STROKE AND BALE COUNTER - Allied Systems Company
Contents
1. WFREEMAN Stroke amp Bale Sater STROKE AND BALE COUNTER OPERATOR S INSTALLATION AND PARTS MANUAL 89 063 A Product of Sherwood Oregon USA 89 063 Rev 05 2013 Contents EE 3 5 MERERI TE 6 7 AS CAN c 8 19 erus 20 dc m 21 89 063 Rev 05 2013 WFREEMAN Safety Safety Symbols The following symbols terms are used to emphasize safety precautions and notices in this manual General The following pages contain general safety warnings which supplement specific warnings and cautions appearing elsewhere in this manual All electrical and hydraulic equipment is potentially hazardous You must thoroughly review and understand this Safety Section before attempting to operate troubleshoot maintain or service this Stroke and Bale Counter Time money and effort have been invested in mak ing your Stroke and Bale Counter a safe product The dividend from this investment is YOUR PERSONAL SAFETY However it must be realized that no power driven equipment can be any safer than the person behind the controls If you don t operate and maintain your Freeman equipment safely our efforts will have been in vain The safety instructions and warnings as documented in this manual and shipped with the2. C La Needle Yoke Drill and Tap 1 4 20 UNC Hole Thru 1 Wall Figure 6 Drill and Tap Hole in Needle Yoke 89 063 Rev 05 2013 11 Installing Bale Counter Sensor Mount Return the needle yoke to the fully raised position Again place the bale counter sensor mount longer bracket on the side of the frame above the needle yoke Leave about 9 16 between the mounting hole and the magnet Make sure that the mounting face is parallel to the face of the magnet paint from the bracket and frame in this area Tack weld the bracket in place Check that the sensor mounting hole and magnet line up with one another and that there is approximately 9 16 clearance between the two Adjust as necessary then weld in place Paint over the welded area to protect it from the ele ments Magnet Figure 7 Install Needle Yoke Magnet and Bale Counter Sensor Mount 12 89 063 Rev 05 2013 WFREEMAN Install amp Adjust Plunger Magnet amp Sensor Place the remaining magnet in the mount located on the plunger with the magnet facing the outside of the OTI plunger and secure with the nut see Figure 8 Place the sensor with the blue wire plunger sensor in Be mindful that as the wear pads on the plunger the plunger sensor mount are worn over time this gap could lessen To reduce the chance of damage check this gap periodically to ensure that there is a minimum of 1 4 gap when the plun
3. 1 Total Press this button to reset the number shown in the Total Bales display to zero 0 Once at zero the Total Bales display will increment by one for each bale that is tied 2 Stroke Press this button to reset the number shown in the Stroke display to zero 0 Under normal operation the Stroke display will display the total number of plunger strokes to form the last bale that was tied This effectively gives you the number of flakes for the previous bale 3 Display On Off This button toggles the display power on and off Make sure that the display is connected properly to a 12VDC power source At the beginning of a Baling session press the Display On Off button to turn the display on then reset both the bale count and the stroke count since values from the previous session will still be displayed they are maintained in memory Note The stroke count is counted between tie cycles The stroke count for the first bale of every windrow will likely be too high since the plunger is active even when the baler is not taking in mate rial Total Bales HEN WFREEMAN Division of Allied Systems Company Stroke amp Bale Counter p Reset D Sensors E ON ET c n A A gt T E C CM Stroke Zs Stroke 21433 Oregon St Sherwood OR USA 1 800 285 7000 www alliedsystems com Display On Off Ge Figure 17 Operati
4. explosive gases Keep sparks flame and ciga rettes away Ventilate when charging or servicing in an enclosed space Always shield your eyes when working near batter ies When removing battery cables disconnect the negative cable first When installing a battery always connect the positive cable first This procedure will help to prevent a spark which could cause an explosion Safety Equipment Ensure test equipment is in good condition If an instrument must be held while taking mea surements ground the case of the instrument before energizing equipment Do not touch live equipment or personnel work ing on live equipment while holding a multimeter Some types of measuring devices should not be grounded do not hold such devices while taking measurements Prevent personal injury or equipment damage by using a lifting device with a lifting capacity greater than twice the weight of any equipment to be lifted Always use personal protective equipment PPE appropriate to the situation This may include the use of hearing protection eye protection a respi rator a hard hat leather gloves steel toed boots CO 89 063 Rev 05 2013 Electrical Hazards An electric shock could be fatal Ensure power to the baler is OFF before opening electrical panels All electrical cables and connectors must be in good condition free of corrosion damage etc Use caution in wet weather to avoid
