RP 502 RP 520. tbidbo RP 520 FARMER

Transcription

1 RP 502 RP 520 tbidbo RP 520 FARMER Operating Manual from year of manufacture 2002

2 Contents 1 VARIANTS YOUR SAFETY NOISE LEVEL FIRE PREVENTION TAILGATE SAFEGUARD HYDRAULIC SYSTEM PROTECTIVE GUARDS WARNING SYMBOLS SYMBOLS FOR THE OPERATION OF THE BALER PROPER USE ELECTROMAGNETIC COMPATIBILITY (EMC) PRECAUTIONS FOR DRIVING ON THE ROAD COMPONENT OVERVIEW PUTTING INTO OPERATION ATTACHING THE BALER UNIVERSAL DRIVE SHAFT HYDRAULIC HOSES ELECTRICAL SYSTEM PREPARING THE NET WRAPPING FIELD USE LOCKING THE TAILGATE ADJUSTING THE BALE DIAMETER ADJUSTING THE BALE DENSITY PICK-UP DRIVING ON THE ROAD WINDROWING FEED GUIDE PLATE CUTTING DEVICE* PTO SHAFT SPEED DRIVING WITH THE BALER WRAPPING EJECTING THE BALE OVERLOAD PROTECTION REVERSING THE MAIN DRIVE HYDRAULIC SWIVEL FLOOR* STANDBY OPERATION MAINTENANCE / SETTINGS GENERAL INSTRUCTIONS MAINTENANCE OF THE NET WRAPPING SYSTEM* SETTING THE DEFLECTORS TENSIONING THE ROLLER CHAINS TYRE AIR PRESSURE CHAIN LUBRICATION LUBRICATION CHART LUBRICATION POINTS TECHNICAL DATA The machine number is entered onto the data plate shown opposite and is located on the right hand side of the baler. Warranty claims and enquiries cannot be processed without this number. Please enter this number here below immediately after delivery: Ident - Nr. max. Ges. Gewicht/Gross Weight max. Achslast/Axle Load Baujahr/Year of Manufacture Typ Ausführung max. Stützlast/Imposed Load Höchstgeschw./max. Speed Lely Welger Maschinenfabrik GmbH Gebrüder - Welger-Str. 3 D Wolfenbüttel Made in Germany Read the operating manual and safety instructions before putting the baler into operation. We have inserted a warning sign in this operating manual at points concerning your safety. Please also pass on all safety instructions to other users. The warning and instruction plates on the baler provide important information for safe operation. Paying attention to them is for your own safety! * Please note that the features marked with a [*] in this operating manual are fitted only to some models as standard or are only available for particular models as additional features. These features may also not be supplied to all export countries. Reproduction prohibited - all rights reserved. Design and construction subject to alterations. The illustrations shown are non-binding for model, form and equipment by Lely Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany. Lely Maschinenfabrik GmbH Postfach Wolfenbüttel / Germany Telefon: (05331) Telefax: (05331) lelymaschinenfabrik@lely.de Manufacturer:

3 Handover declaration Please complete this form fully on delivery of the machine and return to the importer. Guarantee claims cannot be processed until this form has been received. LELY Maschinenfabrik GmbH Technical Support Postfach 1965 D Wolfenbüttel / Germany (1) Date of delivery (2) Type: WELGER RP... Maschine-No.: (refer to type plate: #) (3) Address of customer Name: Address: Postcode: Phone: Town: (4) The machine schown in (2) was purchased / put into use by me. The Instruction manual including the EC Statement of Conformity has been passed to me on delivery of the machine. The safety, operating and maintenance regulations contained in it were explained to my understanding Date Signature of customer (5) Address of sales agent / importer Company stamp / signature Company stamp / signature if not the same as (5) (6) The machine has been delivered to the customer in accordance with the manufacturer s instructions Date Signature of the Customer Service specialist Ueber.DOC

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5 1 Variants RP 502 SPECIAL RP 520 FARMER RP 520 MASTER Pick-up width 2.00 m 2.25 m NONCUT Rotor Tine rotor MASTERCUT PROFICUT Cutting device MASTERCUT 12-blade PROFICUT 23-blade Feeder bottom plate Securely bolted HYDROFLEXCONTROL Wrapping VARIONET net wrapping kit Control BALERCONTROL E BALERCONTROL III with E-LINK control box = Standard equipment = Variant = not available WELGER RP 502 RP 520 1

6 2 Your Safety All the protective devices such as the safety covers, rubber aprons or safety brackets are provided for your safety! Never operate the baler with defective safety devices or if the safety devices have been removed! Always keep components which are relevant to safety in a suitable condition. All guards must be fitted and closed before putting the baler into operation! Never carry out adjustments, repairs or maintenance and service work on the baler while it is running. Always first stop the power take off (pto) shaft, detach the universal drive shaft from the pto shaft stub and disconnect the electrical connection between the tractor and the baler prior to working on any of the baler s moving parts. Never try to remove hay, straw or other harvested crop from the baler while it is running. Always first stop the pto shaft, and switch off the tractor engine. While work is in progress, only the driver should be on the tractor. Passengers are not allowed on the baler! Do not climb on the drawbar or other parts of the baler when it is in operation. Also, keep your distance from the pick-up unit. Do not reach into the working area of the transport units. Before threading in the binding material, switch off the baler drive and tractor engine and remove the ignition key All protective guards must be fitted to the baler and must be in sound condition. Before opening the guards, stop the pto shaft and the tractor engine, remove the ignition key and wait until the baler has stopped. Before detaching the baler from the tractor, secure it with the aid of the chocks to prevent it from rolling away. Carry the chocks with the baler when the baler is transported or used. Upon opening the tailgate, maintain at least 2 metres safety distance from the high voltage cables. All maintenance and repair work beyond that described in the descriptions in these operating instructions must always be carried out by authorised persons. Wear parts of the brake system must always be replaced on both sides. Secure the baler from tipping backwards before detaching the complete pick up unit. Warning! The baler is inherently dangerous even if all the points listed above are followed exactly. Therefore always take care when working with the baler to avoid endangering yourself or other people! 2 WELGER RP 502 RP 520

7 2.1 Noise level EU Directive EEC concerning noise at the workplace instructs employers and employees to measure and control the noise level at the workplace. The noise level during normal field work is subject to various fluctuations which depend on the noise level of the tractor, and also on the conditions under which the baler is being used. The noise level generated by WELGER balers, measured at the driver's head height with the tractor window open, is less than 70 db(a) under normal working conditions. The combined noise level generated by the baler and tractor primarily depends on the level of tractor noise (radios are an additional source of noise). We recommend that the tractor be driven with the cabin windows closed. 2.2 Fire prevention fig. 1 Crop materials are very combustible. Always keep the baler free of crop remnants and oil contamination. Should overheating of the baler components occur, determine the cause and resolve accordingly. Always keep the electrical circuits of the tractor and baler, as well as the tractor s exhaust system, in perfect working order. The supplied cabling may not be used for purposes other than for factory-installed or approved electrical equipment. Overloading the electrical cables leads to excessive heating. Smoking is forbidden in the vicinity of the baler. Always keep a suitable fire extinguisher within easy reach. WELGER RP 502 RP 520 3

