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Operation and Maintenance
Manual Transtacker 4100
Please read and follow all instructions before operating the machine
It is the responsibility of the operator to read and understand the contents of this manual
before operating the machine for the first time.
The Operators manual must accompany the machine at all times. If the machine is resold
the Operators manual must be given with the machine to the new owners.
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Troubleshooting
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Summary of Contents for BIG BALE Transtacker 4100
- Page 1 Operation and Maintenance Manual Transtacker 4100 Please read and follow all instructions before operating the machine It is the responsibility of the operator to read and understand the contents of this manual before operating the machine for the first time.
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Page 2: Table Of Contents
Contents Title Page Introduction …………………………………………………………………………….. 1 Description ………………………………………………………..1 SAFETY ALERT SYSMBOLS ……………………………………. 1 Machine Identification Plate ……………………………….. 1 Intended Use of the Machine ………………………………. 1 Construction and Use Act UK ………………………………. 2 Noise Declaration ……………………………………………….. 2 Accessories and Attachments ………………………………... - Page 3 Contents Title Page Setting Page 4 – Pressure Transducer Address …… 35 Setting Page 5 – Settings …………………………….………. 35 Bale Counter ……………………………………………………….. 36 Trouble Shooting ……………………………………………………………………… 37 Connecting to the Tractor …………………………………… 37 Pickup …………………………………………………………………. 37 Stacking ………………………………………………………………. 37 Initial Troubleshooting …………………………………………...
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Page 4: Introduction
Max Drawbar Load ________________________ Intended Use of the Machine The Big Bale Transtacker is designed to assemble various sized big bales, 2.4m (8') long, into completed stacks and erect them into a tower. The various sizes of bales must have a width or depth which can, (when arranged side by side in some multiple), form a rectangle that is 2.4m(8') square. -
Page 5: Construction And Use Act Uk
Above 30 kph (20 mph), A.B.S. with air brakes may be required. Air Brakes and A.B.S comes standard with the Transtacker 4100 but needs installing into the tractor if it is not already standard on the tractor. It is important to note that high-speed use on highways may be restricted by a machine width in excess of 2.55 m. -
Page 6: Machine Overview
Machine Overview... -
Page 7: Safety
If any of the notices become detached or defaced, they must be replaced immediately. These are available from your local Big Bale Transtacker agent. They are included in the spare parts list and examples to aid identification are reproduced on the following pages. - Page 8 Safety WARNING: Keep side Gate pins in place when transporting on highways. When traveling along roads the side clamps are subject to variable and high loads. Failure or inadvertent operation of the side clamps could cause very serious injury or damage to others.
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Page 9: Operation
Remove links if necessary. Big Bale will not be responsible if the operator turns to tight and damages the machine or any component. -
Page 10: Electrical
Ram Mounts will be provided with both Screen and Joystick. This allows you to securely fasten them safely to the tractor cab. If additional fasteners are needed, contact Big Bale Co South Ltd. Note: Do not forget to thread any cable through the service post and any cab entry points. -
Page 11: Joystick Functions
Operation Joystick Functions Direction of Travel Fig. 9 OPS (Operator Pressure Switch) Button Joystick position Function in Field Mode Function Stack Mode Tip Bed Down None Auto Stack Auto Tip Bed Up Open RH Gate Open RH Gate Open LH Gate Open LH Gate Raise Pickup 1 (Yellow) -
Page 12: Screen Functions
Operation Screen Functions OK / Save Scroll Right Scroll Up Scroll Down Scroll Left Back / Cancel Fig. 12... -
Page 13: Auto Function
Button 'Road Mode' for 3 seconds (Fig. 12). 3. Enter 'Stack Configuration' (Fig. 12) before using the Transtacker 4100 for the first time. Or if you have changed bale sizes (Fig. 14). Fig. 14 3.1. Once you have entered 'Stack Configuration', use keys D and H to navigate to your chosen bale size (Fig. - Page 14 Operation Auto Function Continued..4. Once 'Stack Configuration' is set up, click 'Auto Mode' (Fig. 12). This will start the process of getting the Transtacker ready for collecting bales. The following functions will start to open: a. Side Gates b. Rear Clamps c.