5. danger from electrical shock Never attempt electrical testing or repair while standing in water Do not wear electri cally conductive jewelry clothing or other items while working on the electrical system Compressed Air Hazards When using compressed air to dry parts pressure should not exceed 30 psi 200 kPa Air pressure penetrating your skin can be fatal Never direct compressed air at anyone General The Freeman Stroke and Bale Counter allows the op erator to monitor the number of strokes per bale and total number of bales per session in real time from the cab This counter is built to the same exacting stan dards as Freeman balers and is easily mounted to any new or existing side feed Freeman Baler The kit contains a display unit which is mounted in the cab a power cable a signal cable two magnets and all necessary mounting hardware Note the display unit is not weather proof and is intended to be mounted in a dry environment inside a cab for example The instructions and illustrations in this manual depict a 2012 2013 Freeman 370 baler Your baler may vary and require slightly different installation procedures Head all of the instructions before beginning the instal lation Unpacking Immediately upon receiving the Stroke and Bale Counter kit it should be unpacked and an inventory taken See Figure 1 for a list of items that should be included Report any missing or damaged it
6. own safety legislation is in the operator s own interest to be conversant with these regulations and to comply with them in full This also applies to local bylaws and regulations in force on a particular worksite Should the recommendations in this manual ate from those in the user country the national regulations should be followed Never attempt to disconnect any of the safety devices built into the baler or tractor Maintain proper clearance from energized equip ment energized power lines or other power sources High voltage electricity can discharge to ground without direct contact with the baler s or tractor s structure If the baler or tractor contacts energized equipment or if electrical energy does discharge through the machine stay clear and prevent anyone else from coming in contact with the baler or tractor If you are on the tractor stand fast avoid contact with metal surfaces and do not permit anyone to come into contact with the tractor or baler Finally Do not jump off Maintenance Safety Maintenance lubrication and repair of this ma chine can be dangerous unless performed prop erly In order to ensure safety each person work ing on the Stroke and Bale Counter must have the necessary skills information tools and equipment and satisfy himself that his work method is safe correct and meets his own company s require ments Do not attempt to make adjustments or perform repairs unless
7. aint and Weld on Capscrews In 5 Places Approximately as Shown Figure 10 Install Cable Clamps as Shown 89 063 Rev 05 2013 15 Place washer on the outside of each clamp Secure the clamps with the ESNA nuts Place one cable tie around the sensor wire next to each clamp to help prevent the wire from slipping through the clamp and interfering with baler opera tions Route the sensor cable up under the knotter drive chain to the top of the baler frame Run the cable along side the existing wire harness Use ty straps to secure the cable to the existing harness See Figure 12 and Figure 13 After the cable exits the front left side of the baler frame secure it again using ty straps to the existing tension and throttle control cables for routing to the cab Figure 12 Secure Sensor Cable to Wire Harness 16 89 063 Rev 05 2013 m Figure 13 Route Sensor Cable to Cab 89 063 Rev 05 2013 17 Modify Plunger Shield A notch must be cut into the plunger shield that was removed to make room for the Plunger Mount and Sensor se
8. e Figure 14 NOTICE There should be a minimum of 1 8 clearance between the edge of the slot and the signal cable Remove all burrs and sharp edges from the cut surface Replace the plunger shield Heplace the pickup shield brackets and shield See Figure 2 Replace the knotter drive chain shield Cut Notch Remove Burrs and Sharp Edges Figure 14 Notch Shield as Shown and Install 18 89 063 Rev 05 2013 Prepare Display Connect the sensor cable to the control box See Figure 16 Mount the display in the cab where it will be easily Only qualified personnel should make the elec seen by the operator but where it will not interfere with trical connections described in this section vehicle operations Ensure that the location is dry and out of the weather Connect the bare end of the power pigtail to a 12VDC power source Connect the red wire to 12VDC power The display contains a large magnet on its rear face and the black wire to negative ground Secure the display to a flat metal surface or modify the mounting to suite your application as required Connect the end with the plug to the display s power cord See Figure 15 Figure 15 Connect Power Plug to Display Figure 16 Connect Sensor Cable to Display 89 063 Rev 05 2013 19 Operation Once installed and connected operation of your Stroke and Bale Counter is simple There are three buttons
