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Taarup BIO+ B4000 Operator's Manual

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Operator's manual
Model Taarup BIO+ B4000
Operator`s manual
BIO+
processor B4000 English,
issue 07-06, document version 6, programme version
Bale processor
with options
1.04
16655216_EN

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  • Page 1 Operator’s manual Bale processor Model Taarup BIO+ B4000 with options 16655216_EN Operator`s manual BIO+ processor B4000 English, issue 07-06, document version 6, programme version 1.04...
  • Page 2 Operator´s manual BIO bale processor B4000...
  • Page 3 Hauptstrasse 99 D-78244 Gottmadingen Germany declare under our sole responsibility that the product: Bale processor type Taarup B4000 to which this declaration relates corresponds to the relevant basic safety and health requirements of Directive 98/37/EU. Gottmadingen, July 2006 Casper Böhme...

  • Page 4: Guarantee

    Operator´s manual BIO bale processor B4000 Guarantee Guarantee Taarup products are guaranteed for a period of one year from the date of delivery, against defects in material and workmanship. Components not manufactured by Kverneland, i.e. electrics and hydraulics, PTO shafts and tyres are guaranteed according to the original manufacturer’s recommendation.

  • Page 5: Table Of Contents

    Content Content CE certificate of conformity ........ 3 The computerised control system ..45 Guarantee ............4 Mode of operation - sensors and valves 45 Introduction ............6 The command panel ......45 Machine identification ......... 7 Symbols ..........46 Technical specifications ........

  • Page 6: Introduction

    Operator´s manual BIO bale processor B4000 Introduction Introduction We congratulate you on the purchase of your new Taarup product. You have chosen a product which will give you satisfaction through a network of efficient dealers where function, finish, after sales service and spare parts are always at hand.

  • Page 7: Machine Identification

    Machine identification Machine identification The machine’s serial number and the manufacturer’s address are found on the number plate of the machine. See illustration below. The serial number and year of manufacture for this machine is given below. This number is im- portant with regard to service and the correct supply of spare parts.

  • Page 8: Technical Specifications

    Operator´s manual BIO bale processor B4000 Technical specifications Technical specifications Valid for standard equipped machine with wheel size 500/50-17" Description Data Dimensions Total length ................4500 mm Width ..................2800 mm Height ................... 2300 mm Weight ..................3250 kg Wheel dimension Regular.................

  • Page 9: Dimensions

    Dimensions Dimensions Valid for machine with wheel size 500/50-17" All measures are in mm (1" = 25.4mm) 2800 2300 4500...

  • Page 10: Model Descriptions

    Operator´s manual BIO bale processor B4000 Model descriptions Model descriptions Regular specifications Fixed chamber bale processor provided with hydraulic operated pick-up. Mechanic drive of pick- up, cutting unit and roller chamber during baling. Hydraulic drive of baling chamber and pre- stretcher ring during stretch film wrapping.

  • Page 11: Summary Of Operator's Instructions

    Summary of operator’s instructions Summary of operator’s instructions This summary is intended to give a survey only. Before operation you must make yourself familiar with the safety advice and detailed descriptions as contained in the complete Operator’s Manual. a) Connect bale processor’s drawbar to trac- f) Check the oil flow from the tractor at a PTO tor’s drawbar.

  • Page 12: Safety

    Operator´s manual BIO bale processor B4000 Safety Safety Before operating, adjusting or servicing the The machine must be connected to a machine it is important that the safety in- correctly sized tractor structions in this manual are carefully read The weight of the tractor must correspond to and understood by those, which are directly the maximum weight of the machine when concerned.
  • Page 13 Safety Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8...
  • Page 14 (Fig. 10) parts. The use of spurious spare parts will Prior to transporting the machine along public cause the Taarup product guarantee to be roads, check wheel bolts and couplings. invalid. (Fig. 13) Disconnect or lock the hydraulic system.
  • Page 15 Safety Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13...
  • Page 16 Operator´s manual BIO bale processor B4000 Safety Supplementary safety instructions for the BIO bale processor This machine is designed for the purpose Warning sign UH220538. Keep distance to of baling & stretch film wrapping of grass or the moving cutter arm. Hand or foot can be other straw material in the form of round trapped and cut.
  • Page 17 Safety UH220532 UH220534 UH220548 UH220900 UH220524 UH220538 UH220543 UH220903 UH220902 UH220901 UH220528 UH220530...
  • Page 18 Operator´s manual BIO bale processor B4000 Safety New machine - be careful Read the operator’s manual. Great care must Carefully do as described below when start- be taken when starting a brand new machine ing a new machine. for the first time. Incorrect assembly, faulty Check that the machine is mounted correctly operations etc.