8 2.3 Tailgate safeguard If maintenance or installation/assembly work is performed with the tailgate open, it is essential for safety reasons to secure the tailgate to prevent it from falling. Use the stop valve on the left side of the baler for this purpose. In the locked state, the actuating handle is situated at right angles to the direction of flow (fig. 2). The stop valve may only be actuated from the left side of the machine. fig. 2 Return the valve to its original position after completing maintenance and installation/assembly work fig. 3 4 WELGER RP 502 RP 520

9 2.4 Hydraulic system Max. operating pressure of the hydraulic system: 210 bar When carrying out assembly work on the hydraulic system, particularly when using accumulators (fig. 4): Depressurise the hydraulic system (control unit set to Lower ) Mechanically secure hydraulically operated components (pick-up device, cutting unit) to prevent uncontrolled movements fig. 4 According to DIN 20066, the period of use of a hose line, including any storage period, should not exceed six years. 2.5 Protective guards In order to comply with European safety regulations EN 704, the manufacturer of machines is required since to supply fixed partitioned protective guards that are self locking but require the use of a tool to be opened. Opening the protective guards: 1. Gently turn the hexagon head of the lock anti-clockwise with a 13 mm spanner the guard cover engages into a safety notch. fig Push the safety notch downwards the guard cover opens fully. To close, push the guard cover against the baler until the lock is heard to engage. The baler must never be operated with the protective guards open! Only open the protective guards if a free swing area is available. Never operate the machine with defective or removed protective (e. g. guard casings and safety bracket). Before opening the guards: switch off p.t.o. drive shaft and tractor engine, wait until the machine has stopped, remove ignition key. fig. 6 WELGER RP 502 RP 520 5

10 2.6 Warning symbols Explanation of the symbols Danger areas which cannot be made safe by design measures are identified by yellow warning symbols. Since these are signs without texts in most cases, their precise meaning is described below. The warning symbols must always be kept in a recognizable state. If there are no warning symbols on your baler or if they are damaged, replace them. Warning symbol Description/Spare part No. Read and adhere to the operating manual and safety notes before starting up for the first time. Spare part No.: Close protective guards before putting baler into operation! Spare part No.: Never reach into the baler pick-up area as long as the tractor engine is running with the pto shaft connected. Spare part No.: Always switch off the engine and remove the ignition key before starting any maintenance and repair work. Spare part No.: WELGER RP 502 RP 520

11 Switch off the engine and pull out the plug from the power supply before starting any repair, maintenance and cleaning work. Spare part No.: Stay clear of tailgate swinging area while in operation. Spare part No.: Do not ride on platform or ladder. Spare part No.: Handle the cutting unit blades only if you are wearing gloves and using suitable tools. Spare part No.: The accumulator is under gas pressure or oil pressure. Depressurise the hydraulic system before removal and repairs. Spare part No.: Activate the tailgate safeguard before entering the roll chamber. Spare part No.: WELGER RP 502 RP 520 7

12 2.7 Symbols for the operation of the baler The most important operating instructions are shown as symbols for the purpose of clarity. The exact descriptions are given below. Symbol Description/Spare part No. The two lifting eyes in the upper part of the baler are identified by this symbol. No other fixing points may be used for hooking up a crane. Spare part No.: Locking lever for the cutter blades To unlock the cutter blades, the lever must be swivelled down by approx. 90. Spare part No.: and Tailgate safeguard If the lever is transverse with respect to the flow direction, the tailgate is secure against lowering. Spare part No.: Maximum permissible hydraulic pressure The machine may only be connected to a hydraulic system which supplies a maximum oil pressure of 210 bar. Spare part No.: WELGER RP 502 RP 520

13 Stopping the belt rocker arm for maintenance purposes Spare part No.: Adjusting the bale density Spare part No.: Opening the side guard casings: 1. Turn the screw head anti-clockwise with a 13 mm spanner until the casings fly open. 2. Push the lever down and open the casings sideways. Spare part No.: (right) Spare part No.: (left) WELGER RP 502 RP 520 9

14 2.8 Proper use The baler has been built exclusively for producing bales compressed from agricultural straw material lying on the ground (proper use). Usage beyond this does not constitute proper use. The manufacturer is not liable for damage resulting from improper use; the user alone bears the risk. Proper use also includes compliance with the operating, maintenance and servicing conditions specified by the manufacturer. The baler may only be used, maintained and repaired by persons who are familiar with working with such machines and who have been informed of the dangers. The attachment of auxiliary equipment to the baler, other than at the factory pre-set positions, is prohibited. Only auxiliary units approved by the manufacturer may be used. The relevant accident prevention regulations, regional safety standards and other generally recognized safety regulations are to be observed. Unauthorized alterations and the installation of non-approved parts and equipment on the baler exclude the manufacturer from any liability for damage resulting from this. Alteration of any of the safety-related components invalidates both the conformity declaration and the CE-symbol. 2.9 Electromagnetic compatibility (EMC) The baler is equipped with electronic constituents and component parts whose function can be influenced by electromagnetic radiation from other appliances. Such influences can generate hazards for persons if the following safety precautions are not taken into account. In the case of a supplementary installation of electrical and electronic appliances and/or constituents in the baler with a connection to the onboard system, the user has to verify whether the installation causes disturbances to the electronics of the vehicle or of other constituents. In particular, it has to be taken into account that any additionally installed electrical and electronic components comply with the EMC Directive 89/336/EEC in the respective current version and that they are CE labeled. 10 WELGER RP 502 RP 520

