RP 405 / RP 435 RP 505 / RP 535. RP 435 Master Operating Manual from year of manufacture 2006

Transcription

1 RP 405 / RP 435 RP 505 / RP 535 RP 435 Master Operating Manual from year of manufacture

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3 Send back to: Welger Maschinenfabrik GmbH Abteilung CSC Postfach 1965 D Wolfenbüttel Handover declaration 1 (Copy for the Manufacturer) Complete and return this document when the machine is delivered. Possible guarantee requests cannot be handled before this document has not been sentback. Date of delivery:... Machine type: RP 405 / RP 435 / RP 505 / RP Machine no. on the data plate (e. g ):... I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine. Some components of the machine may have been removed for transportation.do not use the machine unless these components have been correctly installed again! The following components must be reinstalled prior to first commissioning: RP 405 / RP 435: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20) Drawbar head: see spare parts list page B20 Branch deflector on machine roof: see spare parts list page J80 (item 45) Sensor support with sensor: see spare parts list page J80 (items 25, 32) Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 3 5) Hydraulic system control block: see operating manual page 31 RP 505 / RP 535: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20), page B35 (items 5 6) Drawbar head: see spare parts list page B20 Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 32 33) Hydraulic system control block: see operating manual page 31 Before first use: Unlock hydraulic of bottom door (see chapter "7.4.2 Release bottom door") Date Customer's signature

4 Send back to: Welger Maschinenfabrik GmbH Abteilung CSC Postfach 1965 D Wolfenbüttel M Complete and return this document when the machine is delivered. Possible guarantee requests cannot be handled before this document has not been sentback. Customer Name:... Postcode/Place:... Phone:... Street:... Land/State: Marketing partner/importer Name:... Postcode/Place:... Phone:... Street:... Land/State: Date Customer's signature

5 Handover declaration 2 (Copy for the Customer) Complete this document when the machine is delivered and keep it. Date of delivery:... Machine type: RP 405 / RP 435 / RP 505 / RP Machine no. on the data plate (e. g ):... I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine. Some components of the machine may have been removed for transportation.do not use the machine unless these components have been correctly installed again! The following components must be reinstalled prior to first commissioning: RP 405 / RP 435: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20) Drawbar head: see spare parts list page B20 Branch deflector on machine roof: see spare parts list page J80 (item 45) Sensor support with sensor: see spare parts list page J80 (items 25, 32) Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 3 5) Hydraulic system control block: see operating manual page 31 RP 505 / RP 535: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20), page B35 (items 5 6) Drawbar head: see spare parts list page B20 Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 32 33) Hydraulic system control block: see operating manual page 31 Before first use: Unlock hydraulic of bottom door (see chapter "7.4.2 Release bottom door") Date Customer's signature

6 M Complete this document when the machine is delivered and keep it. Customer Name:... Postcode/Place:... Phone:... Street:... Land/State: Marketing partner/importer Name:... Postcode/Place:... Phone:... Street:... Land/State: Date Customer's signature

7 Handover declaration 3 (Copy for the Trader) Complete this document when the machine is delivered and keep it. Date of delivery:... Machine type: RP 405 / RP 435 / RP 505 / RP Machine no. on the data plate (e. g ):... I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine. Some components of the machine may have been removed for transportation.do not use the machine unless these components have been correctly installed again! The following components must be reinstalled prior to first commissioning: RP 405 / RP 435: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20) Drawbar head: see spare parts list page B20 Branch deflector on machine roof: see spare parts list page J80 (item 45) Sensor support with sensor: see spare parts list page J80 (items 25, 32) Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 3 5) Hydraulic system control block: see operating manual page 31 RP 505 / RP 535: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20), page B35 (items 5 6) Drawbar head: see spare parts list page B20 Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 32 33) Hydraulic system control block: see operating manual page 31 Before first use: Unlock hydraulic of bottom door (see chapter "7.4.2 Release bottom door") Date Customer's signature

8 M Complete this document when the machine is delivered and keep it. Customer Name:... Postcode/Place:... Phone:... Street:... Land/State: Marketing partner/importer Name:... Postcode/Place:... Phone:... Street:... Land/State: Date Customer's signature