  • Page 19: Preparing A New Machine

    Preparing a new machine Preparing a new machine 1.1 Packing 1.4 Electronics Remove all kind of packing. Any equipment Connect system to tractor’s power supply. stored in the machine should be removed. Observe! Assure that power supply has sufficient capacity with stable connections. Remove the lifting spreader from the top of Any risk of short breaks in power supply will the machine prior to any kind of operation of...

  • Page 20: Operating The Machine

    Operator´s manual BIO bale processor B4000 Operating the machine Operating the machine 4.1 Connecting machine Caution: Adjusting, maintenance and repair work is only to be carried out when the motor is switched off and the machine is at a standstill. Remove ignition key.
  • Page 21 Operating the machine It is sometimes necessary to correct the when taking all curves and when driving length of the universal drive shaft due to the straight, ensure that: different hitching possibilities and various – a minimum overlap of b = 200 mm is tractor types.
  • Page 22 Operator´s manual BIO bale processor B4000 Operating the machine 4.1.2 Continuous hydraulic motor drive on tractors with closed centre system tractor hydraulic’s safety valve with a risk of damaging the tractors hydraulic pump! When connected to a tractor with constant The oilflow from the tractor should be adju- pressure hydraulics (such as John Deere 30, sted to approx 35 l/min.

  • Page 23: Use Clean Hydraulic Oil

    Operating the machine 4.1.4 Pressurize hydraulic cylinder circuits During stand still over a period pressure of vital hydraulic circuits might have been released. By simply pushing Select key no. 1 while (within 5 seconds) system is powering up, hydraulic pressure will be activated for a short time on film cutters, chamber top section and chamber bottom section in order to make sure that components are in correct position with check valves closed.

  • Page 24: Set-Up Of Pick-Up

    Operator´s manual BIO bale processor B4000 Operating the machine 4.3 Set-up of pick-up 4.3.1 Pick-up height The pick-up is raised and lowered hydrauli- cally being operated from the control panel’s joystick keys. The working height of pick-up is set using two support wheels (right and left).
  • Page 25 Operating the machine 4.3.4 Pick-up overload protection feature In order to prevent damage, the pick-up is equipped with a torque protector in the drive mechanism. When there is overloading, the power flux is interrupted by the breaking of shear bolt M8 x 45 8.8 DIN 931 (a) and pick- up stops.

  • Page 26: Crop Cutting System

    Operator´s manual BIO bale processor B4000 4.4 Crop cutting system 4.4.1 General Feed drum (1) with double tines configured in a spiral (2) ensures a regular drawing cut of the blades (3). The OptiCut cutting system gives the option to have the crop cut to a theoretical length of 70 or 45 mm at a maximum of 14 or 23 cutting points.
  • Page 27 Operating the machine 4.4.2 OptiCut 14 The OptiCut 14 has 14 knives and a theoretical cutting length of 70 mm. The knives can be installed in two different positions: Blade shaft, pos. 1 – steep cutting angle for ‘precision cutting’ Blade shaft, pos.
  • Page 28 Operator´s manual BIO bale processor B4000 Operating the machine 4.4.3 OptiCut 23 The OptiCut 23 system is fitted with 23 blades giving 45 mm theoretical length of cut. Knives are individually secured against foreign objects by hydraulic rams (1). (A) When depressurized the hydraulic rams are held in retracted position by a spring.
  • Page 29 Note: Swinging the blades out during crop collection will speed up the process. Variable blade engagement in groups The 23 blades of the OptiCut crop cutting mechanism can be engaged in different groups. Using the two taps on the right-hand machine side it is possible to preselect 0, 11, 12 or 23 blades.
  • Page 30 Operator´s manual BIO bale processor B4000 Operating the machine 4.4.4 Adjusting the conveying drum scrapers Re scrapers (1) position relative to conveyor drum (2). Move out the cutting system hydraulically Open the chamber top section hydraulical- Secure the top section - close the upper lock valve in front of the machine (a) Switch off the tractor engine Loosen bolts (b) of scraper beam on both...