15 2.10 Precautions for driving on the road Before driving on the road... the baling chamber must be completely emptied (in accordance with Road Traffic Vehicle Registration Regulations (RTVRR); the baler must be cleared of any harvested crop attached to it; the universal drive shaft must always be fitted to the tractor pto shaft; the tubes of the bale ejector* must be pushed in. the lighting equipment of the attached machinery must be connected to the tractor and its function checked (also in daylight); the support wheels of the pick-up unit must be detached (working width 2.25 m) and placed in the park position. Information shall be requested from the manufacturer before the baler is operated using attached machinery (e.g. bale wrapping device). The wheel chocks, which are part of the safety equipment (two in number), are to be carried on the baler at all times. The permissible maximum speeds for individual components (e.g. the drawbar or the axle) do not affect the maximum permitted speed limit for the entire baler (see data plate on the right side of the baler). Model-dependent maximum speeds limits have been exclusively specified in this operating manual. Current relevant national regulations, which may differ from manufacturers instructions, are always required to be observed. Pneumatic braking system*: Do not start driving with an attached baler until both coupling heads (yellow and red) are connected to the tractor and the pressure gauge in the tractor cabin indicates the required operating pressure. Hydraulic braking system*: Do not start driving with the attached baler until the appropriate hydraulic hose is connected to the tractor. Germany (StVZO): Agricultural equipment with a permissible total weight more than 3000 kg are required to have an operating permit. (Technical changes, e.g. fitting a trailer hook, result in the operating permit becoming void). Before making intended changes to the attached working unit, it is essential to clarify whether the change is permissible without further requirements and can be entered in the vehicle s documents following approval by an officially recognised expert. Furthermore, the national regulations from the country of use are to be observed. WELGER RP 502 RP

16 Details on the data plate 6 1 Ident - Nr. Typ Ausführung 7 2 max. Ges. Gewicht/Gross Weight max. Stützlast/Imposed Load 8 3 max. Achslast/Axle Load Höchstgeschw./max. Speed 9 4 Baujahr/Year of Manufacture 10 5 Lely Welger Maschinenfabrik GmbH Gebrüder - Welger-Str. 3 D Wolfenbüttel Made in Germany fig. 7 Item Meaning 1 ID number individual machine number. Always quote in the event of queries 2 Permissible total weight for operation on public roads. The machine s actual weight can be less. 3 Permissible axle load for operation on public roads 4 Machine s year of construction 5 Not applicable 6 Trade designation of the machine 7 Details of the systematic structure of the general operating permit (ABE) 8 Max. imposed load on the drawbar eye. The open-type hitch on the tractor must be approved for this imposed load. 9 Permissible type-related maximum speed of the machine. National regulations may specify a lower speed! 10 Internal control number 12 WELGER RP 502 RP 520

17 3 Component Overview fig. 8 Pos. Component Pos. Component 1 E-LINK control box* 7 End roller 2 BALERCONTROL E control box* 8 Lock 3 Net wrapping 9 HYDROFLEXCONTROL swivel floor* 4 Belt 10 Pick-up 5 Rocker arm 11 MASTERCUT cutting device* 6 Tailgate WELGER RP 502 RP

18 4 Putting Into Operation When handling parts of the machine in the area of the drawbar, make sure that the machine is safeguarded from rolling away. Do not crank up the support foot until the baler is securely coupled to the tractor. Do not disconnect the baler until: The surface is level and supports the road wheels and the support foot The baler chamber is empty and the tailgate is closed The machine s road wheels are blocked by chocks The hydraulic hoses are depressurised There is no load applied to the drawbar eye Do not step between the tractor and baler until the vehicles are safeguarded from rolling away by means of the parking brake and/or the wheel chocks! Do not start driving with the machine coupled unless the parking brake has been fully released. Otherwise there is danger of fire by brakes running hot. Children must be kept away from the baler at all times! 4.1 Attaching the baler Correct baler attachment and drive shaft set-up to the tractor is important to ensure trouble-free operation of the baler. After attaching the baler, screw in the support foot with the hand crank until there is sufficient clearance from the ground Parking brake (according to model) Before coupling the machine to the tractor: apply parking brake (by turning the crank of the parking brake clockwise). After coupling the machine to the tractor: release parking brake (by turning the crank of the parking brake counterclockwise). 14 WELGER RP 502 RP 520

19 4.1.2 Drawbar configuration (all dimensions in [mm]) fig Adjusting the trailer hitch Any adjustment in the height set-up, and therefore a displacement in the drawbar eye position, shall only be carried out by the manufacturer or an approved specialist workshop. Position the baler on even ground Screw out the support foot until the baler is standing level. Alignment: Axle plates...horizontal Support leg...vertical fig. 10 Measure the height of the tractor towing hitch; Measure the height of the baler drawbar eye. With reference to fig. 9, align the drawbar with the hole configuration that gives the closest fit to the desired dimension. The locking nuts must be replaced by new ones each time they are undone. After aligning the trailor hitch, the drawbar eye needs to be brought into a horizontal position. Do this by undoing the fastening screws of the drawbar eye and correct the alignment of the drawbar eye with the help of the threaded pin. All fastening screws and nuts must be done up tightly: WELGER RP 502 RP

20 4.1.4 Configuration of the tow hitch If the baler is attached to the tractor tow hitch, compliance with the following dimensions is necessary: (see Table 1). Tow hitches other than as shown in fig. 11 and Table 1 are not permitted! Danger of breakage! Corresponding category fig. 11 Catch opening dimensions Catch opening outer radius Position Vertical support load ISO d b r 1) c 2) l F +1 min. max. min. ±10 kg ) Various configurations for the tow hitch are permissible if the external radius r is complied with (see fig. 11) 2) The upper part of the tow hitch can be dismantled to comply with dimension c. Dimensions are in millimeters Table 1: Dimensions, location and support load of the tow hitch 16 WELGER RP 502 RP 520

21 4.2 Universal drive shaft Connecting the cam-type cut-out clutch* Depending on the model, the universal drive shaft is fitted with an automatic overload safety cut out (cam-type cut-out clutch). Clean and grease the splines of the connecting shaft before installation. Undo and pull out the clamping cone [1]. fig. 12 Open the maintenance hole in the protective cone. Push the clutch unit onto the connecting shaft until the locator hole [2] points to the maintenance hole. Position the locator hole for the clamping cone above the snap ring groove [3] of the connecting shaft. Turn the clamping cone within the locator hole and gently move the hub backwards and forwards lengthways to seat it securely (approx. 70 Nm). Check that the clutch hub is properly located and securely fixed by pushing and pulling on it. During this process, the proper location of the clutch should be checked at regular intervals. fig Removing the cam-type cut-out clutch* Undo the clamping cone and pull it out of the clutch hub. If that cannot be done by hand, the clamping cone can also be driven out from the other side with the help of a pin punch. fig. 14 WELGER RP 502 RP