9 Handover declaration 4 (Copy for the Importer) Complete this document when the machine is delivered and keep it. Date of delivery:... Machine type: RP 405 / RP 435 / RP 505 / RP Machine no. on the data plate (e. g ):... I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine. Some components of the machine may have been removed for transportation.do not use the machine unless these components have been correctly installed again! The following components must be reinstalled prior to first commissioning: RP 405 / RP 435: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20) Drawbar head: see spare parts list page B20 Branch deflector on machine roof: see spare parts list page J80 (item 45) Sensor support with sensor: see spare parts list page J80 (items 25, 32) Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 3 5) Hydraulic system control block: see operating manual page 31 RP 505 / RP 535: Wheels: see spare parts list pages A10, A20, A21 Maintenance platform: see spare parts list page K25 (items 01 06, 08 10, 12 14) Railing: see spare parts list page K25 (item 11) Guard hoods on pick-up: see spare parts list page C25 (items 7, 8) Pick-up guide wheel: see spare parts list pages C30, C35 Pick-up guard rail: see spare parts list page K25 (item 7) Support foot: see spare parts list page B30 Ladder on support foot: see spare parts list page K25 (items 15-20), page B35 (items 5 6) Drawbar head: see spare parts list page B20 Chain tensioning blocks: see spare parts list page C10 (item 11) Bale ejector shock absorber: see spare parts list page B70 Handles of side cover: see spare parts list pages K10, K11 (items 32 33) Hydraulic system control block: see operating manual page 31 Before first use: Unlock hydraulic of bottom door (see chapter "7.4.2 Release bottom door") Date Customer's signature

10 M Complete this document when the machine is delivered and keep it. Customer Name:... Postcode/Place:... Phone:... Street:... Land/State: Marketing partner/importer Name:... Postcode/Place:... Phone:... Street:... Land/State: Date Customer's signature

11 The serial number is shown on data plate on the right machine side, as shown aside. Warranty claims and queries cannot be dealt with unless the serial number is stated. Please enter this number here immediately after delivery:... Read and heed the operating instruction and safety instructions prior to commission the machine. In this operating instruction all positions required for safety reasons are marked with a warning sign. Instruct all other operators in safety instructions! The warning- and information signs located at the machine give information for safe operation. Watch them for safety reasons! Read and heed the separate operating instruction "E-LINK for RP 435 MASTER / RP 535 MASTER". * Please watch, that the equipment marked with a [*] in this operating instruction, belong only to defined types of the machine or that they are only deliverable for defined types as additional equipment. Copy is not permitted - copyright and technical changes are reserved. Illustrations are not binding on form and design by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany. Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 D Wolfenbüttel Phone: (+49) / Fax: (+49) / wmf@welger.com WELGER RP 405 RP 435 RP 505 RP 535 3

12 Table of Contents 1 VARIANTS SAFETY General safety instructions Noise level Instructions for fire protection Tail gate safeguard Maintenance Platform and Ladder Hydraulic System Guard casings WARNING SYMBOLS Symbolised operating instructions Proper use Electromagnetic compatibility To heed in the road traffic Environment/Disposal ASSEMBLY GROUPS START UP Coupling the baler Drive shaft Hydraulic System Electrical system Compressed-air braking system Hydraulic braking system TWINE TYING* Threading the twine Adjusting the twine brake Setting the edge clearances Adjusting the wrapping distance Edge wrapping adjustment NET TYING* Inserting the net Tightening the net knife Adjusting the net length CUTTING DEVICE* Equipment Knife groups Moving in and out the cutting device Lock bottom door Brittle crop material Assembly and disassembly of the cutting device knives Regrinding the cutting device knives WELGER RP 405 RP 435 RP 505 RP 535

13 8 FIELD USE Locking the tail gate Adjusting the bale diameter Setting the bale density Raising / lowering the pick-up Pick-up guide wheels Windguard / Pick-up shield* Feed guide plate PTO speed Driving style Safety clutch OPERATION / TYING BALERCONTROL E control box E-LINK control box Eject bales Emergency operation REMOVING A MATERIAL JAM Main drive reversing Hydraulic bottom door* MAINTENANCE / SETTING General notes Grease knife lever Tensioners Maintenance of the net tying unit Tensioning the roller chains Hydraulic layouts Tire air pressure RP 405 / RP Tire air pressure RP 505 / RP Chain lubrication (oil lubrication) Winter pause Lubrication chart Lubrication points TECHNICAL DATA WELGER RP 405 RP 435 RP 505 RP 535 5

14 1 Variants RP 405 SPECIAL RP 435 RP 435 MASTER Pick-up width 2.00 m 2.25 m NONCUT Rotor Ring type rotor PROFICUT without cutting device Cutting device MASTERCUT 13-knife XtraCut knife XtraCut knife firmly bolted Bottom FLEXCONTROL HYDROFLEXCONTROL Tying Net tying Twine tying Control BALERCONTROL E with BCE control box BALERCONTROL III with E-LINK control box = series equipment = variant = not available 6 WELGER RP 405 RP 435 RP 505 RP 535

