AGCO HayBoss G2 596 Operation Manual
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AGCO HayBoss G2 596 Operation Manual

AGCO HayBoss G2 596 Operation Manual

100 and 110 gallon preservative applicator
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Operation Manual
Model 596
100 & 110 Gallon Preservative Applicator
010-0596-OPR
1
Revised 11/12
For AGCO part cross-reference visit: www.harvesttec.com/system.html

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Summary of Contents for AGCO HayBoss G2 596

  • Page 1 Operation Manual Model 596 100 & 110 Gallon Preservative Applicator 010-0596-OPR Revised 11/12 For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 2: Table Of Contents

    Wiring diagrams 31-32 33-59 Parts breakdown Tank, Saddle & Legs Pump manifold Star wheel sensors Control boxes and wiring harnesses Hose and drain/fill line Installation kits specific to balers 38-59 Notes Warranty statement Back page For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 3: Installation Kit Reference Chart

    030-4494B Ferguson 2050 roto-cutter 030-4500B 2150 – 2190 030-4518B 2150 – 2170 roto-cutter 030-4519B 2150 – 2190 packer cutter 030-4527B 2170XD with roto-cutter 030-4530B New Idea 7233 030-4490B 7234 030-4492B 7244 030-4491B 7333 030-4494B For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 4: Introduction

    Carefully read and understand all of the baler safety signs before installing or servicing the baler. Always use the supplied safety equipment on the baler to service the applicator. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 5: Safety Sign Locations

    Safety Signs Locations 3, 4, 5 3, 5 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 6 Part no. DCL-8001 Number 4 Read and understand the operator’s manual before using or working around the equipment. Part no. DCL-8000 Number 5 Open (unlocked) and closed (locked) position of the ball valve. Part no. DCL-8004 For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 7: Preparing The Applicator For Operation

    The Harvest Tec model 9212 transfer pump is recommended for this process. Water is recommended for first time and annual start up procedures. Drain/Fill line on right side of baler Enlarged view of the drain/fill line valve and cam-coupler assembly. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 8: Connecting Power And Communication Harnesses

    The ball valve is located on the left side of the baler, connected to the pumping manifold. See arrow below. Open valve position Closed valve position For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 9 Standby This powers down the display only. The application unit will not fully power down unless the keyed power is turned off. Press anywhere on the screen to power back on (with the key on). For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 10: Automatic Mode

    Screen Menus Use the below listed screen menus to navigate through all of the operation screens. Automatic Mode: For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 11: Manual Mode

    Manual Mode: For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 12: Diagnostics

    Diagnostics: For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 13: Setup Mode

    Setup Mode: For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 14 Setup Mode Continued: For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 15: Job Records

    Job Records: For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 16: First Time And Annual Start Up

    NOTE: It is recommended that the system be run with the bale rate sensors on. Press the SETUP MODE key and turn the bale rate sensors back on for normal operation. (Also see Baling Rate to adjust bale weight, length, and time.) For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 17: Application Rate

    7. Next press the BACK key found on the bottom left hand figure of the screen to return to Setup Mode screen or press the MAIN MENU key on the bottom right hand figure of the screen to return to the opening screen. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 18: Baling Rate

    8. Press the OPTION key to adjust the touchscreen between metric and standard units and languages. The Hay Indicators can also be turned on or off in the OPTION screen. Press the underlined ON/OFF next to EOR. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 19: Operating Instructions

    7. Last Bale shows the average moisture content for the last bale. 8. Any Status Alerts for the system will appear in this area. See the STATUS ALERTS section for information. 9. Press the MAIN MENU key to return to the opening screen. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 20: Manual Mode

    8. This graph shows the moisture trend from the last 90 seconds of baling (one reading every 3 seconds). 9. Last Bale shows the average moisture content for the last bale. 10. Press the MAIN MENU key to return to the opening screen. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 21: Job Records

    Use the up and down arrows to scroll through five bales at a time. Press Back to go to the Job Details screen or Main Menu for the main screen. Continued on the next page For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 22 8. The job record in excel will show as above. The Bale ID column will need to be adjusted for proper viewing. 9. The job record in Notepad will show as above. You will need to move right to see all the information. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 23: Diagnostics

    6. Press the Versions key to check all software versions of modules attached to the PIP. 7. When done in this mode, press the MAIN MENU key. For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 24 Press accept when done. 10. How can I turn the optional Hay Indicators on/off from the cab? In the Setup Mode screen press options. Press the on/off underlined area next to EOR sensor. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 25: Maintenance

    (A). Unscrew the bottom section of the filter bowl and remove the strainer. (B) Clean off any debris and soak in warm water with a mild soap if necessary. Once the screen is clean reinstall by following the directions in reverse. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 26: Tips & Tip Screen Cleaning

    11/16 inch wrench. Remove the tip, and screen. Clean off any debris and soak in warm water with a mild soap if necessary. Once the tips and screens are cleaned reinstall by following the directions in reverse. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 27: Tank Lid Cleaning