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Page 15: Erecting A Complete Tower
Operation Fig. 26 Erecting a Complete Tower Manoeuvre the machine to the stack site. Check the following: A. The ground is firm and flat and not sloping excessively to either side or forward i.e. more than 5°. B. Check there are no overhead obstacles or power lines. It is recommended to keep 10 meters away from power lines. -
Page 16: Placing Towers Against Existing Towers
Operation Erecting a Complete Tower Continued. 10a. After you have released the stack vertically, drive Fig. 33 away from the stack (make sure it is stable). Move the joystick forward (Fig. 33) to bring the machine down manually about 5-10 degrees. 10b. -
Page 17: Erecting A Part Load Tower
Operation 5.10 Erecting a Part Load Tower 1. Performing a 'Part Load' is done automatically by the Fig. 38 Transtacker. To do a 'Part Load' successfully there are some pointers you have to obied by: i. The recommended minimum amount of layers a 'Part Load' can be is;... -
Page 18: Re-Picking A Complete Tower
Operation Fig. 43 5.11 Re-Picking a Complete Tower 1. Exit ‘Road mode’ and ensure 'Stack Mode' is selected. 2. Hold down the 'BLACK' button and move the joystick back (Fig. 43) to ‘Open Clamps’. 3. Move the joystick left and right (Fig. 44) to open the Fig. - Page 19 Operation 5.11 Re-Picking a Complete Tower Continued. Fig. 49 7. Hold the 'RED' button and pull the joystick back to close the 'Rear Clamps' (Fig. 49). Ensure that the rear clamp 'Paddles' has gripped under the bales tight. 8. Whilst still holding the 'RED' button, push the joystick left Fig.
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Page 20: Getting Started Manually
Having entered the field, stop and set up the machine ready to operate as follows. Some adjustments to your Transtacker 4100 will be needed, follow Section 6.0 Adjustments for further details. 1. Engage PTO if it is safe to do so as instructed on the main screen (Fig. - Page 21 5.14 Pickup with Grab Arm (Manual) Note: See Section 6.0 Adjustments for the correct height adjustment for the 'Pickup'. 1. When all sets in section 5.12 are complete, proceed with the following steps below. Fig. 56 2. When the bale is in the correct position, hold down the 'BLACK' button and push forward to 'Close Grab arm' (Fig.
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Page 22: Stacking (Automatic)
Operation 5.15 Stacking (Automatic) 1. Before operating the stacking function, ensure the following: A. The pickup has returned fully (Fig. 63). B. The table is full and the bales are tight, central and well aligned. This is very important (Fig. 64). Fig. -
Page 23: Stacking Without Tie (Manual)
Operation Fig. 66 5.16 Stacking Without Tie (Manual) WARNING: While it is possible to stack manually, it is recommended to 'Auto Stack' or 'Auto Mode'. Unless operated by a competent user, it is likely the machine could get damaged. Ensure you are in 'Stack Manual Mode'. If this is the first layer of your stack please proceed to Section 5.16. -
Page 24: Stacking Tie (Manual)
Operation Fig. 72 Stacking Tie (Manual) 5.17 A. Ensure you are in 'Stack Manual Mode'. This section includes how to 'Stack' manually for all layers including the first one. 1. Carry out the same checks as in Section 5.14 'Stacking (Automatic)'. - Page 25 Operation Operation Fig. 78 Stacking Tie (Manually) Continued. 5.17 8. Hold down the 'BLACK' button and push the joystick forward (Fig. 78) to 'Retract Hooks' all the way out. 9. Hold down the 'BLACK' button and move the joystick Fig. 79 left (Fig.