22 4.2.3 Adjusting the universal drive shaft Pay attention to the maximum operating length Lmax and minimum operating length Lmin! Aim for the greatest possible overlap. a) Shortest operating length, i.e., fully covered b) During normal operation, the overlap of the tube section should be at least 2/3 of the overlap LU. c) The universal drive shaft can be operated with length Lmax for short periods, i.e., with a tube section overlap of 1/3 LU. fig. 15 If necessary, adjust the length. To do this, hold the drive shaft tubes next to each other in the shortest operating position and mark them. Saw off the inner and outer tubes by equal amounts so that a sliding travel of 40 mm is retained in the shortest operating position. Prevent the protective tube of the universal drive shaft from rotating by fastening the retaining chain. Check the universal drive shaft each time before start-up to ensure that the locks are properly engaged. fig. 16 Important: When turning around sharp bends, ensure that the angle at the wide-angle joint (at the tractor) does not exceed the maximum value quoted by the manufacturer of the universal drive shaft. Pay attention to the operating instructions from the universal drive shaft manufacturer as well as to country-specific approved product labels for the protection of universal drive shafts. Warning: Only universal drive shafts approved by the manufacturer may be used. A wedge-type freewheel device that is an integral part of the universal drive shaft protects the machine drive against follow-on weights. When the machine is disconnected, always deposit the universal drive shaft on the universal drive shaft support (fig. 17). In the case of attachment below, swivel the support upwards as appropriate. fig. 17 The protective tube and cone of the universal drive shaft and the pto protection device must be fitted and must be in sound working order. Before starting the pto shaft, ensure that the selected rpm of the tractor is in accordance with the permissible rpm and direction of rotation of the machine (540 min -1 ). Only start the pto shaft at idling speed! 18 WELGER RP 502 RP 520

23 4.3 Hydraulic hoses Symbol on hydraulic hose Baler Function Tractor connection Colour identification RP 502 RP 520 Open and close tailgate single-acting yellow RP 502 RP 520 w/o SW Raise and lower pick up single-acting red RP 520 Activate floor flap* and double- (only FARMER) cutting knife* acting green RP 520 w. CD Hydraulic switch* with the functions floor flap* double- red (only MASTER) pick up unit cutting device* acting CD = cutting device* WELGER RP 502 RP

24 Note: In order to find the correct oil coupling sleeves quickly when hooking up the baler on later occasions, it is advisable to transfer the colour identification used for the hydraulic hoses to the couplings at the tractor end. Clean the coupling parts of the hydraulic pipes with a clean cloth and plug in to the sockets at the tractor. Check hoses and pipelines regularly for damage, deterioration and safe functioning. Defective parts are to be replaced immediately by original WELGER replacement parts. Hoses and hose lines are subject to natural deterioration even under normal operating loads. As a result, the useful service life is limited. Hydraulic hoses should not be used longer than six years! 20 WELGER RP 502 RP 520

25 4.4 Electrical system Lighting To connect the lighting system, insert the 7-pin plug into the corresponding socket on the tractor. Before travelling on the road check that the lighting system functions correctly (also in daylight). Balercontrol E RP 502 SPECIAL RP 520 FARMER 12 V "Balercontrol" and "E Link" Electronic Controller The control panel is provided with a plate which should be fastened within easy reach of the tractor driver. The control panel of the Balercontrol control system is also provided with a magnetic plate on the rear and can be attached to a metallic surface within easy reach of the driver. Once the plug is inserted in the socket, power is supplied to the unit and a short sequence of beeps is heard fig. 18 Note: When connecting the Balercontrol electronic controller, a power socket conforming to DIN 9680 must be fitted on the tractor. (Supplied with the baler.) The fuse rating must be 16 A. The socket with connecting cable and fuse can be supplied under part No as a retrofit part for an additional tractor. E - LINK RP 520 MASTER fig. 19 WELGER RP 502 RP

26 4.5 Preparing the net wrapping Inserting the net In order to handle the net roll safely, insert it together with the help of a second person! fig. 20 Open all protective covers. First place the net roll at an angle over both net roll recesses from the left side (fig. 20); Unscrew the hand-wheel [1] on the disc brake anticlockwise. Pull out the axle tube [2] from its mounting. Push the net tensioner [3] backwards and lock with a plug-in split pin. Push the net roll onto the spindle to the right (in the driving direction) (fig. 21); Lift the net roll onto the left side of baler, push in and lock the axle tube [2] (fig. 22); Align the net roll sideways so that it is in the middle of the roll chamber. Screw the hand-wheel [1] on the disc brake clockwise. fig. 21 fig WELGER RP 502 RP 520

27 fig. 23 Guide the net from the roll around the upper deflection roller [4] and finally around the net tensioner [3]. Place the beginning of the net over the sideways tensioner [5] and then between the rubber roller [6] and steel roller [7]. Turn the rubber roller manually until the net is caught. So that the net does not prematurely enter the roll chamber during baling operation, the start of the net must not project more than approx. 10 cm. Move the net tensioner [3] forward into its working position. fig. 24 fig. 25 WELGER RP 502 RP

28 4.5.2 Tensioning the net cutting knife The net cutting knife is automatically tensioned (reset) each time the tailgate is opened. If a new net wrapping is required without opening the tailgate while the bale chamber is full, due to a net changeover or fault, the tensioning process can be done manually. This is done by pulling the knife holder forwards against the spring (fig. 26). It can be released as described in the Section Wrapping. fig Setting the net wraps With help from the scale (fig. 27) a variable number of net wraps around the roll bales can be set. After loosening the wing nut, the net length can be set by moving the nut within the slot. Tip: First, select the setting in the centre of the slot. To save binding material, adjust stepwise in the ( - ) direction for the following bales. fig. 27 However, the bales must still be held together securely. With very smooth material and a high pressing density, a greater amount of net may be needed. The setting specifies the net length used, i.e. when the bale diameter is changed, the net length must also be adjusted accordingly. 24 WELGER RP 502 RP 520

29 5 Field use The roll baler is safeguarded against foreseeable accidents. In spite of this, necessary precautions must still be taken when working. Each time before use, check that all safety devices on the roll baler are in proper working order. Never attempt to correct malfunctions while the machine is in operation. Take special care when opening and closing the tailgate. Stay clear of swing area of the tailgate at all times. Before entering the bale chamber, lock the tailgate (fig. 5)! Machines not coupled to the tractor must be safeguarded from accidental rolling away by wheel chocks and the parking brake applied (if any). 5.1 Locking the tailgate Before picking up the crop and after each bale ejection, the tailgate must be locked properly. To do this, keep the tractor control valve for tailgate actuation in the "lower" position. This will automatically lock the tailgate. RP 502 Special/RP 520 Farmer: The fact that the tailgate is fully locked, is signalled to the by the light going out. RP 520 Master: The fact that the tailgate is fully locked is signalled to the tractor driver by: a single beep of the E-Link control box the tailgate is shown closed on the display. the swath on the display runs in machine direction. Note: So as not to place any unnecessary load on the hydraulic pump, leave the control valve in the floating position during baling. fig. 28 The upper lamp [3] should only light up if the tailgate is unlocked. If the lamp also lights up during baling, check the sensor setting. The lower lamp [4] should only light up briefly while the bale rolls over the bale ejector. The tailgate must not be closed whilst the lower lamp [4] is lit! WELGER RP 502 RP

