Development of operational diagnostic and maintenance system for the Metal-Fach Z-562 roll baler

Abstract

The results of developing a comprehensive system for operational diagnostics and maintenance of the Metal-Fach Z-562 roll baler are discussed. The relevance of the study is determined by the crucial role of this equipment in forage harvesting where its reliable operation directly impacts economic efficiency. The issues of long downtime due to malfunctions and the inadequacy of standard manuals determined the research goal: to create a clear and practical guide for rapid diagnosis and repair. The research employed a set of methods including field observations of the baler operation under real conditions, structural and functional analysis of its key components, systematization of malfunctions, and technical measurements. The primary result is the development of five interrelated diagnostic tables covering all critical units of the baler: the compression chamber, pickup and crushing apparatus, binding mechanism and the general system problems (drive, hydraulics, and twine feeding). Each table establishes a clear link between symptoms, root causes, and a detailed step-by-step troubleshooting algorithm tailored for the Z-562 model. Furthermore, based on failure analysis, a structured schedule for planned preventive maintenance was proposed divided into daily, periodic (every 50-100 running hours), and seasonal servicing. The practical significance of the work lies in systematizing scattered operational experience and creating a standardized tool for technicians. This approach reduces equipment downtime, minimizes reliance on the subjective skills of personnel, and facilitates a shift from emergency repair to preventive maintenance. Consequently, it enhances the overall reliability and productivity of the baler during the harvesting campaign.