Metal-Fach Z593-0E User manual

OPERATION INSTRUCTIONS
Automatic bale wrapper
Z593-0E
Issue: 01
Year of issue: 2014
The original operating manual language is Polish.

1
Original Instructions
Thank you for choosing our Z593-0E automatic bale wrapping machine designed for efficient
operation.
The following manual will let you fully use the advantages of our wrapping machine and to
optimise the bale wrapping process.
The manual contains a detailed table of contents followed by descriptions which will allow to
easily identify the device and to make the best use of it.
The information regarding safety and comfort of operation, description of coupling with a
tractor, operation during work, technical service activities and storage conditions are listed on the
following pages of the manual.
A spare parts catalogue containing the list of the wrapping machine major components
allowing for easy ordering is attached to the manual in a digital form on a CD.
A printed version of the catalogue may be purchased at authorised dealers or directly from the
manufacturer.
Both the manual and the spare parts catalogue contain basic information on the product. The
elements fitted to the equipment may be slightly different from the ones presented in the manual.
The manufacturer reserves the right to introduce changes without notice.

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Contents
1 Wrapping machine identification, general safety rules .................................................................. 4
1.1 Wrapping machine identification............................................................................................ 4
1.2 Wrapping machine construction............................................................................................. 6
1.3 Wrapping machine characteristics.......................................................................................... 7
1.4 Bale wrapper's hydraulic system............................................................................................. 8
1.5 Wrapping machine dimensions............................................................................................... 9
1.6 Symbol placement................................................................................................................. 10
1.7 Warning symbols................................................................................................................... 11
1.8 General safety rules............................................................................................................... 12
2 Drive operation.............................................................................................................................. 14
2.1 Coupling with drive................................................................................................................ 14
2.2 Disconnecting from the drive................................................................................................ 15
3 First start-up .................................................................................................................................. 15
4 Controls and operation of wrapper............................................................................................... 16
4.1 Description of buttons on the ARASO-V1 control panel ....................................................... 16
4.2 Operating the control panel .................................................................................................. 18
4.2.1 Activating the panel....................................................................................................... 18
4.2.2 Powering off the panel .................................................................................................. 18
4.2.3 Collision protection ....................................................................................................... 18
4.2.4 Wrapper manual control ............................................................................................... 20
4.2.5 Semi-automatic mode operation .................................................................................. 20
4.2.6 Automatic operation ..................................................................................................... 21
4.2.7 Transport position ......................................................................................................... 21
4.2.8 Stop during wrapping .................................................................................................... 23
4.2.9 Emergency stop ............................................................................................................. 23
5 Ongoing adjustments .................................................................................................................... 24
5.1 Correcting sensor settings..................................................................................................... 25
5.2 Adjustment of bale on end kit support ................................................................................. 26
5.3 Adjustable hydraulic valves ................................................................................................... 28
5.4 Towbar position change ........................................................................................................ 29
5.5 Installing film ......................................................................................................................... 30
5.6 Adjustment of driving chain .................................................................................................. 31
5.7 Film cutter ............................................................................................................................. 31
6 Wrapping ....................................................................................................................................... 32

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6.1 Wrapper preparation ............................................................................................................ 32
6.2 Bale loading ........................................................................................................................... 32
6.3 Wrapping ............................................................................................................................... 33
6.4 Unloading a wrapped bale .................................................................................................... 34
6.5 Finishing work........................................................................................................................ 35
7 Periodical inspections.................................................................................................................... 36
7.1 User inspection...................................................................................................................... 36
7.2 Service checks........................................................................................................................ 36
8 Authorised service......................................................................................................................... 37
8.1 Warranty service ................................................................................................................... 37
8.2 Ongoing maintenance ........................................................................................................... 37
8.3 Ordering spare parts.............................................................................................................. 37
9 Transporting the bale wrapper ..................................................................................................... 37
9.1 Transporting a load ............................................................................................................... 37
9.2 Driving on public roads.......................................................................................................... 38
10 Bale wrapper storage .................................................................................................................... 39
11 Hazards .......................................................................................................................................... 40
11.1 Description of residual risk.................................................................................................... 40
11.2 Assessment of residual risk ................................................................................................... 40
12 Bale wrapper disposal ................................................................................................................... 41
13 Typical problems and troubleshooting.......................................................................................... 41
14 Accessories .................................................................................................................................... 42
15 Names and abbreviations.............................................................................................................. 43
Warranty card........................................................................................................................................ 44

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1Wrapping machine identification, general safety rules
1.1 Wrapping machine identification
The wrapping machine is identified by its nameplate securely fastened to the main frame of
the machine.
Fig. 1. The information presented on the nameplate is shown on the diagram below.
Caution!
It is forbidden to drive the machine on public roads without its nameplate or with an illegible
nameplate.
Fig. 2. Nameplate location.
When purchasing the machine check the serial number indicated in the Manual and the
warranty sheet against the serial number stamped on the nameplate.
The Manual is a part of the Z593-0E wrapping machine equipment.
If the machine is sold to another user, it must be supplied with the operating manual. It is
advised that the supplier has a confirmation stating that the manual was transferred together with
the machine, signed by the buyer and filed.

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Carefully read the operating manual.
If the rules stated in this manual are complied with, it will help prevent hazards and operate
the machine efficiently; it will also allow to retain the warranty throughout the period granted by the
manufacturer.
Detailed information on the structure, operating principles, technology and other details may
be obtained from authorised outlets and the wrapping machine manufacturer.
Caution!
It is forbidden for persons who have not read the manual to operate the machine.
The wrapping machine shall be operated according to its intended use by coupling it with a
tractor with nominal power exceeding 30 kW and towing power class of 0.9. The Z593-0E bale
wrapping machine is designed to pick up bales from the ground, wrap them in film and unload to the
ground.
Dry grass and other papilionaceous plants with humidity of approx. 60%1shall be rolled into
bales using the collecting and wrapping presses. The bale wrapping process should be conducted on
the field or in the storage yard practically immediately after they have been rolled (up to 2 hours2).
The wrapped bales should be stacked in up to two layers on a dry and even surface making sure the
wrapping film is not torn.
The fermentation process must continue for 6 to 8 weeks at positive temperatures. Thus
provided silage is fit for use as a wholesome feed for animals.
During operation, the operator is not subject to noise which may cause the loss of hearing, as
the noise level of the machine does not exceed 70 dB (A) and the operator works inside the tractor
cabin.
During the operation, the operator is not subject to harmful vibration as the vibration level
transferred to the upper limbs does not exceed 2.5 m/s2, and the vibration level transferred to the
body is lower than 0.5 m/s2and the operator is positioned in the tractor cabin.
Caution!
Any unauthorised changes to the machine structure absolve the manufacturer from all
responsibility for the threats and damage it may cause.
1Grass and other papilionaceous plants prepared for ensilage and wrapping should be mowed
in the early phase of heading (best done in the afternoon). On the next day, after a few hours of
drying, the mowed material should be gathered using the wrapping presses. Maximum bale
compression must be maintained.
2An unwanted decomposition process takes place in bales left unwrapped for a longer time.

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1.2 Wrapping machine construction
The Z593-0E wrapping machine consists of the following units:
Complete axle with ground wheels item 1
Lower frame item 2
Rotary frame item 3
Loading arm item 4
Unloading unit item 5
Drawbar item 6
Wrapping film feeder item 7
Support stand item 8
Cutting assembly item 9
Wheel lock wedge item 10
Side wheel item 11
Hydraulic control unit item 12
Control unit item 13
Electronic control panel item 14
Fig. 3. Wrapping machine construction.
The drawbar (6) is attached to the bottom frame (2) and equipped with an adjustable hitch
ring for the connection of the wrapping machine to the tractor and its levelling for a working or
transport position.
A rotary frame (3) is attached to the bottom frame (2). The loading arm (4) and the bale
unloading unit (5) are mounted to the bottom frame (2) in a movable way. The film feeder (7) is
attached to the bottom frame (2). A pictogram presenting the film movement during the wrapping
machine operation is placed on the film feeder.
Film movement
diagram

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1.3 Wrapping machine characteristics
No.
Description
Measure unit
1
Type
Z593-0E
2
Coupling method with the tractor
Hitched
3
Undercarriage type
Mono-axial
4
Overall dimensions in the working position
Length/width/height
mm
6050/3000/2600
5
Overall dimensions in the transport position
Length/width/height
mm
5220/2390/2600
6
Machine weight
kg
1250
7
Maximum bale weight
kg
800
8
Wrapped bale dimensions
Length
Diameter
mm
1200 1000-1200
9
Maximum service speed
km/h
10
10
Maximum transport speed
km/h
15
11
Coupling with a tractor by
-
Agricultural hitch
12
Tractor class
-
0.9
13
Minimum tractor power output
kW
30
14
Required pressure in the tractor power hydraulic
system:
MPa
14
15
Recommended tractor pump output
l/min
min. 22
16
Hydraulic oil cleanliness
-
not lower than 8 in accordance
NAS 1638 (category 19/17/14 in
accordance ISO 4406-1996)
17
Tractor hitch load
kN
1.2
18
Wheel track
mm
2000
19
Tyres
-
26.5x14.00-12
20
Tyre pressure
bar
1.7
21
Tow bar hitch-ring diameter
mm
40
22
Wrapping machine drive
-
Hydraulic, from the tractor
power hydraulic system
23
Rotary frame drive
-
Hydraulic motor
24
Maximum rotational speed of the rotary frame
RPM
35
25
Bale loading method
-
Automatic, using a loading arm
26
Bale unloading method
-
Automatic with the unloading
unit
27
Film cutting
-
Automatic during unloading
28
Film width
mm
500; 750
29
Number of the rotary frame (table) revolutions using
film:
500 mm
750 mm
revs.
24
16
30
Bale wrapping time (loading, wrapping, unloading)
min
2
31
Number of operators
-
1 (tractor driver)
32
Control panel
-
Electronic, type ARASO-V1
33
Electrical system voltage
V
12
34
Machine lights
-
Following the requirements of
the traffic code

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1.4 Bale wrapper's hydraulic system
The wrapping machine's hydraulic system is powered from the tractor hydraulic system. To
attach the machine to the tractor hydraulic system, the attachment cables are connected to the
hydraulic controls and further to the wrapping machine's hydraulic motor and hydraulic actuators.
The hydraulic motor uses chain transmission to drive turntable which in turn uses intersecting axis
gear to drive drums onto which a silage bale is being loaded. The purpose of double-acting actuators:
•Tilting the turntable and the unloading unit to the vertical and horizontal positions;
•Lifting and lowering the loading arm.
The Z593-0E bale wrapper is equipped with a power hydraulic system (fig. 4.) which includes
the following elements:
•flow controller item. 1
•electrically-driven hydraulic block item. 2
•three-way electric valve item 3
•throttle-check valve item 4
•hydraulic motor with brake item. 5
•protective valve for loading arm item 6
•loading arm lifting actuator item 7
•loading arm grip actuator item 8
•turntable frame tipping actuator item 9
•bale on end kit actuator item 10
•cradle actuator item 11
Fig. 4 Wrapper hydraulic system.
•Section I —Turntable
•Section II —Loading arm

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•Section III —Turntable frame and bale on end kit frame
•Section IV —bale on end kit cradle
Engine and hydraulic actuators are controlled using an electronic control panel located inside
the tractor operator's cabin. The panel is coupled with the control module via D-sub DE-9 type cable
which directly controls solenoid valves in the hydraulic block.
The 4-sectional control unit (1) is protected against high pressure from the hydraulic system by
means of a safety valve.
The bale wrapper's hydraulic system is protected against excessive volume output from the
tractor's power hydraulic system by means of a flow controller.
1.5 Wrapping machine dimensions
Fig. 5. Overall dimensions of a bale wrapper in the transport setup. The dimensions of the
machine in a working position are given in table: Bale wrapper properties chapter 1.3 of the manual.

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1.6 Symbol placement
Fig. 6. Location of symbols –right side. The meaning of pictograms is explained in section 1.7
of the Manual.
Fig. 7. Location of symbols –left side. The meaning of pictograms is explained in section 1.7 of
the Manual.

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1.7 Warning symbols
The warning pictograms placed on the machine (chapter 1.6) inform the operator about the
hazards and dangers which may occur during work. Keep the symbols clean and legible.
Replace illegible symbols with new ones, available from the manufacturer.
Symbol 1
Refer to the operating manual before
performing this action.
Symbol 8
Danger zone. Install a support before
starting maintenance activities.
Symbol 2
Turn off the engine and remove the
ignition key before servicing or repairs.
Symbol 9
Danger of crushing.
Symbol 3
Do not stand near the pull
rods of an operating
wrapping machine.
Symbol 10
Avoid contact with liquids under
pressure.
Symbol 4
Do not open or remove the safety
guards during machine operation.
Symbol 11
Do not stand on ladders and platforms
while the tractor is moving.
Symbol 5
Do not touch rotating elements during
the machine operation.
Symbol 12
Warning label.
Symbol 6
Do not approach the working machine.
Danger of being crushed by a bale.
Symbol 13
Warning label.
Symbol 7
Keep a safe distance from the raised
arm.
Danger of being crushed.
Symbol 14
40 x 950 warning sign.

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Symbol 15
50 x 300 warning sign.
Symbol 20
Correct location of a sensor in front
of actuator.
Symbol 16
40 x 800 warning sign.
Symbol 21
Recommended wrapping machine
tire pressure.
Symbol 17
Use protective gloves during
maintenance operations.
Symbol 22
CE requirements conformity
symbol.
Symbol 18
Attachment points for loading on a
means of transport.
Symbol 23
Lubrication point.
Symbol 19
Film wrapping diagram.
1.8 General safety rules
1) During operation and repair of the wrapping machine the farming health and safety
regulations contained in the Regulation of the Minister of Agriculture and Food Economy of
12 January 1998 must be complied with.
2) Only an adult with a valid agricultural tractor driver's licence and familiarised with the
occupational health and safety regulations regarding agricultural equipment and this Manual
may operate this machine.
3) The following manual must be read and adhered to, paying special attention to directions
regarding the safe operation of the wrapping machine.
4) The manual indicates the machine parts which pose a potential threat. Hazardous areas are
marked with yellow stickers with warning symbols. Pay special attention to the hazardous
areas and strictly adhere to the rules.
5) The operator must familiarise themselves with the meaning of the symbols.
6) It is prohibited to use a wrapping machine without protective covers in place.
7) Before every start up of wrapper, check the machine condition, completeness of the machine
and the fixing of covers.
8) Before every drive, starting the wrapper and driving on public roads, check the correctness of
coupling of the machine with tractor, tightening of wheel bolts and correctness of tractor-
hitch connection.
9) All adjustment, repair and maintenance works shall be conducted with the tractor engine
turned off and making sure that the machine is secured against accidental start.
10) Before commencing loading and during this process, make sure that there are no bystanders,
especially children, nearby.
11) During the operation of the wrapping machine, allow for free space near the rotating
elements. During bale wrapping, no people or animals are allowed near the rotating
elements.
12) Exercise extreme caution when working on inclined terrain. Note that the bales may roll
down slopes.

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13) It is forbidden to operate the wrapping machine with any of the assemblies lifted.
14) Do not stand between the wrapping machine and the tractor when the tractor engine is
running.
15) Exercise extreme caution when coupling and uncoupling the wrapping machine with/from
the tractor. The machine should be coupled with the tractor equipped with an agricultural
hitch able to withstand the vertical load larger than the vertical load on the wrapping
machine's drawbar.
16) During operation, use appropriate protective clothing and shoes with anti-slip soles.
17) Bale wrapping film should be installed after stopping the tractor's engine and protecting the
engine against inadvertent start (ignition key removed and service brake applied).
18) It is forbidden to operate damaged hydraulic lines. The damaged lines must be immediately
replaced with new ones. During the replacement of hydraulic lines, use impermeable
protective clothing.
19) The machine hydraulic system shall only be operated from the tractor cabin.
20) Follow the traffic code regulations and the manufacturer's recommendations when travelling
on public roads.
21) Visually inspect the machine being transported before entering a public road.
22) It is forbidden to remain on the wrapping machine during transport and operation.
23) It is forbidden to carry bales of swath or silage on the wrapper during transport on public
roads.
24) It is forbidden to operate the wrapping machine while under influence of alcohol.
25) It is forbidden to operate the wrapping machine while under influence of drugs or medicines
with similar effects.
26) It is forbidden to operate the wrapping machine while under influence of medicines which
affect the ability to drive vehicles or reduce psychophysical fitness or cause concentration
disorders and delay reaction time.
27) It is forbidden to drive the wrapping machine near sources of open flame.
28) It is required to strictly adhere to the fire protection regulations and immediately extinguish
any fire which may occur during the wrapping machine use or at its standstill.
29) Eliminate fire sources using powder fire extinguisher.
30) Do not approach the working wrapping machine with open flame and do not smoke near the
machine.
31) Every time before commencing work, check if the tractor is equipped with a dry powder
extinguisher. If not, place a dry powder fire extinguisher on the tractor.
32) In case of emergency, press STOP button on the control panel. Turn off the tractor engine,
remove the ignition key and engage the tractor parking brake. Locate the fault and fix it or
have an authorised service point repair it.

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2Drive operation
2.1 Coupling with drive
The Z593-0E bale wrapper should be coupled with agricultural tractors with minimum 30 kW
power and 0.9 draw class with two power hydraulic system connection.
•The wrapper shall be coupled to the tractor's lower hitch which allows the transfer of
vertical maximum vertical load of 1.2 kN.
•Make sure that there are no bystanders, especially children, in the coupling area.
Caution!
During coupling the equipment to the tractor, place the wrapper in the tractor axis on
hard, flat and level ground. Turn off the tractor engine, remove the ignition key and engage the
tractor parking brake. Level the wrapper by selecting the appropriate adjustment opening in the
hitch.
Caution!
Couple the hitch-ring only with the tractor's hitch and check whether the machine is properly
connected and secured against accidental disconnection.
Caution!
Make sure that the tractor hydraulic system is tight.
•Connect the electric supply. Secure the plugs of electric harness against accidental
disconnection. Secure against accidental damage.
•Check if the electric and signalling systems work properly.
•Connect the hydraulic power source.
•Reposition the drawbar from transport position to working position (chapter 5.4).
•Remove the protective device from the bale on end kit arm.
•Check tightness of bale wrapper's drive wheels pins.
•Check the correct operation of hydraulic systems without bale and without film in
manual mode (chapter 4.2):
-move the loading arm in manual operation mode, maximum lifting and lowering
height of the arm,
-make couple of revolutions with the turntable moving slow and fast. Stop the table at
the unloading position (table drums in parallel to the front beam of the main frame),
-perform unloading, move the bottom frame of the turntable to the position of
maximum deflection. Next, lower the turntable,
-move and lower the bale on end kit's cradle,
Check the correct operation of power hydraulic systems without bale and without film in semi-
automatic mode (chapter 4.2):
-load the machine in semi-automatic mode.
-make 10 revolutions with table in semi-automatic mode (first, set the number of
revolutions on the control panel). The table shall move in counterclockwise direction,
starting and slowing down should be smooth. The table should stop after making the

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preprogrammed number of revolutions and stop at the unload position. If not, manually
set the table to the correct stop position using slow movements.
-unload the machine in semi-automatic mode.
If the hydraulic and control systems work correctly, load the first bale and make sure if the
load on the tractor's front axle is larger than 20% of the tractor's weight. This is manifested by full
steering quality of the tractor.
2.2 Disconnecting from the drive
•Make sure that there are no bystanders, especially children, in the coupling area.
•Place the wrapper on a hard, flat, level ground at the storage location. Turn off the
tractor engine, remove the ignition key and engage the tractor parking brake.
•Disconnect the electric power supply.
•Disconnect the power hydraulic system.
•Lower the main frame support.
•Disconnect the hitch-ring from the transport hitch.
•Make sure that the machine will not move accidentally, if necessary, place chock (included
with the wrapper, on drawbar) under the wheel.
3First start-up
The commissioning of a newly purchased bale wrapper should be performed by the dealer's
service representative.
Caution!
Before commissioning, familiarise yourself with the following manual, paying special
attention to the fragments regarding the safety of the operator and bystanders.
If there are any doubts regarding safety issues, please contact your sales representative or the
manufacturer.
Before each start up of the machine, the control panel shall be installed in the tractor
operator's cabin.

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4Controls and operation of wrapper
4.1 Description of buttons on the ARASO-V1 control panel
Button
(symbol)
Designation
Function
STOP
Emergency stop —locks all functions of the wrapper. Unlocked
with the F1+F2 combination or by turning off.
Power switch
Activates the control panel
SET
Views current time and date
Plus
Changes/increases the current value
Minus
Changes/decreases the current value
Menu
Enters the control panel's menu (selected with F1 and F2
buttons):
- Resets bale counter
- Setting time and date —+ and - buttons
- Resets all fields counter
- Setting the number of wraps (10-99) –+ and - buttons
- Selects the field (16 fields available) –+ and - buttons
Confirmation: Enter
Escape
Exits menu and other locations
Statistics
Viewing the current wrapper's operational statistics

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Enter
Confirms the entered changes or enters other selection levels (on
a menu)
F1
1 press: Resets the counter of current number of revolutions for
a table
2 presses: Resets the current bale status (shows if the bale is
placed on the turntable)
In automatic mode, selects the operation:
- Automatic loading of bale
- Automatic wrapping
- Automatic unloading of bale
Selected with buttons: + and -
Confirmation: Enter
F2
Selecting wrapper's operation mode:
- Automatic
- Semi-automatic
- Transport position.
Selected with buttons: + and -
Confirmation: Enter
Table rotation —free
movement
Holding the button activates free movement of the turntable.
Table rotation —fast
movement
Holding the button activates fast movement of the turntable.
First rotation is slow.
Tipping the cradle
Pressing and holding the button tips the bale on end kit's cradle.
Cradle return
Pressing and holding the button returns the cradle to home
position
Tipping the turntable
Press and hold this button to move the turntable frame and lift
the bale on end kit (unloading to the bale on end kit's cradle).
Turntable return
Press and holding this button lowers the turntable frame and the
bale on end kit to home position (the bale is located on the bale
on end kit's cradle).
Lifting the loading
arm
Press and hold to lift the loading arm (loading a bale on the
turntable)
Lowering the loading
arm
Press and hold to lower the loading arm.
Start/Stop
Starts the automatic or semiautomatic bale wrapping process.
Press again during the process to stop.
Automat/Manual
Activates/deactivates automatic mode. The Start/Stop button is
inactive during the process.

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4.2 Operating the control panel
The panel is an electronic device for operating the wrapper; it also provides the user with
information on the current settings and the condition of the machine.
4.2.1 Activating the panel
1. Insert the wrapper's plug to the tractor's 12 V socket.
2. Connect the panel to control module with D-sub DE-9 L=10 m cable.
3. Switch the panel's power switch from 0 to I. The switch is located on the panel's side.
4. If the LED next to the Start/Stop button flashes green then the power status is correct.
5. Turn on the control panel using button. This starts the communication of the
panel with the control module. Wait for approx. 5 s until the communication is
completed successfully. If the communication is unsuccessful, check if the cables are
connected to the control module correctly.
4.2.2 Powering off the panel
1. Make sure that the operational elements are locked at transport position or at their
home positions (loading arm lowered, turntable in parallel to the wrapper's frame, table
frame lowered).
2. Power off the panel with button
3. Disconnect the panel from the power supply by switching the switch on the side from I
to 0.
4.2.3 Collision protection
The wrapper is software protected against actions which might collide with the turntable.
When you try to perform such a move, a message with the information about incorrect positioning of
a work element as well as the solution to make such a move possible.
The turntable movement is impossible:
- when the loading arm is lifted above the non-collision position,
- if the table's frame is not fully lowered,
- if the cradle is not at the home position (lowered).
If the loading arm has been lifted to the maximum height and then lowered to the end, the
program will not let the arm lift to the top again. According to the program, after such an operation,
there is a bale loaded on the turntable and after the arm is lowered, it can be lifted only to the
collision-less position. To enable lifting the arm again, unload the bale or reset the bale status (2xF1 -
> Enter).
Caution!
You must not move the turntable if the bale on end kit's arm is in transport position (a
protective device against falling of the kit is installed) and the loading arm is lowered!

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The wrapper returns to the home position after each full work cycle. The home position refers
to a situation when all moving elements of the machine are placed in position ready for work, i.e.
loading the next bale. In the home position, the working elements of the wrapper are positioned as
follows:
- loading arm is lowered and open,
- turntable positioned in parallel to the front beam of the wrapper's main frame,
- turntable frame lowered, bale on end kit frame horizontal,
- bale on end kit cradle lowered (not tipped)
Fig. 8. Bale wrapper in home position.