30 5.2 Adjusting the bale diameter RP 502 and RP 520 FARMER Loosen the wing nut (arrow in fig. 29) and set the desired diameter with the indicator. The attainable diameters are between approx and 2.00 m Read off the currently attained bale diameter on display 2 in fig. 34 fig RP 520 MASTER Press the right-hand function key (arrow in fig. 30) several times until the symbol for bale diameter (fig. 31) appears in the display field of the control box. The desired bale diameter is pre-selected using the + and - keys in steps of The arrow next to the bar diagram changes position according to the specified diameter (fig. 32). fig. 30 fig. 31 fig WELGER RP 502 RP 520

31 5.3 Adjusting the bale density RP 502 and RP 520 FARMER Basic setting: Turn the hand-wheel (fig. 33) clockwise until it comes to a stop. Turn back the hand-wheel one full rotation. Compress and assess the test bales. Correct the baling pressure if necessary. fig. 33 Note: Reduction of compression density recommended for hay if a lighter bale core is required... extremely short and dry material if obstructions occur in the feed area. Tip: The pre-set pressure can also be read off without test bales on the manometer [1] (fig. 34): interrupt the power supply to the baler control box (remove plug) open tailgate (here, the tailgate opens more slowly and does not reach the highest position) read off the pre-set pressure on the manometer [1]. fig. 34 WELGER RP 502 RP

32 5.3.2 Type: RP 520 MASTER 1. Press the right-hand function key (arrow in fig. 30) several times until the symbol for bale density (fig. 36) appears in the display field of the control box. 2. The desired bale density is pre-selected in steps of 1 10 using the + and - keys. Note: Reduction of compression density recommended for hay if a lighter bale core is required... extremely short and dry material if obstructions occur in the feed area. fig. 35 fig WELGER RP 502 RP 520

33 5.4 Pick-up Raising/lowering the pick-up Type: RP 502 and RP 520 FARMER The pick-up is raised/lowered directly via the connected tractor distribution valve RP 520 MASTER 1. Press the middle function key (arrow in fig. 37) several times until the symbol for Raise/Lower pick-up appears in the display field of the control box (fig. 38). 2. Activate the connected tractor distribution valve. (The direction of actuation can be changed by reversing the two connected hydraulic hoses.) fig. 37 fig Support wheels* 1. Ground clearance of tines in field use: min. 2 cm 2. Raise pick-up unit 3. Pull out spring retainer [1] 4. Align bracket [2] with desired hole 5. Secure support wheels again with spring retainer 6. Provide same setting on both sides. fig. 39 WELGER RP 502 RP

34 5.5 Driving on the road 1. Lift the pick-up unit to its highest position. 2. Close the shut-off valve on the hydraulic hose for the pickup unit. The pick-up unit is now hydraulically secured in the transport position. 3. For pick-up units with 2.25 m* width: also move the pick-up unit support wheels into the park position (fig. 40). 4. Do not start driving with the machine coupled unless the parking brake has been fully released. Otherwise there is danger of fire by brakes running hot. fig Windrowing The full capacity of the baler and good bale formation can be only achieved by careful windrow preparation. Therefore the windrows should be laid down uniformly. The windrow width should be: m Windguard/Pick-up guide shield* For all types of pick-up unit, the windguard is movable and hangs over the pick-up drum. The height of the windguard rake can be adjusted by using the chain to allow for various windrow thicknesses. The upper end of the chain must always be hung on the hook in order to prevent it from being caught up in the pick-up unit. For pick-up units with pick-up width of 2.25 m, both support wheels cover the sides of the rotating tines and therefore also form part of the installed safety equipment. When using the baler, both support wheels must be installed at all times. fig WELGER RP 502 RP 520

35 5.7 Feed guide plate The streamlined feed guide plate [1] is factory-installed in the roll chamber. Should material become jammed due to unusual crop conditions, then the feed guide plate may be removed. To do this, take out screws (arrow in fig. 42) on the right side (in the driving direction) and remove the plate from the roll chamber. fig. 42 WELGER RP 502 RP

36 5.8 Cutting device* Activating and deactivating the cutting device Attention: For Daily Operation the two ball valves must be positioned in parallel (see fig. 43)!! RP 520 FARMER (with cutting device, with HYDROFLEXCONTROL swivel floor) Activating the cutting device: 1. (Left machine side, fig. 43 and fig. 44:) Left ball valve of the hydraulic block must be set to the position 35 bar. Right ball valve of the hydraulic block must point towards the machine. 2. Activate the "raise" function on the connected tractor valve until the cutting device moves into its working position. (If the swivel floor (HYDROFLEXCONTROL) was open, it will also move upwards). 3. In order for the hydraulic accumulators to fill, continue to activate the control valve for another 5 seconds after the cutter blades have moved in. fig. 43 Deactivating the cutting device: 1. (Left machine side, fig. 43 and fig. 44:) Left ball valve of the hydraulic block must be set to position 35 bar. Right ball valve of the hydraulic block must point towards the machine. 2. Activate the Lower on the connected tractor control valve for about 5 10 s. Tip: In order to ensure free movement of the individual blades, switch the cutting device on and off several times each day. fig WELGER RP 502 RP 520

37 Hydraulic protection of the cutter blades Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This activates at a factory-set pressure limit. This is also the only pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked. Attention: For Daily Operation the two ball valves must be positioned in parallel (see fig. 45)! Abhilfe: 1. (Left machine side, fig. 45 and fig. 46:) Left ball cock of the hydraulic block must be set to position 180 bar. Right ball valve of the hydraulic block must point towards the machine. 2. Activate the "raise" function on the connected tractor valve until the cutting device moves into its working position. fig Activate the Lower function on the connected tractor control valve until the cutting device disappears again in the swivel floor 4. Repeat points 2 and 3 as needed until the blades are operating smoothly. 5. (Left machine side, fig. 45 and fig. 46:) Reset left ball valve of the hydraulic block to position 35 bar. 6. Activate the "raise" function on the tractor control valve until the cutting device is in its working position. 7. Activate the Lower function on the connected tractor control valve until the cutting device disappears again in the swivel floor. fig. 46 Attention: If the ball valve lever (fig. 47) points to position 180 bar, the common protection of the cutter blades is deactivated! After raising of the cutting device, the lever of the ball valve must be reset to the 35 bar position! It is absolutely necessary that finally the cutting device is once again lowered and raised (see points 2 and 3). Otherwise machine overload will result in a cancellation of the warranty! fig. 47 WELGER RP 502 RP