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Page 26: Finishing A Stack
Operation 5.18 Finishing a Stack When the platform is full a sensor on the rear of the platform will be activated, this will show on the screen 'FULL'. Or in manual mode - the top middle where the layer count is, it will show blue. The stacking cycle will stop and the rear clamps will automatically clamp the bales (Fig. -
Page 27: Adjustments
WARNING: Adjustments should only be made by competent persons who have read and understood the contents of this manual. If in doubt, contact Big Bale Co. South Ltd. WARNING: Be careful to support raised mechanisms that may fall when hydraulic connections are undone. This is particularly applicable to a partially raised platform, side and rear clamps, forks, table lift, table retract and raised pickups. -
Page 28: Fork Cable Adjustments
Big Bale Co South Ltd, will NOT take responsibility for miss adjustments. Contact Big Bale Co South Ltd for more in depth detail for adjustments. CAUTION: The 'Forks' are used for every load and can NOT be bolted down to the platform. -
Page 29: 900Mm Stop
CAUTION: Ensure there is enough ground clearance as this can cause considerable damage if not operated correctly. Big Bale Co South Ltd, will NOT take responsibility for miss adjustments. Contact Big Bale Co South Ltd for more in depth detail for adjustments. -
Page 30: Grab Arm Ctf Paddle
Note: If the LED on the rear of the sensor is Flashing, then the sensor is too far away from the target so re-adjust. Note: Big Bale Co South Ltd does NOT take responsibility for incorrectly adjusted sensors. Contact Big Bale Co South Ltd for more in depth detail for adjustments. -
Page 31: Turntable - Middle
Note: This is only a guide. For finer adjustment use other holes around suggested adjustment. Note: Big Bale Co South Ltd does NOT take responsibility for incorrectly adjusted sensors. Contact Big Bale Co South Ltd for more in depth detail for adjustments. Fig. 108... -
Page 32: Gates Open Lh/Rh
Refer to Fig. 118 to see the angle the platform will be at when the platform is at its maximum angle of 40 degree. Note: Big Bale Co South Ltd does NOT take responsibility for incorrectly adjusted sensors. Contact Big Bale Co South... -
Page 33: Rotary Sensors
122). Again press the 'Set Position' button. 3. To save these final calibration settings, press the 'O' button as instructed on the screen (Fig. 123). If these changes have not worked, contact Big Bale Co South Ltd for further advice. -
Page 34: Adjustable Stop On Grab Arm And Turntable Rotate
If this is the case adjust appropriately. Note: Big Bale Co South Ltd does NOT take responsibility for incorrectly adjusted sensors. Contact Big Bale Co South Ltd for more in depth detail for adjustments. -
Page 35: Pressurizing The Bump Paddle
Adjustments Pressurizing the Bump Paddle 6.11 The Bump Paddle requires 65-70BAR of pressure in its system. This is maintained by a closed hydraulic circuit. However if you change any components or a leak is formed you will have to re-pressurize the system. The Transtacker will constantly view this pressure and if it drops below 70BAR the box it is contained in will go red (Fig. -
Page 36: Pulley Beam Trolley Wear Pads
Adjustments Pulley Beam Trolley Wear Pads 6.13 The Pulley Beam Trolleys have X4 adjustable nylons which allow you to keep the trolley tight to the platform and to take out any 'Slop' that occurs. These are located on the Pulley Beam Trollies (Fig. -
Page 37: Diagnostics / Settings
Section Troubleshooting 8.0 if this occurs. Diagnostics Page 3 - Rotary Sensors Diagnostics Page 3 - Rotary Sensors The Transtacker 4100 uses 3 Non - Contact Rotary Sensors (Fig. 136). These Sensors are used on the: Angle of the 'Pickup Lift' from 0 to 180... -
Page 38: Setting Page 1 - Rotary Transducers Address
Diagnostics / Settings Settings Page 1 - Rotary Transducers Address This page shows you the current address each Rotary Sensor has been assigned (Fig. 137). You will only need this page is guided to it. Below is the standard address which have been assigned from factory. Raise Pickup - 213 Raise Turntable - 217 Rotate Turntable - 211... -
Page 39: Bale Counter
Diagnostics / Settings 7.10 Bale Counter and Weight Counter The machine is fitted with four bale counters. Bales are added to these counts by the number of cycles the Pickup does. When the turntable releases its hooks before coming down during an 'Auto Stack' function, this will be the time it adds to your layer count on the visual Transtacker in the top middle of your screen, or if in 'Auto Mode', in the centre. -
Page 40: Troubleshooting
If all connections and voltages to the controller are good then check connections inside the box to the stop switch and PCB terminal blocks carefully. If in doubt, contact Big Bale Co South Ltd for further technical information. -
Page 41: Initial Troubleshooting
The second option is to take a 9mm spanner and manually operate the valve block. The location of the 9mm nut is located the bottom of each slice (The Transtacker 4100 has 11 of these). The exact location can been seen in Fig. 143. Only operate a slice if its safe to do so. Not all slices will be able to operate due to some having selector valves in its hydraulic system which requires an electrical signal. -
Page 42: Hydraulic Troubleshooting
Troubleshooting Hydraulic Troubleshooting Assuming you have worked through the initial troubleshooting and come to this stage, the first reference point to check is the LED diagnostics located on the solenoids of the valve block. This may require for covers to be taken off the valve block to show the electrical side of the block. -
Page 43: Auto Open Troubleshooting
Troubleshooting Auto Open Troubleshooting Auto Open (Can operating in Manual Functions) Function Symptom Cause Machine PTO off Turn PTO on (540) Take off layers on the Transtacker (Section 9.4). Transtacker might think Or manually open all there are layers on its count Transtacker functions (Section 5.12) Machine is not in Auto... - Page 44 Troubleshooting Auto Open Troubleshooting Continued. Not pressurised all the way Forks Pressure Sensor has Increase the trigger hit its desired pressure pressure Fork pressure trigger has Decrease Fork trigger not been satisfied pressure No power to selector valve Check for power supply to solenoid solenoid, wiring loom fault The sensor may be...