  • Page 31: Net Binding

    Operating the machine 4.5 Net binding 4.5.1 General The numbers of net wraps should be selected the bale processor together with the film rolls. with the control panel. For bales that are wrapped with stretch film, 1.5 wraps of net is Warning: required as a minimum, while 2.5 net wraps When inserting new rolls of net and when...
  • Page 32 Operator´s manual BIO bale processor B4000 4.5.3 Adjusting the net roll brake Brake springs (8) should be set hard enough to make flex guide (2) be in rear (tensioned) position during regular feeding of net. If the net brake unit starts vibrating (espe- cially at nearly empty net roll), tension the bolts (9) of the lock &...
  • Page 33 Operating the machine 4.5.4 Adjusting the net cutting knife Check the parallelism of anvil (1) and cutting bar (2) to ensure that the net is cut correctly. To adjust proceed as follows: Cutting bar must be released (in contact with the anvil) Undo the securing bolts (3) of the anvil Release the lock nuts and use setting screws (4) until the anvil is parallel to the...

  • Page 34: Shear Bolts On Roller Drive

    Operator´s manual BIO bale processor B4000 Operating the machine 4.7 Shear bolts on roller drive In order to avoid damage to the rollers, two shear bolts M10 x 50-8.8 act as main safe- guard (one each in the upper and lower sec- tion of the baling chamber) in the roller drive.
  • Page 35 Operating the machine 4.9.2 Adjusting closed cutter position 4.9.2.1 Sidewise positioning Close cutters completely. Check position- ing of grip roller at the corrugated grip block. Inner end of plastic roller should be aligned with inner end of grip block. Required adjustment is done by means of screw (2).

  • Page 36: Processing Bales

    Operator´s manual BIO bale processor B4000 Operating the machine 4.10 Processing bales 4.10.1 How the BIO bale processor functions During baling the bale processor is driven by reached 100% filling, a continuous alarm the PTO shaft providing required power to sounds.
  • Page 37 Operating the machine 4.10.2.2 Working speed further speed increase of pre-stretcher due to The tractor engine speed/oil flow should be the flow restrictor integrated in the spool adjusted to achieve valve block. approx. 540 revs/min on PTO shaft while baling When processing silage bales, it is of great and 50 revs/min of the prestretcher ring while importance to make high density bales.
  • Page 38 Operator´s manual BIO bale processor B4000 Operating the machine 4.10.2.5 Tips for practical use Number of net wraps: minimum 1,5 wraps are required in order to achieve proper binding of wrapped bales. In case of baling without any film wrapping 2.5 net wraps are required.
  • Page 39 Operating the machine 4.10.3 Quick introduction to control system ver. 1.14 4.10.3.1. Operating modes Idle mode: Bale processor is in safe/stop situation, light at STOP key Process mode: Bale processor can be operated manually or automatically. Light at Stop key off. «Manual»...
  • Page 40 Operator´s manual BIO bale processor B4000 Operating the machine 4.10.3.3 Parameter change procedure Start from Idle mode: Enter Select Edit Save Exit Parameter Clear: General setting of user functions Add: See list Deduct: Clear: General setting of dealer functions Add: &...
  • Page 41 Operating the machine 4.10.3.6 Disengaging and re-engaging film wrapping Start from Process mode: Press Select key no. 3 for ON/OFF: Selecting OFF, net wrap is set to value B (icon on left-hand Se- lect key disappears) Selecting ON, net wrap is set to value BW 4.10.3.7 Operating pick-up Move joystick up/down Note! Lower lock valve at the pressure filter need to be open in...
  • Page 42 Operator´s manual BIO bale processor B4000 Operating the machine Select User functions screen 5: Control of net wrapping, film wrapping, discharge & closing of baling chamber 0 = auto 1 = controlled by OK switch 3 = operate OK switch once for discharging and once more to close chamber (valid value for discharging set-up only) Confirm set-up 4.10.3.11...
  • Page 43 Operating the machine 4.10.3.15 Automatic lifting and lowering of pick-up With this function activated, pick-up is automatically lifted when net binding starts. Pick-up is lowered to working position when chamber is closed for next baling sequence. Select User function 6, lower parameter: 0 = function not activated, pick-up being operated by joystick 1 = function activated Confirm by:...
  • Page 44 Operator´s manual BIO bale processor B4000 Operating the machine 4.10.4 Reversing conveyor drum Experience shows that when the bales are nearly finished, the system can become ob- structed or the cam coupling can be trig- gered. It is possible to bind and wrap these bales without having to eliminate the obstruction in the vicinity of the cutting rotor.

  • Page 45: Parking

    Operating the machine 4.10.4.2 Hydraulic (option) Hydraulic cylinder (H) available as an option can be used to disengage the drive system between feed unit (pick-up / feed roller) and bale chamber from the tractor cab. For all other steps follow the procedure as described in section 4.10.4.1.

