AGCO HayBoss G2 596 User manual

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

For AGCO part cross-reference visit: www.harvesttec.com/system.html
2
Harvest Tec 596 Table of Contents
PAGE
Installation kit reference chart 3-4
Introduction 5
Safety 4-6
Safety Sign Locations 5
Preparing the applicator for operation 7-8
Filling the tank 7
Connecting power and communication harnesses 8
Operation of the main ball valve 8
Descriptions of screens and menus 9-15
Automatic mode 10
Manual mode 11
Diagnostics 12
Setup mode 13-14
Job records 15
First time and annual start up 16
Setting up Application and Bale Weight Parameters 17-18
Application rate 17
Selecting high and low tips 17
Baling rate 18
Operating instructions 19-23
Automatic mode 19
Manual mode 20
Job records 21-22
Diagnostics 23
Common questions about operation of the applicator 24
Maintenance 25-27
Maintenance schedule 25
Diagnostics 25
Filter bowl cleaning 25
Tips & tip screen cleaning 26
Tank lid cleaning 27
Dielectric grease connections 27
Rebuild pumps 27
Battery connections 27
Check valves 27
Miscellaneous maintenance 27
Winter storage 28
Status alerts 28
Troubleshooting 29-30
Wiring diagrams 31-32
Parts breakdown 33-59
Tank, Saddle & Legs 33
Pump manifold 34
Star wheel sensors 35
Control boxes and wiring harnesses 36
Hose and drain/fill line 37
Installation kits specific to balers 38-59
Notes 61
Warranty statement Back page

For AGCO part cross-reference visit: www.harvesttec.com/system.html
3
Installation kit reference chart
BALER MAKE MODEL INSTALL KIT
AGCO
Hesston
4750-4755
4760
4790
4900-4910
4760 roto-cutter
4790 roto-cutter
7430
7430 roto-cutter
7433-7444
7433-7434 roto-cutter
2150 – 2190
2150 – 2190 roto-cutter
2150 – 2190 packer cutter
030-4490B
030-4494B
030-4492B
030-4491B
030-4500B
030-4501B
030-4494B
030-4500B
030-4518B
030-4519B
030-4518B
030-4519B
030-4527B
Case IH 8570-8575
8585
8580-8590
LBX331-332 STD or packer
LBX431-432 STD or packer
LBX331-332 roto-cutter
LBX431-432 roto-cutter
LB333 – 433 STD or packer
LB333-433 roto-cutter
LB 433 STD or packer (2011-2012)
LB 433 roto-cuter (2011-2012)
030-4490B
030-4492B
030-4491B
030-4495B
030-4495B
030-4497B
030-4497B
030-4495B
030-4497B
030-4528B
030-4529B
Challenger LB33
LB34
LB44
LB33B – LB44B
LB33B – LB34B roto-cutter
LB33B – LB34B packer cutter
030-4494B
030-4492B
030-4491B
030-4518B
030-4519B
030-4527B
Krone VFS 88
VFS 88 cutter
VFS 128
VFS 128 cutter
890-12130 XC
890-12130
030-4498B
030-4495B
030-4498B
030-4495B
030-4514B
030-4515B
Kuhn LSB 870 – 890
LSB 1270 – 1290
Omni-cut
030-4510B
030-4511B
030-4525B
Claas
2200/1200/3200/3300/3400
2100 030-4499B 030-4509B
Massey
Ferguson 2050
2050 roto-cutter
2150 – 2190
2150 – 2170 roto-cutter
2150 – 2190 packer cutter
2170XD with roto-cutter
030-4494B
030-4500B
030-4518B
030-4519B
030-4527B
030-4530B
New Idea 7233
7234
7244
7333
030-4490B
030-4492B
030-4491B
030-4494B

For AGCO part cross-reference visit: www.harvesttec.com/system.html
4
Installation kit reference chart continued:
New Holland 590-BB9080 STD or packer
BB940-BB9080 roto-cutter
BB9080 STD or packer (2011-2012)
BB9080 roto-cutter (2011-2012)
030-4495B
030-4497B
030-4528B
030-4529B
Taarup 6570 – 6570 OC
6670 – 6690 OC 030-4510B 030-4511B
Vermeer SQ2731
SQ3347 030-4438B 030-4439B
Vicon LB 8200
LB 12200 030-4510B 030-4511B
Introduction
Congratulations on purchasing a Harvest Tec Model 596 applicator. This 596 applicator is designed to apply a buffered
propionic acid on to the forage crop as it is being baled. The 596 applicator will adjust the rates based on the moisture
and tonnage of the crop being harvested. This manual will take you through the steps of operation of the applicator and
also point out all safety precautions that need to be made while using the applicator. Read this manual carefully to learn
how to operate the equipment correctly. Failure to do this can result in personal injury or equipment malfunction. If you
are unsure about operating the system after consulting this manual, contact your local authorized dealership for additional
assistance. If you are in need of parts for the system please see your Installation Manual and contact your local
authorized dealer to order the parts. This applicator is designed to apply Harvest Tec buffered propionic acid.
Right and Left sides are determined by facing in the direction of forward travel.
Safety
Carefully read all the safety signs in this manual and on the applicator before use. Keep signs clean and in good working
order. Replace missing or damaged safety signs. Replacement signs are available from your local authorized dealer.
See your installation manual for under the replacement parts section for the correct part numbers.
Keep your applicator in proper working condition. Unauthorized modifications to the applicator may impair the function
and/or safety of the machine.
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
5
Safety Signs Locations
3, 4, 5
1
2
3, 5