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Page 45: Auto Pickup Troubleshooting
Troubleshooting Auto Pickup Troubleshooting Auto Pickup Function Symptom Cause Machine PTO off Turn PTO on (540) Change mode of machine to Machine not in auto-mode auto-mode and try again Auto Pickup Doesn’t Check mechanical alignment Grab Arm commence/ Grab Arm of Proximity sensor and Doesn’t Fold In Bale Detect - Pickup sensor... - Page 46 Troubleshooting Auto Pickup Troubleshooting Continued. Pickup height not correctly set for bale size Trigger point needs adjusting Rotary Sensor requires Calibration (Section 6.9). Faulty Sensor Faulty wiring Tines Retract pressure Increase Tines Retract Tines Don’t Fully Retract sensor has hit its desired Trigger Pressure pressure Check for power supply to...
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Page 47: Auto Stack Troubleshooting
Troubleshooting 8.10 Auto Stack Troubleshooting Auto Stack with Rotate (Without Rotate, Skip rotate function) (Can operate in Manual functions) Function Symptom Cause Machine PTO off Turn PTO on (540) Check for power supply to Hooks Don’t Insert Power to Solenoid solenoid, wiring loom fault Solenoid could be faulty Hooks Insert... - Page 48 Troubleshooting 8.10 Auto Stack Troubleshooting Continued. If the side gate wiring loom is on the opposite side to Wiring to solenoid wrong Side Gates Open unevenly what it should be, it will way around create a problem with the proximity sensors Adjust appropriately.
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Page 49: Auto Tip Bed Down Troubleshooting
Troubleshooting 8.10 Auto Stack Troubleshooting Continued. Side Gate Left or right or Hooks retract pressure Decrease the appropriate transducer has not achieved pressure transducer Turntable doesn’t lower its trigger pressure Turntable Lift Rotary sensor Re-calibrate Rotate Rotary calibration sensor (Section 6.9) Turntable Lower (Works Turntable rotate rotary Re-calibrate sensor/faulty... -
Page 50: Auto Tip Bed Up Troubleshooting
Troubleshooting Auto Tip Bed Up Without Part load (Can operate in 8.12 Auto Tip Bed Up Troubleshooting Manual Functions) Function Symptom Cause Machine PTO off Turn PTO on (540) Forks may be caught under Forks don’t lower Obstruction string of a bale. Unhook to free Forks Forwards Forks may have got trapped... -
Page 51: Tips And Information
Tips and Information Side by Side Stacking To stack side by side, either side gate can be lowered to enable closer placing of stacks. Removal of either side gate (see Section 6.15), however do not lower the pin is required side gate until the trailer is tipped to approximately 45 degrees. -
Page 52: Extra Pickup Bale
Tips and Information Extra Pickup Bale If you wish to further increase speed and efficiency, the Transtacker can help you do so. If the turntable is in the process of loading 2 bales onto the platform, the Auto Pickup function can still be activated. Simply drive a bale into the bump paddle activating the pickup sequence. The pickup will then lift and hold the bale at 90 degrees to the ground ready for the turntable to be back in its home position. -
Page 53: 10.0 Electrical System
10.0 Electrical System 10.1 Electrical System Structure The system has two CAN Networks and an analogue system. The systems are broken down as listed below: • CAN 0 – Communication between the controller, the joystick, the HMI (Human Machine Interface) and the Telemetry unit if fitted. •... -