  • Page 46: The Computerised Control System

    Operator´s manual BIO bale processor B4000 The computerised control system The computerised control system The computerised control system for the BIO erator’s approval is given by the OK switch) bale processor includes two main compo- - Tool mode (by pressing manual keys and nents.
  • Page 47 The computerised control system 5.2.1 Single functions 5.2.1.1 Manual/Auto key Idle mode: Start the machine process mode. Process mode: Selects type of process mode (indicated in upper right-hand corner of screen) Tool mode – light ON: Manual/Auto key + Joystick Function Key give access.
  • Page 48 Operator´s manual BIO bale processor B4000 The computerised control system Select key no. 4 in Process mode: Press to stop the prestretcher ring in initial position (prestretch- ers at film cutters). Only applicable during ring movement. 5.2.1.5 Joystick function key Process Mode in Tool: Select joystick function group for manual control (in Tool mode only).
  • Page 49 The computerised control system 5.2.1.8 Joystick +/up Process Mode in Auto or Manual: Pick-up up Process Mode in Tool: Depending on selected joystick function group Edit Mode: The plus switch will increase the edited value by the pre-pro- grammed step value (usually 1). When the switch remains active the value will continue to increase using a larger step size.
  • Page 50 Operator´s manual BIO bale processor B4000 The computerised control system 5.2.2 Special keys and key/switch combinations The following sections describe special key or key/switch combi- nations. Key or key/switch combinations mentioned below have to be activated at the same time. 5.2.2.1 Joystick function &...

  • Page 51: Display Information Regarding Panel Connection

    The computerised control system 5.3 Display information regarding panel connec- tion 5.3.1 Power-up The power-up screen indicates a correct communication be- tween panel and driver module. 5.3.2 Connection error If connection takes too long time, flashing screen indicates con- nection error. After a timeout period of 6 seconds this will stop. Then the following error screen is shown: The error message is indicating a break of cable or contact failure.

  • Page 52: User Functions Screen Displays

    Operator´s manual BIO bale processor B4000 The computerised control system 5.5 User functions screen displays User function screens offer parameters that may be changed/configured by the operator. The user functions can be activated when the Joystick function key is pressed in the Idle mode.
  • Page 53 The computerised control system 5.5.6 Film break sensor Activates film break sensor and eventually ½ speed by film end. 0 = Film break sensor not activated 1 = Film break sensor activated Film break is notified by audio signal, the ring continues to rotate until STOP is pressed by the user.
  • Page 54 Operator´s manual BIO bale processor B4000 5.5.8 Next lubrication The next lubrication time (processed no. of bales) is presented in this screen. The operator can edit this value. When the internal lubrication timer reaches zero, a lubrication warning will appear in any of the main process screens.

  • Page 55: Process Mode Screen Displays

    L’unità di controllo computerizzata L’unità di controllo computerizzata The computerised control system 5.6 Process mode screen displays 5.6.1 Tool mode screens & simultaneously, then press twice Process screens with all manual joystick operation modes: The first process screen shows that the joystick manual control is assigned to the pick-up and cutter knives adjustment.
  • Page 56 Operator´s manual BIO bale processor B4000 The computerised control system 5.6.4 Error/warning codes The following table gives an explanation on the error codes: Error Symbol Description Remarks mes- sage No pulse from net roll during net binding sequence Net is applied without net binding se- quence being activated Net knife not under tension No pulse from net actuator...
  • Page 57 The computerised control system 5.6.5 Process states The following paragraphs are describing the symbols being displayed during ordinary operation. For every symbol it is indicated in which mode of operation this can occur: Tool, Automatic or Manual. 5.6.5.1 Pick-up down The pick-up is lowered.
  • Page 58 Operator´s manual BIO bale processor B4000 The computerised control system 5.6.5.9 Chamber top section up The top section is raised. Mode: Tool, Automatic and Manual. 5.6.5.10 Chamber top section down The top section is lowered. Mode: Tool, Automatic and Manual. 5.6.5.11 Chamber bottom section up The bottom section is raised and the ring is lowered.

  • Page 59: Dealer Functions

    The computerised control system 5.7 Dealer functions Dealer function screens offer parameters that may be changed/configured by dealer level service people. The dealer functions can be activated when the [Joystick Function key & Joystick Up switch] combination are activated at the same time in the Idle mode. The screens that appear are listed in the next section. Stepping to the next screen can be accomplished by operating the joystick.
  • Page 60 Operator´s manual BIO bale processor B4000 The computerised control system 5.7.6 ½ speed sensor If a film break occurs at one of the rollers, the bale can be finished using the other film roller. = ½ speed automatically activated on film break 1/2 F = ½...
  • Page 61 The computerised control system 5.7.11Sensor input test This screen shows all the digital and analogue input values in real- time. The line on top (D:) shows the digital input sensors starting on the left with input 1. The line below (A:) shows the values of the analogue inputs in counts (range 0-255, 8-bit).