38 RP 520 FARMER with cutting device and without swivel floor The cutting device is directly actuated with the double-acting tractor control valve. (Caution: the actuating direction can be changed by swapping the connected hydraulic hoses.) In order to ensure free movement of the individual blades, it is recommended to move the cutting device in and out several times each day. fig Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This activates at a factory-set pressure limit. This is therefore the only pressure available for moving in the blades. The hydraulic pressure may not necessarily suffice if the blade grooves are blocked. Remedy: 1. Move the ball valve under the left protective guard towards the back (fig. 48); 2. Activate the control valve until the blades are in the cutting position. 3. Move the ball valve once again towards the middle of the baler (fig. 49); 4. Move the blades once more in and out. Only after this process can the baler be brought into normal operation. Warning: If the ball valve lever (fig. 48) is pointing towards the back, the common protection of the cutter blades is deactivated! After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler (fig. 49)! After setting back the ball valve, it is absolutely necessary for the blades to be moved in and out again. Otherwise, the machine overload will result in a cancellation of the warranty! fig WELGER RP 502 RP 520

39 RP 520 MASTER Press the middle function key (arrow in fig. 50) several times until the symbol for activate cutting device (fig. 51) appears in the display field. Activate the connected tractor distribution valve. (The actuating direction can be changed by swapping the connected hydraulic hoses.) When the blades are in the cutting position, the symbol for cutting device active appears in the display field of the control box (fig. 52). In order to fill the hydraulic accumulators, operate the distribution valve for at least another 2 seconds. fig. 50 In order to ensure free movement of the individual blades, it is recommended to move the cutting device in and out several times each day. Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This is activated at a factory set pressure limit. This is also the only pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade slots are blocked. fig. 51 Tip: 1. Do not release the middle function key (fig. 50) after selecting the activate cutting device function. 2. Activate the distribution valve of the tractor for at least 3-4 seconds. 3. Repeat point 2 if necessary until the blades are in the cutting position. Warning: The common protection for the cutter blades is disabled whilst the middle function key is depressed! Finally, the blades must be moved in and out once again without the need to depress the middle function key. Otherwise, the machine overload will result in a cancellation of the warranty! fig. 52 WELGER RP 502 RP

40 5.8.2 Brittle crops It is recommended when baling brittle crops to hydraulically move the cutting device out of the cutting position before wrapping. The bales are then enclosed by long material and crumbling losses are avoided to a large extent Installation and removal of the cutter blades The cutting length for the pressed material can be adjusted by removing individual blades. All of the blades can be removed if the cutting function is not needed for a longer period of time: Move the cutting device into the cutting position. Lower the HYDROFLEXCONTROL swivel floor* approximately halfway (fig. 53). Open and secure the tailgate. fig. 53 Pull down the blade lock lever on the conveyor housing on the right-hand side (in the driving direction) by approx. 90 until it stops. From the roll chamber, pull out the blades using pliers diagonally up from the blade axle and remove it from the slot. Warning! Danger of injury! Wear protective gloves when handling blades. If maintenance or assembly work is to be performed when the tailgate is open, then for safety reasons it is absolutely necessary that the tailgate be secured from lowering. fig. 54 Once removed, the blades can be stored behind the right door panel and secured in place with a plug-in split pin and a lever. (fig. 54). Note: To prevent soiling of the blade slots removed blades should be replaced by dummy blades* (part no ). 36 WELGER RP 502 RP 520

41 5.8.4 Sharpening the cutter blades In order to ensure an optimum throughput of crops, it is recommended that the cutter blades be sharpened after 500 bales have been cut at the latest. Depending on the operating conditions, sharpening may also be required sooner. As described above, remove the blades and grind the cutting edge from the smooth side. Pay attention that the hardened cutting edges are not drawn when grinding. A grinder is available as a spare part. (Part no ) Warning: Never strike the installed blades with a hammer from underneath the baler the magnets can be damaged! WELGER RP 502 RP

42 5.9 Pto shaft speed Operate the baler with a standard pto shaft speed of 540 min -1. Only universal drive shafts approved by the manufacturer may be used. The protective tube and cone of the universal drive shaft and the pto shaft protection device must be fitted and must be in sound working order. Always check that the universal drive shaft is correctly installed and well secured! Secure the universal drive shaft guard by attaching the chain to prevent it from turning! Before starting the pto shaft, ensure that no person is within the danger zone of the machine! 5.10 Driving with the baler fig. 55 To obtain high output and well-shaped round bales, an appropriate driving style is required so that the roll chamber is evenly fed with material over the entire baler width. For narrow windrows - i.e. the width of the windrow is narrower than the pick-up unit width - uniform feeding of the bale chamber can be achieved by driving into the left and right side of the windrow in an alternating fashion (fig. 55). At the beginning of each bale, switch quickly between left and right, i.e. switch to the other swath side after approx. 5 m each time. Always use the full absorption volume of the pick-up. If only a little baling material was taken up, switch off the pto during empty runs. When turning around sharp bends, ensure that the angle at the wide-angle joint (at the tractor) does not exceed 80. Otherwise there is a danger of breakage during operation and at rest. 38 WELGER RP 502 RP 520

43 5.11 Wrapping Wrapping is triggered using the following control boxes: Balercontrol E E-LINK RP 502 SPECIAL RP 520 FARMER RP 520 MASTER Safety The BALERCONTROL and E-LINK control system has been designed and manufactured with utmost attention to detail and maximum precision. Each unit has been checked and tested for correct functioning before delivery. Despite all the precautions, malfunctions can still occur. For this reason, the Balercontrol and its associated balers should always be operated in such a way as to avoid injury or damage. Never carry out adjustments, repairs, maintenance and service work on the "Balercontrol" while the machinery is running. Always stop the pto shaft and detach the drive shaft from the power take off stub before working on or near moving machine components. A safety clearance from the machine must be maintained during baler control diagnosis Protection of the control system All assembly work (connection and disconnection of sensors, valves, control box etc., replacing of fuses) must be carried out with the power supply disconnected BALERCONTROL and E-LINK is designed to operate with a 12 volt power supply. The system must not be connected to other on-board power supplies! The control box should at all times be in a position where it is protected from water spray (tractor cab or the baler twine compartment, with the cable outlet pointing downwards). When welding on the baler: Do not allow the welding current to pass through the control unit; Disconnect the power supply between the tractor and the baler; WELGER RP 502 RP