15 RP 505 SPECIAL RP 535 RP 535 MASTER Pick-up width 2.00 m 2.25 m NONCUT Rotor Ring type rotor PROFICUT without cutting device Cutting device MASTERCUT 13-knife XtraCut knife XtraCut knife firmly bolted Bottom FLEXCONTROL HYDROFLEXCONTROL Tying Net tying Twine tying Control BALERCONTROL E with BCE control box BALERCONTROL III with E-LINKControl box = series equipment = variant = not available WELGER RP 405 RP 435 RP 505 RP 535 7

16 2 Safety 2.1 General safety instructions Attention! Even if all instructions are observed the machine involves residual dangers. Always handle the machine with care to avoid danger to yourself and others! Before starting work perform a visual inspection of the machine. Check whether any device has been changed or is missing and pay attention to any unusual noise or leaks which occur during operation. All protective devices, as for example casing sheets, rubber skirts or distance brackets are for your safety! Never operate the machine with defective or removed protective devices e. Keep all safety relevant parts always in correct function. Before commissioning all guard casings must be mounted and closed! Never perform maintenance- and repair works during machine is in operation. In case of all work on movable parts or in the range of action of movable parts: Switch off power take-off shaft, switch off tractor engine, remove ignition key and disconnect drive shaft from power take-off shaft end. Interrupt electrical connection between tractor and machine. Bring no metal parts close to the machine, as long the electric control is in operation (e.g. tools, safety boots with metal caps). Reason: unintentional triggering of proximity switches and thus unexpected machine moves. When carrying out work on the opened tail gate: insert tail gate safeguard (chapter 2.4 Tail gate safeguard ). Never remove any crop material from the machine while the drive is running, or while the disconnected machine is still moving. Always switch-off power take-off shaft and tractor engine first. During work only the driver must be on the tractor. Riding on the machine is prohibited! Never step onto the maintenance platform during machine is in motion. Before stepping onto the maintenance platform: stop machine, switch-off power take-off shaft and tractor motor, take out ignition key and wait for standstill of the machine. 8 WELGER RP 405 RP 435 RP 505 RP 535

17 Do not step onto the drawbar or other parts of the machine, when the machine is in operation. Keep sufficient distance to baler (pick-up, running gear, bale unloading area). Before threading the tying material: stop machine, switch-off power take-off shaft and tractor motor, take out ignition key and wait for standstill of the machine. Make the control powerless (disconnect electrical connection to the tractor). All protection devices must be mounted to the baler and must be in correct state. Prior to opening the protection devices switch-off power take-off shaft and tractor motor and wait for standstill of the machine. Block the wheels of the baler with wheel chocks when machine is parked. Carry the chocks on the machine when transporting it or during field use. When opening the tail gate keep a minimum distance of 2 m from electrical high-voltage lines. There is danger of cutting during works at the net knife or at the knives of the cutting device of the baler. Wear protective gloves. Works at the magnets of the knife holders: the function of cardiac pacemakers can be interrupted by magnetic fields. Works at the magnets of the knife holders: Danger of injury by splinters never hit the inserted knives from below with a striking tool. Magnets could be damaged! Maintenance work may be carried out by trained persons only. All maintenance- and repair works that are not part of this operating instruction must be carried out by authorised personnel only. Replace wearing parts of the braking system only at both sides. Prior to disassembling the complete pick-up the machine must be secured against backward tilt. In case of locations on a slope: place the round bales always so that they cannot move automatically. WELGER RP 405 RP 435 RP 505 RP 535 9

18 2.2 Noise level The EC directive 86/188/EEC (or EC directive 2003/10/EC) concerning noise at the workplace instructs employers and employees to assess noise at the place of work and to control it. The noise level during normal field work is subject to variations which depend on the one hand on the noise level of the tractor and on the other hand on the deployment conditions of the baler. The noise level generated by the WELGER balers, measured at the head height of the driver with the tractor cabin window open, is, under normal operating conditions, less than 70 db (A). The combined noise level of baler and tractor primarily depends on the level of the noise from the tractor (radios are an additional source of noise). We recommend that the tractor is operated with closed windows. 2.3 Instructions for fire protection Figure 1 The harvested crop can easily ignite! To prevent fire: remove crop remains and oil leaks. If any machine parts run hot: find and remove cause. Do not begin a journey with the machine attached unless the manually operated brake has been completely released. Otherwise there is danger of fire by brakes running hot (e. g. in the field). Keep the electrical systems of tractor and baler and the exhaust system of the tractor in proper condition. The existing wiring must not be used for any other consumers than those installed in the factory or approved by the manufacturer. Overloading the electrical lines leads to excessive heating. Do not smoke in the vicinity of the machine. Keep fire extinguisher within reach. 10 WELGER RP 405 RP 435 RP 505 RP 535

