are completely under the bale Raise the forks enough to lift the bale off the ground Note If a bale is frozen to the ground dislodge it by rocking the machine to impact the bale and loosen it Note Ensure flail drum and feed rollers are not turning while loading a bale Raise the lift forks until the bale falls...

Страница 44: ...n the hydraulic lift assembly 7 Start the PTO to engage the flail drum Stay clear from discharge side when PTO is engaged Do not operate within 100 ft 30m of any person Discharged material or objects leaving the discharge area can cause serious injury or death The CFR 650 shall not be operated without the guards in place or in good condition Engage the tractor PTO at an idle Increase the tractor R...

Страница 45: ...tes excessively immediately disengage PTO and stop the tractor Wait for all flail drum rotation to stop before approaching the processor Inspect for blockages missing flails or other causes of the vibration 9 Adjust the direction of bale rotation Rotate the bale with the feed rollers so that the top of the bale moves toward the discharge side of the processor If material begins to bunch up near th...

Страница 46: ... discharged Lower Number less material discharged 11 Re adjust the level of the lower discharge deflector if needed To increase the discharge height raise the door to the one of the upper slots Pull the lower handle and raise or lower the door as required 12 Stop the feed rollers before loading another bale into the processor Re Adjust Discharge Rate Lever If needed 214087 2 Re Adjust Lower Deflec...

Страница 47: ...y pushing the PTO into the tractor or into the drivebox on the hitch arm or downward onto the PTO shaft breaking it off 14 Making turns Do not make turns sharper than 80 Angles greater than 80 can result in damage to the constant velocity joint and other driveline components Ensure that the tractor tire does not contact the CFR 650 deck or tongue Cross Ditch at 30 Angle 107072 Driveline Collapsed ...

Страница 48: ...g the N L G I 2 specifications and containing no more than 1 molybdenum disulfide Every 8 Hours PTO Lubricate 5 points on the PTO every 8 hours 1 point each constant velocity joint Continued angled operation will require lubrication every 4 hours 1 point on each joint collar 1 point at the telescoping section Every 50 Hours Lubricate 1 point on the rear flail drum bearing at the back of the machin...

Страница 49: ...ings Leaks at fitting or in hose Kinked crushed flattened or twisted hose Blistered soft degraded or loose cover Check the Fluid Level in the Gearbox Check the oil fluid level by removing the oil level plug 1 in the center of the gearbox The oil should be at the level of the plug If oil needs to be added add through the plug 2 on the top of the gearbox Use gear oil Grade 80W90 that meets or exceed...

Страница 50: ...CFR 650 before any work is done to prevent the CFR 650 from moving during servicing 1 Drain the oil from the gearbox Remove the drain plug on the bottom of the gearbox Allow the oil to drain completely from the gearbox Catch the oil in a container 2 Replace the drain plug and tighten 3 Fill the Gearbox Remove the top fill plug 2 Fill with 300 ml of 80W90 gear oil that meets or exceeds API service ...

Страница 51: ...the oil level in the gearbox Removing the oil level plug 1 in the center of the gearbox The oil should be at the level of the plug If oil needs to be added add through the plug on the top of the gearbox Check Gearbox Oil Level 201225C Page 5 4 ...

Страница 52: ...e the nut 4 and bolt 5 that holds the flail 3 to the drum 1 2 Remove the pipe 2 inside the flail This pipe will be used again 3 Remove the flail that is on the opposite side of the flail drum Note To maintain rotary balance the flail on the opposite side of the drum must be replaced at the same time 4 Install the 2 new flails with the pipe bolt and nut between the tabs on the drum Ensure that the ...

Страница 53: ...ire Pressure Fill the tires to 24 psi 165 Kpa Transport speed for should not exceed 25 mph 40 kmh When replacing the tires refer to the Specification Section for the size and type of tires Axles Check That the Axle U bolts are Tight Torque the axle u bolts 1 to 250 lb ft 339 Nm to ensure the axles do not slide out of the frame Maximum axle extension is 14 355 mm from the main tube edge to the insi...

Страница 54: ...taining the CFR 650 Remove any twine that is built up around the axle spindle and hub Be careful to not damage the grease seal on the bearing while removing twine Remove Twine From the Spindle and Hub 212021 Page 5 7 ...