44 RP 502 / RP 520 FARMER The following wrapping types can be pre-selected: manual net wrapping automatic net wrapping BALERCONTROL E control box The BALERCONTROL E control box contains the following functions and displays (fig. 56) No. Component Function 1 Green LED Correct power supply 2 Red LED Set bale density reached or exceeded 3 Yellow LED Automatic net wrapping selected. (Flashes when the net clutch is in operation) 4 Yellow LED No function at present 5 Button Changes between manual and automatic wrapping (manual: lights [3] and [4] go out). Depress for 5 seconds: resets the bale counter (DLC) to zero. 6 Button Trigger the net wrapping by hand 7 Button No function at present 8 Display Top row: non-resetting life time counter (LTC); fig Buzzer (on back side) Bottom row: daily counter (DLC) can be reset; Pre-selected bale density reached 40 WELGER RP 502 RP 520

45 Triggering the wrapping (BALERCONTROL E) When the pre-selected bale density is reached, the tractor driver is notified by the red LED [2] and the buzzer [9]. Depending on the selected wrapping mode, the wrapping is triggered either automatically or manually from the appropriate button [6] or automatically. Manual net wrapping Selection: Depress button [5] several times until both yellow LEDs go out. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds. Stop driving the tractor and allow the pick up unit to clear. Depress the net button [6] for approx. 5 seconds; the corresponding yellow LED flashes. Allow the net to wrap the bale at normal speed. Check the net is running by the detection pulley. As soon as the detection pulley stops the wrapping process is finished. Open the tailgate and eject the bale. Note: Wrapping can also be triggered if the pre-selected bale diameter has not yet been attained. Such bales are not taken into account by the bale counter. Automatic net wrapping Selection: Depress button [5] several times until the left yellow LED [4] lights up. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds. Immediately stop driving the tractor and allow the pick-up unit to run clear. About 4 seconds after the sounding of the buzzer, the net is automatically driven into the roll chamber. The corresponding yellow LED flashes simultaneously. With normal pto speed allow the net to wrap the bale. Check the net is running by the detection pulley. As soon as the detection pulley stops, the wrapping process is finished. Open the tailgate and eject the bale. WELGER RP 502 RP

46 RP 520 MASTER The following wrapping types can be pre-selected: manual net wrapping automatic net wrapping Selecting the wrapping type Press the middle function key (arrow in fig. 57) several times until the symbol for automatic net wrapping (fig. 58) or manual net wrapping (fig. 59) appears in the display field of the control box Manual triggering of the winding fig Audible and visible signal when the pre-selected bale diameter is attained. 2. Stop driving the tractor and allow the pick-up unit to operate freely. 3. Depress the START/STOP button for approx. 3 s. 4. If the roll of net stops after the START/STOP button is released, please repeat point Open the tailgate after completing the net wrapping (net knife has been operated). fig. 58 Note: When the pto shaft is in operation, wrapping can be started manually at any time Automatic triggering of the wrapping 1. Wrapping starts without any action from the driver on reaching the pre-selected baling diameter. fig The driver will be signalled to stop driving by a continuous tone lasting for 3 seconds. (This signal begins 0, 2.5 or 5 s before commencement of net wrapping. The delay can be adjusted in the set-up menu). 3. After net wrapping has been triggered, the symbol for wrapping in progress appears in the display (fig. 60). 4. Open the tailgate after completing the net wrapping (net knife has been operated). fig WELGER RP 502 RP 520

47 5.12 Ejecting the bale After completing the wrapping process, open the tailgate hydraulically so that the bale rolls out. Keep the tractor distribution valve on "raise" until the tailgate has completely opened. To close the tailgate, keep the tractor distribution valve on "lower" until the tailgate has been securely locked RP 502 / RP 520 FARMER fig. 61 The upper white lamp [3] (fig. 62) is lit up whilst the tailgate is unlocked. The lower white lamp [4] lights up briefly while the bale rolls over the bale ejector. The tailgate must not be closed again until the lower white lamp [4] goes out. Otherwise the bale remains in the swing range of the tailgate. The upper lamp [3] goes out as soon as the tailgate is locked. The uptake of straw for the next bale can then be commenced. Move the tractor distribution valve into the floating position after actuation. fig RP 520 MASTER After the bale has been rolled over the bale ejector, the request to close the tailgate appears in the display (fig. 63). As soon as the tailgate is locked on both sides, the normal baling display (fig. 64) appears, and the uptake of straw for the next bale can be commenced. Move the tractor distribution valve into the floating position after actuation. fig. 63 Take special care when opening and closing the tailgate. Stay clear of the swing area of the tailgate at all times. If the ground is uneven, the bale may start to roll or tip over onto its side. Employ suitable measures to eliminate this risk. All persons must move away from the possible movement area of the bale. fig. 64 WELGER RP 502 RP

48 5.13 Overload protection Universal drive shaft with shearing bolt clutch* A shearing bolt clutch is installed in the universal drive shaft on the baler side. In the event of overloading, the bolt [1] will shear and must be subsequently replaced by a new one. Only put the machine into operation again when the cause for the overload has been resolved. Use original replacement parts only: fig. 65 Shearing bolt with nut Universal drive shaft with cam-type cut-out clutch* The cam-type cut-out clutch limits the drive torque in the event of overload. Switch off the pto shaft and remedy the cause of the overload. After switching on the pto shaft, the torque increases once again, so that the baler can be put into operation. fig. 66 Avoid long and frequent overloading. Ensure that only the appropriate universal drive shaft is used Reversing the main drive RP 502 / 520 without HYDROFLEXCONTROL* Should the inlet section become blocked for balers without hydraulic swivel floors (HYDROFLEXCONTROL), the main drive can be manually rotated backwards (fig. 67): Switch off the pto shaft Switch off the engine and remove the ignition key Apply the crank lever delivered with the baler (46 mm jaw width) and rotate the drive backwards far enough so that the blockage in the inlet section can be removed; fig. 67 Before restarting the baler, remove the crank lever and close up all protective guards! 44 WELGER RP 502 RP 520

49 5.15 Hydraulic swivel floor* (HYDROFLEXCONTROL)* The swivel floor can be opened hydraulically. This significantly increases the space below the rotor. Any congested material is thereby easily pulled through, grasped by the lower pressing roller and transported into the roll chamber. fig. 68 Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed! Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves! RP 520 MASTER: Procedure in the event of material blockage fig Stop driving and switch off pto shaft. 2. If the cutting device was used, first press the middle function key until the symbol for activate cutting device appears (fig. 69). 3. Using the tractor distribution valve, swing the blades away from the feeder channel. The symbol for cutting device active disappears from the display (fig. 70). fig If the cutting device was not used or the swinging away of the cutting device was not sufficient, press the middle function key until the symbol for activate swivel floor appears (fig. 71). 5. Open the swivel floor using the tractor distribution valve. The symbol for open swivel floor appears in the display (fig. 72). 6. Engage the pto shaft; 7. Return the swivel floor to the working position once the blockage has been removed ( swivel floor display disappears). fig If the cutting function is required, the blades must be swung in once again. fig. 72 WELGER RP 502 RP