    2. Although the pump can run dry, extended operation of a dry pump will increase wear. Watch the preservative level in the tank. 3. If you are using bacterial inoculants, flush your system daily after every use. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 28: Winter Storage

    Status Alert “Bale Records failed – Memory Full”. The system will no longer accept any new data until jobs in the Job Records menu are downloaded and deleted. Follow the instructions in Job Records to accomplish this. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 29: Troubleshooting

    3. Air leak in intake. 3. Look for air bubbles in line. Replace line or other defective area that is allowing air into the system. 4. Using product other than 4. Catch and weigh product to check For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 30 1. Check all connections at PIP and are not communicating. Pump controller including terminating 2. Broke connection between the resistors. display and PIP or Pump control 2. Check, clean, and tighten and PIP. connections. For AGCO part cross-reference visit: www.harvesttec.com/system.html...

  • Page 31: Wiring Diagrams

    Note: Hay indicators are an option that will turn the system on and off automatically as hay enters the pickup of the baler. Pin 1 +12V Pin 2 Black Ground Pin 3 White Signal wire Pin 4 Not used For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 32 Comm channel OH Pin 5 Yellow Comm channel OL Pin 6 Blue Comm channel IH Pin 7 Orange Comm channel IL Pin 8 Black Can ground Pin 9 Black Battery ground Pin 10 Not used For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 33 Not Pictured: Vicon Leg spacers Not pictured: 001-6707BS - qty 2 Handrail Tank handle: Left Leg Part#:001-6707BL Tank Strap 001-6707HR Tank Saddle 001-6707HR – qty 1 001-6707DR (2011 and Part#:001-4402B Part#:001-6707A newer 4 ft wide) For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 34 002-4315B Nipple fitting 003-M1212 Ball valve 002-2212 Street elbow fitting 003-SE12 Hose clamp 003-9003 Hose clamp (Flow Meter) 003-9005 Pump Cable 006-4660Z Elbow 003-EL1212 Pump rebuild kit ( 007-4581 1 per pump Not Pictured For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 35 Part# Description Part# Washer (per side) 006-4642K Insert w/ Ref # 5 Dust Seal (per side) w/006-4642K Wiring grommet 008-0821A Snap Ring (per side) w/006-4642K Star wheel block 006-4641A Swivel 006-4642A Plug Fitting 003-F38 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 36 006-5650F Pump controller harness (Krone balers only) 006-5650F2 End of bale sensor 006-7400 Pump controller 006-5672 End of bale sensor bracket 001-4648 Display 006-5670 Dust plug kit 006-5650PLUGS Suction cup mount 001-2012SCM Not pictured For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 37 030-9016LS ½” Hose (tank to filter) 002-9001 Male Coupler 002-2205G ¾” Hose (tank to drain/fill valve) 002-9002 Valve Holder 001-6702H Straight Fitting 003-A3434 Ball valve 002-2200 Elbow 003-EL3434 Jiffy Clip 008-9010 Hose Clamps 003-9004 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 38 Straight fitting 003-A1414 004-TT110015VP 003-TT14SQ 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4438A Mounting bracket 001-4438B Hose – 1/4" 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 39 Straight fitting 003-A1414 004-TT110015VP 003-TT14SQ 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4439A Mounting bracket 001-4439B Hose – 1/4" 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 40 003-SE14F Tip strainer 004-1203-100 Nozzle body 004-4722 Nozzle cap 004-4723 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4421 Shield holder 001-4421B Backing plate 001-4421A Hose – 1/4" 002-9016 End of bale mount 001-4648H For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 41 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4422 Shield holder 001-4422B Backing plate 001-4422A Hose – 1/4" 002-9016 Ladder bracket 001-6707H End of bale mount 001-4648H For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 42 Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4811A Left shield holder 001-4436DL Right shield holder 001-4436DR Hose – 1/4" 002-9016 Spacer 001-4436S For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 43 Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4810 Left shield holder 001-4436DL Right shield holder 001-4436DR Hose – 1/4" 002-9016 Spacer 001-4436S For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 44 003-TT14SQ 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4431 Shield holder 001-4431B Hose – 1/4" 002-9016 Wind guard stop 001-4431D For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 45 001-4435ES 004-TT110015VP Straight Fitting 003-A1414VB 004-TT11003VP Nozzle Cap 004-4723 004-800067-PT Check Valve 004-1207VB Tip Strainers 004-1203-100 Straight Fitting 003-A1414 Nozzle Body 004-4722 003-TT14SQ Street elbow 003-SE14F Lynch Pin 008-4576 Hose 002-9016 Hose Clamps 003-9002 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 46 004-TT110015VP Straight Fitting 003-A1414VB 004-TT11003VP Check Valve 004-1207VB 004-800067-PT Nozzle