  • Page 62: Service Functions

    Operator´s manual BIO bale processor B4000 The computerised control system 5.8 Service functions Service function screens offer parameters that may be changed/configured by service people from the Factory/sales company/importer organisation. The service functions can be activated when the Joystick Function key & Joystick Down switch combina- tion are activated at the same time in the Idle mode.
  • Page 63 The computerised control system 5.8.7 Ring start & stop parameters This screen displays parameters for speed and position of prestretch- er ring during film cutting sequence. 30% = start speed of ring 30% = ring speed towards cutting posi- tion 8 pls cut = ring position when cutter arms are raised 19 pls stop = ring position when cutter arms are lowered 5.8.8 Bale counters...
  • Page 64 Operator´s manual BIO bale processor B4000 PIA mode Description PIA mode = Process independent activation. PIA mode displays all individual functions of a complete cycle with icons. The desired function is preselected using the joystick and then activated by pressing the OK key. Functions can be controlled independenty from the process mode.
  • Page 65 Swinging up the bottom section of the bale chamber Once the ring lowered and the bottom section of the bale chamber raised, the control system will automatically pass to the next icon: Closing up the top section of the bale chamber When the «top section closed»...

  • Page 66: Maintenance

    Operator´s manual BIO bale processor B4000 Maintenance Maintenance Warning: Never carry out adjustment or repair work, or ing the chamber section. No persons may remain in the moving area while chamber service and maintenance work, on the ma- chine when in operation. Switch off the tractor sections are operated.
  • Page 67 Maintenance 6.1.4 Lubrication See lubrication chart next page. Working conditions Detail Good Average Little dust, no Dusty, no aggressive Wet, aggressive aggressive materials materials materials 1. PTO shaft Daily Daily Daily 2. Gear box 1.3 litres gear oil SAE 90, after first season and thereafter only in case of repair 3.
  • Page 68 Operator´s manual BIO bale processor B4000 Lubrication chart BIO bale processor Grease daily Grease: Good conditions Average conditions Bad conditions 4000 bales 2000 bales daily and after cleaning with high pressure cleaner& before winter storage Oil 1.3l gear oil SAE90 after first season and thereafter at repairs Oil daily **) Every 4000 bales in all conditions...
  • Page 69 Maintenance 6.1.5 Grinding of cutter knives Blunt cutter knives causes increased fuel consumption and increased risk of conveyor drum blocking. Knives might be pressed away from the conveyor drum, causing material to remain uncut. Grinding interval length depends highly on the type and contamination of the straw material. If straw material is mixed with sharp and hard particles, it might be necessary to grind knives every 250 bales.
  • Page 70 Operator´s manual BIO bale processor B4000 6.1.5.2 Changing the blades OC 23 Open the top section of the bale chamber using hydraulic power. Close tap (1) to lock the top section. Swing out the cutting unit using hydraulic power. Close both taps for the variable blade engagement in groups on the right-hand machine side.

  • Page 71: Maintenance Hydraulics

    Maintenance 6.1.7 Check for wear 6.1.8 Cleaning Inspect moving parts for wear. General We recommend the use of pressured air Check tyres for wear and damage. when cleaning the machine. Thus there is less risk of damaging the bearings of the ma- chine.

  • Page 72: Troubleshooting

    Operator´s manual BIO bale processor B4000 Maintenance Troubleshooting It is important to clarify whether the fault is due to mechanic, electrical or hydraulic fac- tors. If a function will not work properly, check whether there is voltage on the solenoid. If so, the fault lies with the valve.

  • Page 73: Troubleshooting Hydraulics

    John Deere). The fault is impossible to repair. c. Fault in spool valve unit. Contact your Taarup dealer. Any kind of infor- Check that the actual spool is moving mation regarding faults found is useful for a smoothly.
  • Page 74 Operator´s manual BIO bale processor B4000 Maintenance 7.2.1 Sensors’ position See overviews on next page. When a sensor is activated the red light (at the cable entrance) is The gap between sensor and inducting steel/magnet should be 3-6 mm. Sensors Sensor Positioned Function Rh side at ring support...

  • Page 76: Notes

    Operator´s manual BIO bale processor B4000 Notes Notes...
  • Page 78 Kverneland Group is the largest specialised producer and distributor of farming implements in the world. The Group is a family of strong brands enabling us to provide both the farmer and dealer with a unique and complete range of high quality products for soil preparation, grass treatment,...

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