Operation and maintenance of large bale baling machines

I. Operating Specifications

1. Preparation before homework

Site inspection

Remove hard objects such as stones, iron wires and plastic films from the operation area to avoid damaging the picker or knotting device.

Check the ground slope (it is recommended to be ≤15°) to prevent equipment from overturning or uneven distribution of materials.

Equipment inspection

Picker: Clear tangled weeds and check if the spring teeth are bent or broken (standard length error ≤2mm).

Compression chamber: Confirm that the piston movement is not jammed and the sealing ring is not damaged (oil leakage will cause insufficient compression density).

Knotting device: Lubricate D-type knotting blades (add 20g of No. 3 lithium-based grease per shift), and clean knotting debris.

Hydraulic system: Check the oil level (the oil quantity should be 10mm below the upper limit of the oil gauge), and the pressure gauge reading should be 16-18MPa.

Transmission system: Check the tension of the chain (which can swing up and down by 10-15mm), and ensure that the belt has no cracks or aging.

2. Parameter adjustment

Moisture content of materials

Hay: 15%-20% (If too high, it is prone to mold; if too low, it is prone to cracking).

Straw: ≤25% (The compression density can be adjusted by the gap of the kneading roller from 0.5 to 2mm).

Binding rope tension

Straw: 120-150N (avoid loose baling).

Hay: 80-120N (reduces the risk of baling rope breakage).

Picking height

Adjust the ground clearance of the picker to 3-5cm (if it is too high, grass will leak out; if it is too low, soil may be sucked in).

3. Operating procedures

Startup sequence

First, start the tractor, then engage the power output shaft (PTO) of the baler, and set the rotational speed to 540 revolutions per minute.

Trial operation

Run at low speed without load for 5 minutes and check if there is any abnormal vibration or noise from each component.

Formal assignment

Maintain a constant speed (3-5km/h is recommended), and avoid sudden acceleration that may cause material accumulation.

After each bundle operation is completed, observe the density of the bundles and the firmness of the binding ropes. Adjust the parameters if necessary.

Ii. Daily Maintenance

1. Daily maintenance

Clean up the residual materials

After turning off the engine, use compressed air to clean the grass debris in the compression chamber, the picker and the knotter.

Check the fasteners

Tighten the spring tooth bolts of the picker (torque value: 25-30N·m) to prevent them from falling off during operation.

Lubrication and maintenance

Apply grease to the drive shaft and bearing housing (50g per shift).

2. Maintenance every 50 hours

Replace the hydraulic oil filter element

The filter element model needs to match the equipment (for example, HY-GARD filter elements are required for John Deere). After replacement, start the equipment and run it for 10 minutes to check if there is any leakage in the oil circuit.

Check the blade wear

Measure the thickness of the cutting edge of the picker blade (standard value ≥3mm). If it is lower than this value, it needs to be replaced (the cost of a single piece is approximately 80 yuan).

Adjust the knotting time

Use a stopwatch to test the knotting period (standard value 1.2-1.5 seconds). Calibration is required if the error exceeds 0.1 seconds.

3. Maintenance every 200 hours

Change the hydraulic oil

Drain the old oil, clean the oil tank and then add new oil (with a capacity of approximately 80L, anti-wear hydraulic oil ISO VG46 should be used).

Inspect the piston sealing ring

Disassemble the end cover of the compression chamber and inspect the aging condition of the sealing ring (cracks or deformations require replacement, with a cost of approximately 200 yuan per set).

Calibrate the tension sensor of the binding rope

Use a tensiometer to test the error between the actual value and the displayed value (allowable range ±5N).

Iii. Common Fault Handling

Fault phenomena, possible causes, solutions, preventive measures

The bundles are loose and the tension of the binding ropes is insufficient

Adjust the pressure of the tension valve to 120N when the knotter malfunctions

Replace the buckle blade and check the remaining balance of the binding rope daily (≥5 turns)

The moisture content of the material in the compression chamber is too high due to blockage

Piston jamming reduces the operation speed to 3km/h

Before cleaning the piston and replacing the sealing ring, test the moisture content of the material (handheld moisture meter)

The grass picker is leaking and the teeth are missing

If the gap between the feeding roller is too large, replace the spring teeth (50 yuan per tooth)

Adjust the gap to 12mm and check the integrity of the spring teeth daily

The hydraulic system overheats and the oil pump leaks inside

Replace the oil pump when the radiator is clogged (cost about 2,000 yuan)

Clean the grass debris on the radiator surface and check the oil temperature (≤80℃) every 50 hours.

Iv. Seasonal Maintenance

Maintenance at the end of the working season

"Clean

Rinse the surface of the equipment with a high-pressure water gun, with a focus on cleaning the compression chamber, the picker and the gaps of the radiator.

Anti-corrosion treatment

Spray anti-rust paint (such as epoxy zinc-rich primer) on exposed metal parts and apply anti-rust oil to chains.

Long-term storage

Park the equipment in a dry and well-ventilated warehouse and support the tires with jacks (to prevent deformation due to long-term pressure).

2. Pre-season inspection of work

Power system

Replace the grease on the power output shaft of the tractor and check the clearance of the universal joint cross shaft (≤0.5mm).

Electrical system

Check whether the indicator light and sensor circuits of the baling machine are damaged, and replace the aged battery (voltage ≥12V).

Trial operation

Run at low speed without load for 30 minutes and observe the temperature rise of the hydraulic oil (≤10℃ for 10 minutes is normal).