9. e of the two smaller brackets approximately 3 down from the top of the gusset The outer edge of the bracket is to be flush with the outer edge of the gusset see Figure 3 Remove paint from the bracket and gusset in this area Tack weld the sensor mount in place Figure 3 Install Plunger Sensor Mount 89 063 Rev 05 2013 9 Installing Plunger Magnet Mount Rotate the flywheel counter clockwise by hand until the plunger is fully extended Locate the plunger magnet mount the second small er bracket on the front end of the plunger in line with the plunger sensor mount see Figure 4 The outer edge of the mount will be flush with the outer edge of the plunger Mark this location or clamp the mount in place Note In Figure 4 surfaces shaded with like colors are flush For easier access rotate the flywheel counter clockwise by hand until the plunger is retracted and the bracket mounting area is more easily accessible through the opening created by the removal of the Pickup Clutch Shield A TT o P XM y Remove paint from the bracket and plunger in this area Tack weld the magnet mount in place Fully extend the plunger to check that the sensor and magnet mounting holes line up with one another and that the brackets will not interfere with any part of the baler Adjust the brackets as necessary then weld both brackets in place Paint over the welded areas to protect them from the ele
10. e term NOTE highlights operating procedures or practices that may improve equipment reliability and or personnel performance or to emphasize a concept Intended Use Statement This Stroke and Bale Counter is intended to count and display the number of strokes per bale formed and bales per session Use in any other way is considered to be contrary to the intended use Operation Warnings Warning Failure to observe the following safe ty rules may result in extreme personal injury dismemberment or death It is the operator s responsibility to understand the proper and safe use of this Stroke and Bale Counter Make sure that you read understand and obey all of the safety precautions and operating instruc tions in this Users Manual Keep this User s Manual with the Stroke and Bale Counter at all times Do not operate the Stroke and Bale Counter un less you are authorized and trained to do so If it has been some time since you last operated the otroke and Bale Counter re familiarize yourself with it before starting then proceed slowly Do not operate the Stroke and Bale Counter if you are aware of any malfunctions needed mainte nance or repairs otop the baler immediately if any problems arise Do not start the tractor if the key had been marked with a DO NOT START or RED tag Never operate any of the tractor s controls from anywhere other than the operator s seat Each country has its
11. ems to Allied Systems Company Service Parts Department 503 625 2560 immediately 89 063 Rev 05 2013 WFREEMAN Power Cable 1 Magnet With Mounting Stud 2 otroke amp Bale Counter Display 1 oignal Cable 1 Components Hardware sensor Mount Bale Counter 1 Sensor Magnet Mount Stroke Counter 2 Q e Cable Ties 15 Capscrew 5 Clip 5 Flat Washer 10 Lock Nut 5 Figure 1 Kit Contents 89 063 Rev 05 2013 7 Installation Preparation WARNING NOTICE Park the baler on level ground and chock the Disconnect battery wire harness from tractor and tires any other sensitive electrical equipment that could be damaged from welding Make sure the tractor and baler are at a com plete stop with the engine s turned off and all systems de energized Follow your company lockout tagout policies Remove the shield to expose the end of the plunger stroke Remove the pickup clutch shield and it s two 2 mounting brackets See Figure 2 Failure to secure the baler before installation may result in severe personal injury or death Remove the knotter drive chain shield Knotter Drive A Chain Shield Pickup Clutch S Shield Bracket Shield Exposes End of Plunger Stroke Figure 2 Remove Shields and Brackets 8 89 063 Rev 05 2013 WFREEMAN Installing Plunger Sensor Mount Locate the top of the plunger sensor mount on
12. ger is pushed as far left as possible in the chamber Readjust if necessary Push the plunger as far to the left side of the chamber as possible Adjust the sensor and or magnet so that the gap between them is 1 4 3 8 Sensor Figure 8 Install Plunger Magnet and the Plunger Sensor Blue Wire 89 063 Rev 05 2013 13 Install 4 Adjust Bale Counter Sensor Place the sensor with the white wire bale sensor in the needle yoke sensor mount Adjust the sensor so that there is 1 4 3 8 between it and the magnet on the needle yoke when the needle yoke is fully raised see Figure 9 NOTICE Be mindful that this gap could change over time To reduce the chance of damage check this gap pe riodically to ensure that there is a minimum of 1 4 gap when the needle yoke is fully raised Readjust if necessary Sensor 1 4 3 8 Figure 9 Install the Bale Counter Sensor White Wire 14 89 063 Rev 05 2013 Route Wire Harness Remove paint from the left side of the baler in the five Paint over the welded areas to protect them from the 5 locations shown see Figure 10 for mounting of elements Place a flat washer on each bolt Weld the heads of the five 5 1 4 3 4 UNC cap screws to the baler frame where paint was removed Install cable clamps around the wire harness and onto the studs as shown see Figure 10 Remove P