Cap 004-4723 Tip Strainers 004-1203-100 003-TT14 Hose Clamps 003-9002 Straight Fitting 003-A1414 Plug 003-F14 Not Pictured Nozzle Body 004-4722 Lynch Pin 008-4576 Hose 002-9006 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 47 Straight fitting 003-A1414 004-TT110015VP 003-TT14SQ 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4439A Shield holder 001-4440 Hose – 1/4" 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 48 004-TT110015VP 003-TT14SQ 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4811A Left shield holder 001-4436CL Right shield holder 001-4436CR Hose 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 49 004-TT11003VP Street elbow 003-SE14F Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Hose clamp 003-9002 Lynch pin 008-4576 Spray shield 001-4436CS Left shield holder 001-4436CL Right shield holder 001-4436CR Hose – 1/4" 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 50 004-TT110015VP Lynch Pins 008-4576 004-TT11003VP Hose Clamps 003-9002 004-800067-PT Straight Fitting 003-A1414VB Tip Strainers 004-1203-100 Check Valve 004-1207VB 003-TT14SQ Straight Fitting 003-A1414 90 degree elbow 003-SE14F Nozzle Cap 004-4723 Nozzle Body 004-4722 Hose 002-9016 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 51 Nozzle cap 004-4723 004-TT11003VP Check valve 003-1207VB 004-800067-PT 003-TT14SQ Hose 002-9016 Straight fitting 003-A1414 Hose clamp 003-9002 Elbow 003-SE14F Shield hanger 001-4704A Shield hanger 001-4704B Lynch pin 008-4576 Nozzle body 004-4722 Tip Strainers 004-1203-100 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 52 Nozzle cap 004-4723 004-TT11003VP Check valve 003-1207VB 004-800067-PT 003-TT14SQ Tip Strainers 004-1203-100 Hose 002-9016 Straight fitting 003-A1414 Hose clamp 003-9002 Elbow 003-SE14F Shield hanger 001-4704A Shield hanger 001-4704B Lynch pin 008-4576 Nozzle body 004-4722 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 53 Straight fitting 003-A1414 Tip Strainers 004-1203-100 Elbow 003-SE14F Nozzle body 004-4722 Lynch pin 008-4576 Hose clamp 002-9002 End of bale sensor mount 001-4648K End of bale sensor mount 001-4648K2 (Krone 12130 only) Not pictured For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 54 Straight fitting 003-A1414 Elbow 003-SE14F Shield holder 001-4435K Nozzle body 004-4722 Lynch pin 008-4576 Tip strainers 004-1203-100 End of bale sensor mount 001-4648K End of bale sensor mount 001-4648K2 (Krone 12130 only) Not pictured For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 55 003-SE14F 004-TT110015VP Straight fitting 003-A1414 004-TT11003VP Hose 002-9016 Hose clamp 003-9002 003-TT14SQ Check valve 004-1207VB Straight fitting 003-A1414VB Lynch pin 008-4576 Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Star wheel spacer 001-6707E For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 56 003-SE14F 004-TT110015VP Straight fitting 003-A1414 004-TT11003VP Hose 002-9016 Hose clamp 003-9002 003-TT14SQ Check valve 004-1207VB Straight fitting 003-A1414VB Lynch pin 008-4576 Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Star wheel spacer 001-6707E For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 57 Shield holder 001-4435EK 004-TT11001VP Elbow 003-SE14SQ 004-TT110015VP Straight fitting 003-A1414 004-TT11003VP Hose 002-9016 Hose clamp 003-9002 003-TT14SQ Check valve 004-1207VB Straight fitting 003-A1414VB Lynch pin 008-4576 Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 58 003-SE14SQ 004-TT110015VP Straight fitting 003-A1414 004-TT11003VP Hose 002-9016 Hose clamp 003-9002 003-TT14SQ Check valve 004-1207VB Straight fitting 003-A1414VB Lynch pin 008-4576 Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Star wheel spacer 001-6707E For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 59 004-TT11003VP Straight fitting 003-A1414 Hose 002-9016 Hose clamp 003-9002 003-TT14SQ Check valve 004-1207VB Straight fitting 003-A1414VB Lynch pin 008-4576 Nozzle body 004-4722 Nozzle cap 004-4723 Tip strainer 004-1203-100 Star wheel spacer 001-6707E Not pictured For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 60 Vicon large square Template For AGCO part cross-reference visit: www.harvesttec.com/system.html...
  • Page 61 Edge of baler chute 9” angle iron Cut here angle iron 5/8” 1/2” Edge of star wheelbase Notch for star wheel should line up with edge of notch 2” 3” Position of star wheel base Star wheel base holes 4 holes, 5/16” diameter...
  • Page 62 NOTES:...
  • Page 63 WARRANTY AND LIABILITY AGREEMENT Harvest Tec, Inc. will repair or replace components that are found to be defective within 12 months from the date of manufacture. Under no circumstances does this warranty cover any components which in the opinion of Harvest Tec, Inc. have been subjected to negligent use, misuse, alteration, accident, or if repairs have been made with parts other than those manufactured and obtainable from Harvest Tec, Inc.
  • Page 64 For Technical assistance: HARVEST TEC, INC. P.O. BOX 63 2821 HARVEY STREET HUDSON, WI 54016 PHONE: 715-386-9100 1-800-635-7468 FAX: 715-381-1792 Email: info@harvesttec.com...

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