For AGCO part cross-reference visit: www.harvesttec.com/system.html
6
Safety Signs – continued
Number 1
Spraying hazard. Disconnect power before servicing the
applicator
Part no. DCL-8003
Number 2
Falling hazard. Do not step in this area.
Part no. DCL-8002
Number 3
Use caution when working around chemicals. Wear all
protective equipment according to the label of the
product.
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
7
Preparing the applicator for operation
After the Applicator has been installed on the baler follow the below steps to prepare for operating the applicator both
safely and correctly.
Filling the tank:
Read the label of the product being filled into the tank to determine what individual protective measures need to be taken.
Locate the drain/fill line on the right side of the baler. Open the cam-couplers (A) and remove the protective plug (B).
Insert the male coupler (found on transfer pump) into the female cam and close the cams (A). To open the ball valve (C)
turn the handle so it is vertical. After the ball valve has been turned on switch the pump to the On position. Monitor the
level on the tank visually and shut off the pump before over filling. Once the pump is turned off, close the ball valve and
remove the male coupler. The handle of the ball valve (C) will be horizontal when closed. Reinstall the protective plug
and close the cams. 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
A
A
B
C
Enlarged view of the drain/fill line valve and
cam-coupler assembly.

For AGCO part cross-reference visit: www.harvesttec.com/system.html
8
Connecting power and communication harnesses
The power (006-5650A & 006-5650B) and communication (006-5650C & 006-5650D) harnesses are color coded. The
power harnesses are color coded red, the communication harnesses are grey. Always connect the communication
harness first and the power second. The power harness should be disconnected whenever service work is to be done to
the baler or applicator.
The harnesses are located at the front of the baler near the hitch and at the back of the tractor near the drawbar. See
arrow below. Make sure all connection wires are free between the hitch of the baler and the back of the tractor, especially
when tractor is turning away.
WARNING: Stop tractor engine and shift to park or neutral, set brakes and remove key before leaving the tractor.
Operation of the main ball valve
The ball valve shall be closed at all times when the applicator is not being used. The valve shall also be closed when any
service work is being done to the baler or applicator.
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
9
Description of Screens & menus of the Harvest Tec monitor
This system is calibrated for use with Harvest Tec buffered propionic acid. The use of other products can
cause application problems and damage to system components. It is designed to apply rates of 44 to 632
pounds of acid per hour and read moisture levels of 6 to 70 percent. The 565 monitor will allow you to set your
bale size, weight, single bale formation time, moisture levels and application rates. The automatic mode will
automatically adjust the application rates as the moisture level changes. Manual mode will allow you to control
the application rates on the go.
Automatic Mode This operating mode automatically adjusts preservative application as you bale. The
following items are displayed in the mode while baling: Moisture, Baling Rate, Application Rate (actual and
target), Last Bale Average Moisture, Tons Baled, and Pounds of Product Used.
Manual Mode This operating mode allows the three different pumps to be turned on at a fixed rate as you
bale. The following items are displayed in the mode while baling: Moisture, Baling Rate, Application Rate
(actual only), Last Bale Average Moisture, Tons Baled, and Pounds of Product Used. This mode can also be
used to prime the pumps.
Setup Mode This mode allows the operator to customize the applicators settings for their baler and baling
needs. This mode allows changes to be made to the following areas: Application Rate, Baling Rate,
Language, US or Metric units, and turn on/off the optional Hay Indicators.
Diagnostics Allows operator to automatically check performance and output of pumps as well as set the date
and time and calibrate the touch screen. The installed software versions can also be viewed here.
Job Records Keeps track of up to 300 jobs with total product used, average moisture content, highest
moisture content, tons baled, date of baling, and total number of bales made. Individual bales are also able to
be viewed and the records can also be downloaded to a USB drive in this mode.
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).
Main menu of the Harvest Tec monitor

For AGCO part cross-reference visit: www.harvesttec.com/system.html
10
Screen Menus
Use the below listed screen menus to navigate through all of the operation screens.
Automatic Mode: