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|Module Automation Systems By: Danny Caddell
Module Automation Systems
Operation & Diagnostic
• Operation of the cab console
• Operation of the remote
• Programming a second remote
• Programming 2006 Systems model with optional hand-held programmer
• Automated system is not operating
• All hydraulic power to builder is lost or slows
• Tramper will go back and forth, but will NOT go up and down
• Tramper will go up and down, but will NOT move back and forth
• Tramper will not stop packing when stop button pressed
• Tramping cylinder is moving down gradually
• Ram moves up or down when bridge is manually moved to front or back
• Remote will not work
• Remote controls two or more builders
• Specific commands will not work on the remote
Caution: DO NOT ENTER PACKING AREA
when automated system toggle switch is in the “ON” position!!!
Please note that system has remote access and may be started
with the hand held remote.
Operation of the Cab Console
Stop button—stops automatic cycle at any time
Step 1 button—begins packing process with long steps and automatically cycles to short
Step 3 button—skips long packing steps and goes directly to third packing cycle (short
Toggle Switch—turns power off to computer
Operation of the Remote
1st button- stop
2nd button—step 1 (see above for definition in cab console operation for step 1 button)
3rd button– lifts tramper and returns it to the cab
Programming a 2nd Remote
1. Press and hold top button of working remote while in close proximity to module
builder for 20 seconds.
Release. Press any button on the 2nd remote to program it to the receiver.
Programming 2006 System Models with optional hand-held programmer
1. Remove front cover to obtain computer control access
2. Plug serial cables into white plug on top center of computer
3. Switch toggle switch to “off” and then back to “on” to enter the programming mode
4. Press “Stop” button to get first variable to edit. Old and new variables will be displayed
5. Press “Step 1” to ADD to variables
6. Press “Step 2” to SUBTRACT from variables.
7. Press “Stop” button to save and move to the next step
NOTE: Down time must always be greater than up time and will determine how long ram
will press down on
cotton. If up time is lengthened, down time must be lengthened.
8. Program your new variables.
. The display screen will show the following options in this order:
Step 1 Tramper Down Stroke Time
Step 1 Tramper Up Stroke Time
Step 1 Horizontal Travel Time
Step 2 Tramper Down Stroke Time
Step 2 Tramper Up Stroke Time
Step 2 Horizontal Travel Time
Step 3 Tramper Down Stroke Time
Step 3 Tramper Up Stroke Time
Step 3 Horizontal Travel Time
9. Press “Step 1” to Run the new program variables
10. Unplug programmer or follow prompts on screen as needed.
Automated System is not operating
1. Check power supply voltage and primary 30 amp fuse
Take cover off computer panel using small Phillips screwdriver. Check two green LED’s
on top left
marked 5v and +Vin. If LED’s are on, power is supplied to computer and this is not the
. If LED’s are not on, check source voltage and primary fuse wiring to computer.
. If LED’s are on, the off button could be stuck in the down position which could cause
the green LED
labeled S4 to stay on at all times. This keeps the system from running as it is the stop
2. Check toggle switch on top of computer panel
It may not be making contact. Switch it off and on to see if it will make contact.
3. Check 5 output fuses on computer board. (see instructions in #1 above for removing
cover of computer
4. Check the Step 1 Button
The step 1 button when depressed should cause the S0 LED to light up if working
. If it is not, check the wiring and button.
5. Check the Step 3 Button
The step 3 button when depressed should cause the S1 LED to light up if working
. If not, check the wiring and button.
All Hydraulic Power to builder is lost or slows
1. Check relief valve located on the top of the aluminum manifold
. The relief valve contains contaminants and may be dumping oil back into tank.
. While system is running, loosen jam nut on relief valve with 3/4 wrench.
. Loosen 1/4 Allen head screw one turn counter-clockwise to free contaminants and then
reset to original
. Examine pump. A worn pump will push metal shavings through the system from it’s
gears and contaminate
the relief valve.
. If the above steps do not work, replace the relief valve. Usually a bad filter or filter
housing will allow
contaminants to circulate through system.
. Examine bypass valve in filter housing located on hydraulic oil tank which is original to
Tramper will go back and forth, but will NOT go up and down
1. Check fuse on OUT 8 (output 8) and OUT 9 (output 9)
2. Check C2 hydraulic valve (the electric/hydraulic valve mounted on big aluminum block)
. The red LED’s should be blinking on the C2 valve when the automated system is
running showing they are
receiving power from the computer. If not, check wiring as the coil or valve could also be
Tramper will go up and down, but will NOT move back and forth
1. Check to see if chain on builder has jumped time and bridge plate is hitting sensors
2. Check to see if bridge will move manually. Bridge may be in a bind or sprockets could
be stripped out.
3. Check Fuses
Check fuse on OUT 10 (output 10) and OUT 11 (output 11) on computer.
4. Check Front and Rear Sensors
. Manually place bridge in center of module builder.
. Check LED S3 and S2
S3 should be activated only when bridge is on the back of the module builder. S2 should
only be a
activated when bridge is next to the cab. If LED’s are lit at any other time, there is a
ground short in
the wiring or sensor. If LED’s do not light the sensor wires are broken or sensors are
5. Check Hydraulic Valves
. Manually place bridge in center of module builder.
. Turn hydraulic pump off, but, leave electrical power on. Hit Step 1 button to start valves
cycling. Pull one
female spade terminal off of 3 way hydra force valve. If coil is good, it should spark. If
spool is good, you
will feel it click when the coil is sparked.
6. Check wiring to hydraulic valves
7. Check to see if Red LED is blinking on C4 Spool located on aluminum manifold.
Tramper will not stop packing when stop button pressed
1. Check Step 1 and/or Step 3 buttons as they may be stuck in down position.
. S0 and S1 LED’s should only be lit when buttons are pressed
2. Check the remote receiver
. A bad remote receiver could also be triggering these switches. Disconnect the wires
from S0 and S1 terminals
until S0 and S1 LED’s are off. This will confirm a bad remote receiver.
Tramping cylinder is moving down gradually
1. Check the tramping cylinder—it is probably an existing problem with the cylinder
packing original to the
. Packing in cylinder is possibly wore or torn and/or piston grooves are cracked causing
cylinder to leak
Ram moves up or down when bridge is manually moved to the front or back
1. Check the cylinder valve (C2 valve on aluminum manifold)
. Pieces or chunks of the cylinder packing may have traveled through the hoses and
lodged into the C2 (up
and down) cylinder valve.
Remote will not work
1. Pull primary fuse on the power source located near the tractor battery. Replace after
20 seconds. Push any button on
the remote while you are in close proximity of the module builder.
2. Check batteries on the hand held remote.
3. Try using your other remote that came with the system.
4. Check wires from the receiver located in the roof of the module builder to computer
switches. (Little black box with
yellow antennae wire hanging out of it).
5. Replace the receiver that is in the little black box mentioned in #6 above. Call Danny
to get a new one.
Remote controls two or more builders
1. Remove primary 30 amp power fuse usually located near the tractor battery from the
target module builder.
Replace after 20 seconds. Push any button on the target remote while in close proximity
to the module
builder to reset. Repeat for other builders.
Specific commands will not work on the remote
1. Check the following to ensure they are performing appropriate commands:
. 1st (or top) button on remote should activate LED S4 (stop) on the computer.
. 2nd button on remote should activate LED SQ (step 1) on the computer.
. 3rd button on remote should activate S5 LED (return to cab) on computer.
2. Check wires from receiver (black box with yellow antennae on roof inside of the cab)
3. Replace hand held remote or program another to test system (see troubleshooting
“remote will not work”
for details on programming the primary remote).
4. Replace the receiver. Call Danny to get a new one.