50 RP 520 FARMER: Procedure in the event of material blockage Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed! Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves! If cutting device is used: 1. Stop driving and switch off p.t.o. drive shaft. 2. (Left machine side, figure 73 and figure 74:) The right ball valve of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine. figure Set the connected tractor control valve to Lower until the knives move into the bottom door. 4. Reconnect the p.t.o. shaft. The material blockage is automatically removed by the running conveying elements. If the material blockage has been removed: see steps 5 and 6. If swiveling back of the cutting device is not sufficient to remove a material blockage, open and close the bottom door (please continue now on the next page). 5. Set the connected tractor control valve to Raise until the knives swivel to working position. figure To enable the hydraulic reservoirs to fill: actuate the control valve for another 5 sec approx. after swiveling-in of the knives. WELGER RP 502 RP 520

51 Opening the bottom door: 1. Stop driving and switch off the p.t.o. drive shaft. 2. (Left machine side, figure 73 and figure 74:) The right ball valve of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine. 3. Set the connected tractor control valve to Lower until the bottom door swivels down and opens completely. 4. Connect p.t.o. drive shaft. The material blockage is automatically removed by the running conveying elements. Subsequently: close the bottom door. Closing the bottom door: 1. Set the connected tractor control valve to Raise until the bottom door swivels up and closes completely. 2. To enable the hydraulic reservoirs to fill: actuate the control valve for another 5 sec approx. after closing of the bottom door. Attention: For daily operation the two ball valves must be positioned in parallel (see figure 73)!! 3. (Left machine side, figure 73 and figure 74:) The right ball valve of the hydraulic block must point again towards the machine. The left ball valve of the hydraulic block must point towards the machine. Attention: While the bottom door is being closed the knives move automatically to working position. If the machine is intended to work without knives, the knives must subsequently be moved to home position again: see chapter 5.8! WELGER RP 502 RP

52 5.16 Standby operation Even if the electronic control system breaks down, the most important machine functions can still be performed. Emergency operation is intended solely for completing work in progress Standby operation: bale diameter The current bale diameter can be monitored at any time by observing the diameter display [2] (fig. 75) on the front of the baler. See Section for instructions on triggering the wrapping. fig Standby operation: net wrapping The net wrapping unit can be operated using the electric lighting system if necessary. The plug-in connection [1] that protrudes from the cable harness on the right side of the baler is used for this. 1. The electrical connector plug [2] is simply inserted into the free plug socket [1]. 2. Net wrapping is triggered by switching on the parking light for such a time until the bale catches onto the net. Note: Interrupt the provisional electrical connection for the net wrapping unit if the vehicle lighting is to be switched on for a long duration, e.g. when driving on the road. fig Standby operation: bale density RP 520 MASTER 1. A hydraulic block is arranged on the back of the machine (fig. 77). Move the lever into the vertical position. 2. Turn the hand-wheel fastened on the side clockwise until it comes to a stop. The highest baling pressure level is set in this position. 3. If a lower baling pressure is required, the hand-wheel can be turned back anti-clockwise. fig WELGER RP 502 RP 520

53 6 Maintenance / Settings Never carry out adjustments and repairs, or maintenance and service work on the baler while it is running. Switch off the engine and remove the ignition key. Wait for the baler to stop. Switch off the pto shaft and disconnect the universal drive shaft from the pto shaft before working on the moving parts of the baler. If maintenance or installation/assembly work is performed with the tailgate open, it is essential to secure the tailgate to prevent it from falling. Use the cut-off valve on the right side of the baler for this purpose. When it is in a locked state, the operating lever is at right angles to the direction of flow (fig. 2). The shut-off valve may only be actuated from the open righthand side guard door. 6.1 General instructions After about the first 20 operating hours, tighten all screws and nuts, including those inside the machine. When doing so, do not change adjustment screws on the net brake. WELGER RP 502 RP

54 Maintenance of the net wrapping system* Setting the disc brakes In order to prevent the net roll from running on, the disc brake must be set such that the brake disc can no longer be turned by hand when the lever [1] is vertical In order to do this, undo screw [2] on the lever [1], tighten up knurled nut [3] until the brake linings lie snugly on the disc. Tighten up screw [2] once again. fig. 78 If there is excessive wear on one side of the brake disc lining [4], undo the lock nut [5], turn the screw [6] until the brake linings are parallel again and re-apply the lock nut [6] Setting the oscillation damper The motion of the net tensioner [12] is braked with an oscillation damper on the left side of the baler. 1 Two wing nuts (arrows in fig. 80) press the friction pads against the net tensioner from both sides. To set the net tensioner, first of all move it into its highest position and do up the wing nut "finger-tight". Do the same for the lowest position. The setting is correct when the net tensioner can still just be moved up and down by hand between the two limiting positions. When operating the net wrapping system, the net tensioner should move slowly enough between the two end positions so that the net always remains tensioned. 2 fig Never reach into the cutting knife area danger of injury! fig WELGER RP 502 RP 520

55 Setting the deflectors In order to prevent binding material from coming out of the roll chamber, two deflectors [1] were built into the area near the front rollers (fig. 81). Upon loosening the fastening screws in the side walls, the deflector clearance to the rollers can be set. For correct setting, the longitudinal section of the operating rollers should just about gently strike the deflectors. Finally tighten the screws once again. 6.4 Tensioning the roller chains The tension of the chains should be checked at the latest every 500 bales and re-adjusted as required. fig. 81 On the pick-up unit or cutting device drive*, loosen the chain tensioning blocks and re-position in the slots. Finally tighten the tensioning blocks well. The other drive chains are elastically tensioned with springs (arrows in fig. 82). Apply the lock nut again after adjustment. If the chain can no longer be tensioned, shorten the chain by removing a link. Insert a shortened chain link if necessary. Note: New chains will lengthen shortly after placing them into operation. Therefore these can be tensioned a little more than usual. fig. 82 WELGER RP 502 RP

56 6.5 Tyre air pressure Tyre size max. speed RP 502 SPECIAL RP 520 FARMER MASTER 15.0/55-17 Impl. 10 PR 40 km/h 2.5 bar 19.0/45-17 Impl. 10 P5 40 km/h 2.3 bar 500/ km/h 1.5 bar 170/60-8 Pick-up guide wheel: 2.0 bar 6.6 Chain lubrication The roller chains are continuously supplied with oil by means of the automatic chain lubrication during field work. Warning: Never operate the automatic chain lubrication without oil! It can lead to damage on the lubrication pump and on the roller chains. To avoid the penetration of dirt into the lubrication system, clean the surrounding area carefully before opening the upper screw-on lid. Oil type: see Section: 6.7; fig WELGER RP 502 RP 520