Страница 55: ...Section 5 Maintaining the CFR 650 This Page Left Blank Page 5 8 ...

Страница 56: ...R 650 on level ground 3 Lubricate all CFR 650 grease points See Section 5 4 Tighten all bolts to the recommended torque 5 Check the CFR 650 for worn and damaged parts Replace as needed 6 Touch up the paint to prevent rusting 7 Lock the CFR 650 flail drum Lock the Flail Drum 201233 Clean Debris from the CFR 650 201203 2 Page 6 1 ...

Страница 57: ... is used to divert hydraulic flow from the feed roller hydraulic circuit switch to provide hydraulic to the door cylinder Place the rubber into the tabs and fasten with the bolts 10 Install the discharge deflector door transport lock Rotate the short link of the transport lock toward the clevis end of the cylinder Install the hair pin Install Deflector Door Transport Lock 201201 Raise Deflector Do...

Страница 58: ...sting on solid level ground or resting on a wood block Raise the hitch until the weight is supported by the jack 12 Remove the driveline from the tractor PTO shaft 13 Disconnect the safety chain from the tractor if present 14 Disconnect the hitch from the tractor Remove the hitch pin Jack on Hitch Raise Hitch 201192 Remove Driveline and Safety Chain 201194 Page 6 3 ...

Страница 59: ...ction 17 Secure the hydraulic hoses and electrical connector to the hose holder on the hitch to keep them off the ground and clean 18 Change the oil in the gearbox See the Maintenance Section for procedures Fill the gearbox to the oil level as outlined in the Maintenance Section Disconnect Hydraulic Hoses Electrical 108008 Page 6 4 ...

Страница 60: ...charge door height Material builds up on one side of bale in tub Bale unwrapping in tub Reverse direction of feed rollers to consume material buildup Difficult to rotate bale in tub Feed rollers not fully engaging bale Increase aggression of flails to help rotate bale Roll bale into the direction of the discharge area Bale on forks contacting bale in tub Lower the bale on the forks Bale Not Rotati...

Страница 61: ... fluid passes through the solenoid valve Not able to get sufficient throw distance Discharge door at bottom is not raised Raise the lower discharge door Throw with the direction of wind Upper deflector door preventing lift of material Raise upper deflector door Upper deflector door not operating Hydraulic cylinder Check hydraulic connections Check electric solenoid if present Discharge door transp...

Страница 62: ...Height Forks Up 126 1 2 3213 mm Lifting Bale 154 1 2 3924 mm With Top GunTM 131 1 4 3334 mm Weight Base CFR Weight 4496 lbs 2039 kg Tongue weight Unloaded 1440 lbs 653 kg CFR With Feed ChopperTM Weight 5296 Lbs 2402 kg Tongue weight Unloaded 1720 lbs 780 kg CFR With MGITM Weight 5206 Lbs 2361 kg Tongue weight Unloaded 1717 lbs 779 kg CFR With Feed ChopperTM and MGITM 6006 Lbs 2724 kg Tongue weight...

Страница 63: ...m Recommended Base CFR 85 63kW 100 75kW CFR With Feed ChopperTM 125 93kW 140 104kW CFR With MGISTM 100 75kW 125 93kW CFR With Feed ChopperTM and MGISTM 125 93kW 140 104kW CFR with Top GunTM 125 93 kw 160 119 kW Tires 16 5LX 16 1 ANS Inflate to 24 psi Gearbox Oil Capacity 300 ml Page 8 2 ...

Страница 64: ...T APPLY TO 1 Any defect which was caused in Highline s sole judgement by other than normal use and service of the Equipment or by any of the following a accident b misuse or negligence c overloading d of reasonable and proper maintenance e improper repair or installation f unsuitable storage g non Highline approved alteration or modification h natural calamities i vandalism j parts oraccessories i...

Страница 65: ... period will receive the balance of the one year New Equipment Limited Warranty Replacement parts after the original machine warranty are warranted to be free from defects of material for ninety 90 days or the part will be repaired or replaced without labour coverage for removal and reinstallation EXCLUSION OF WARRANTIES UNLESS OTHERWISE REQUIRED BY LAW AND EXCEPT FOR THE WARRANTIES EXPRESSLY AND ...

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