13. machine provide the most reliable procedures for the safe operation and maintenance of your Stroke and Bale Counter It s your responsibility to see that they are carried out Allied Systems Company cannot anticipate all worksite conditions local regulations etc It is the responsibility of the end user to be aware of and obey any specific worksite local state or national regulations or proce dures that are applicable to operating this baler NOTE possible safety hazards cannot be antic ipated so as to be included in this manual There fore you must always be alert to potential hazards that could endanger personnel and or damage the equipment 89 063 Rev 05 2013 The DANGER symbol indicates a hazardous situation which if not avoided will result in death or serious injury Carefully read the mes sage that follows to prevent serious injury or death The WARNING symbol indicates a hazardous situation which if not avoided could result in death or serious injury Carefully read the mes sage that follows to prevent serious injury or death The CAUTION symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury or equipment dam age Carefully read the message that follows to prevent minor or moderate injury NOTICE The NOTICE symbol alerts to a situation that is not related to personal injury but may cause equip ment damage NOTE Th
14. ments Figure 4 Install Stroke Plunger Magnet Mount 10 89 063 Rev 05 2013 Installing Needle Yoke Magnet Raise the needle trip arm until it latches on the roller Figure 5 Needle Trip Arm Rotate the flywheel counter clockwise by hand The knotter clutch will trip and the needle yoke will start to raise Continue to rotate the flywheel until the needle yoke is fully raised top dead center See Figure 6 With the needle in the fully raised position temporarily place the bale counter sensor mount longer bracket on the left side of the frame above the needle yoke see Figure 6 Mark on the needle yoke where the center of the hole in the bracket lines up with the center of the needle yoke This will be the magnet s mounting location It may be helpful to temporarily install the white sensor in the bracket to more easily locate the magnet mount ing hole Once marked drill and tap a 1 4 20 UNC hole in the needle yoke It may be easier to drill and tap the hole if you lower the needle yoke Do this by rotating the flywheel counter clockwise by hand until you have good access With the jam nut on the 5 threads install the magnet into the needle yoke about 1 2 way See Figure 7 Secure with the jam nut Bale Counter Sensor Mount
15. on 20 89 063 Rev 05 2013 Total Bales Stroke amp Bale Counter im Reset 77 Display 4 Stroke On Off 1A PWR 12V DC Fuse Total Item Part No Qty Description Item Part No Qty Description 906867 Kit Stroke amp Bale Counter 1 89 063 1 Bale amp Stroke Counter Manual 3 906863 2 Plate Mounting 906801 1 Bale Counter Assembly 4 906864 1 Plate Mounting 2 1 906802 1 Display Bale Counter 5 R13803022 5 Insulated 247710 1 Fuse 1 Amp 6 242601 15 Cable Tie 2 2 906836 1 Cable Power 7 15113W 5 Nut 2 3 906837 1 Cable Signal 8 18460W 5 Capscrew 2 4 906838 2 Magnet 9 15127W 10 Washer 89 063 Rev 05 2013
16. you are authorized and qualified to do so Never attempt to service energized equipment Never attempt servicing while the baler is moving Shut off the tractor and secure power Shut off tractor and baler engine engage the parking brake disengage the baler and wait for all movement to stop before adjusting cleaning or servicing the Stroke and Bale Counter Tag the key switch with a DO NOT START sign and or remove the key Always perform all maintenance procedures with the baler on level ground parked in a safe area Block the tires to keep the machine from rolling Any unauthorized modifications made to the Stroke and Bale Counter by the customer or par ties other than Allied Systems will relieve Allied oystems Company and your Freeman dealer of any liability for damage or injury Replace any worn parts only with genuine Free man parts Call your dealer for assistance Unless specified in service procedures never at tempt maintenance procedures while the baler is moving or the engine is running Engine exhaust fumes can cause death If it is necessary to run the engine in an enclosed space remove the exhaust fumes from the area with an exhaust pipe extension Use ventilation fans and open shop doors to provide adequate ventilation 89 063 Rev 05 2013 WFREEMAN Batteries contain sulfu ric acid which can cause severe burns Avoid contact with skin eyes or clothing Batteries produce
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