Page 54: Can Bus Structure
10.0 Electrical System 10.1.1 CAN Bus Structure Fig. 157 MALE... -
Page 55: Lighting Wiring
10.0 Electrical System 10.1.2 Lighting Wiring Fig. 158... - Page 56 FEMALE IGUS Cable IGUS Cable in Chain loose...
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Page 57: Transtacker Wiring Loom Layout
10.0 Electrical System 10.1.3 Transtacker Wiring Loom Layout Fig. 159 MALE FEMALE... -
Page 58: Sensor Functions
10.0 Electrical System 10.2 Sensor Functions The control system is made up of 3 rotary sensors, 12 pressure transducers and 15 proximity switches. The table below (Fig. 160) shows what sensor is used on each hydraulic function. To understand the diagnostics, each action on the Transtacker has a corresponding sensor that signifies the action is complete and allows the next action to be commenced. -
Page 59: 11.0 Hydraulic System
3/4” Test T-Piece Do NOT attempt to change the Standby Pressure of the can be attached to Hydraulic Pump without Authorization. Big Bale Co South this port. Ltd will not take responsibility of incorrectly adjusted Standby Pressure. You must have a full understanding of the machines hydraulic system to attempt further into this stage. -
Page 60: Valve Block Details
11.0 Hydraulic System 11.3 Valve Block Details Valve Block Wiring The Danfoss PVE-Cl Solenoids are wired up as Fig. 164 & 165 states. Therefore the following pinout for all M12 connectors on the CAN Network are as tabulated below. The pressure transducers are already hard wired however the rotary sensors require wiring but should be wired and sealed from factory. -
Page 63: Valve Block Schematic
11.0 Hydraulic Systems 11.4 Valve Block Schematic Fig. 168... -
Page 64: Electrical & Hydraulic Systems
12.0 Electrical & Hydraulic Systems 12.1 Chassis Sensor Locations Fig. 169... -
Page 66: Maintenance
WARNING: Be careful to support raised mechanisms that may fall when hydraulic connections are undone. This is particularly applicable to a partially raised platform, side and rear clamps, forks, table lift, table retract and raised pickups. If in doubt, contact your local Big Bale Transtacker agent. WARNING: Before Commencing Any Repairs / Maintenance Shut off engine, remove ignition key, and unplug electric box before performing any maintenance or repair work. -
Page 67: Pickup Grease Points
13.0 Maintenance 13.2 Pickup Grease Points Fig. 172... -
Page 68: Grab Arm Grease Points
13.0 Maintenance 13.3 Grab Arm Grease Points Fig. 173... -
Page 69: Turntable/A-Frame Grease Points
13.0 Maintenance 13.4 Turntable/A-Frame Grease Points Fig. 174... -
Page 70: Side Gate Grease Points
13.0 Maintenance 13.5 Side Gate Grease Points Fig. 175... -
Page 71: Rear Clamps Grease Points
13.0 Maintenance 13.6 Rear Clamps Grease Points Fig. 176... -
Page 72: Chassis Grease Points
13.0 Maintenance 13.7 Chassis Grease Points Fig. 177... -
Page 73: Platform Grease Points
13.0 Maintenance 13.8 Platform Grease Points Fig. 178... -
Page 74: Axle Grease Points
13.0 Maintenance 13.9 Axle Grease Points Fig. 179... -
Page 75: Storage
Do not pour waste oil onto the ground, down a drain or into any watercourse. If in doubt as to the proper way to recycle or dispose of waste created by using your Big Bale Transtacker, consult your local environmental or recycling centre, or your local Big Bale Transtacker agent. -
Page 76: Error Codes
15.0 Error Codes... -
Page 84: Operator Notes
16.0 Operators Notes... - Page 88 Big Bale Co. (South) Ltd. Church House Farm, Clewers Hill, Waltham Chase, Southampton Hampshire, U.K. SO32 2LN. Telephone: +44 (0)1489 896346 Fax: +44 (0)1489 892188 Email: elliot@bigbale.co.uk www.transtacker.co.uk Publication No: EOB-BBS-001 Issue No. 1 Issue Date: 10/06/2020...
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