19 2.4 Tail gate safeguard If any short-time maintenance or assembly work is carried out with the tail gate open, the tail gate must be hydraulically secured against lowering: use shut-off valve (on the maintenance platform). When the valve is shut off, the actuating lever is at right angles to the flow direction (Figure 2). In case of longer maintenance or assembly work with the tail gate open, the tail gate must (in addition to the hydraulic safeguard) be mechanically secured against lowering - using suitable means. Figure 2 After completion of any maintenance and/or assembly work reset the valve to its initial position (along flow direction, Figure 3) and/or remove the mechanical safeguard. Figure Maintenance Platform and Ladder Attention, danger of falling! Never step on the maintenance platform [14] (Figure 4), while the machine is in motion. Before stepping on the maintenance platform: stop machine, switch-off power take-off shaft and tractor motor and wait for standstill of the machine. Climb and leave the maintenance platform exclusively via the ladder [10]. Never step on the ladder when folded up always fold down the ladder before using it. Figure 4 (Figure 4) To climb the maintenance platform: fold down the ladder [10]. (Figure 4) Before the machine can move on: fold up and lock the ladder [10] again. (Figure 4, Figure 5) For transportation the railing [15] is removed from the maintenance platform in the factory and enclosed with the machine. The railing must be mounted again before commissioning of the machine: Take the dismounted railing [15] out of the machine. Mount the railing [15] to the maintenance platform using the 6 enclosed screws [16] (Figure 5). Figure 5 WELGER RP 405 RP 435 RP 505 RP

20 2.6 Hydraulic System Max. operating pressure of the hydraulic system: 210 bar During assembly work on the hydraulic system, in particular if accumulators are used (Figure 6): Depressurise the hydraulic system (control unit to "Lower") Secure hydraulically operated components (pick-up, tail gate, cutting device, HYDROFLEXCONTROL bottom door) mechanically against uncontrolled movement. Figure 6 According to DIN hoses must not be older than six years, including storage time. 12 WELGER RP 405 RP 435 RP 505 RP 535

21 2.7 Guard casings To comply with the European safety regulations, since Jan. 1, 1995 manufacturers of machines have been obliged according to EN 704 to design fixed, isolating guard casings in such a way that they can only be opened by means of a tool, and will automatically lock again without the need for a tool. Figure 7 Open guard casings: (Figure 7): Using a 13 mm spanner turn the hexagon head of the locking mechanism slightly in counterclockwise direction the casing engages in a safety catch. (Figure 8): RP 405 / RP 435: Push safety catch up. The casing opens fully. (Figure 9): RP 505 / RP 535: Push safety catch down. The casing opens fully. RP 405 / 435 To close the casing, press the panel against the machine so that the locking mechanism can be heard to engage. Figure 8 Attention, danger of injury! Never operate the machine with open guard casing! Open guard casings only, when a free swivelling area is available. Never operate the machine with defective or removed protective devices (e. g. guard casings and distance bracket). Before opening the protections: Switch off p.t.o. shaft drive and tractor engine, wait until machine has stopped, remove the ignition key. RP 505 / 535 Figure 9 WELGER RP 405 RP 435 RP 505 RP

22 2.8 WARNING SYMBOLS Symbols in this manual Instructions of particular importance in this manual are marked by the following symbols and signal words: Attention! This symbol stands next to warnings: danger to life, danger of injury, possible serious material damage. Caution! This symbol stands next to safety instructions: malfunctions and impairments of correct operation, possible material damage. Note! This symbol stands next to useful information: special information on how to use the machine most efficiently Symbols on the machine Danger zones that cannot be secured by construction are labelled with prohibition signs and yellow warning symbols. Because they are without text in most cases the exact meaning is described in the following. The symbols must always be kept in recognisable state. If any symbols on this machine are missing or have been damaged, they must be replaced. Prohibition signs Meaning / Spare part No. No smoking! Spare part no.: Do not step on the area! Spare part no.: WELGER RP 405 RP 435 RP 505 RP 535

23 Warning symbols Meaning / Spare part No. Read and heed the operating instruction and safety instructions prior to commission the machine. Spare part no.: Close guard casings prior to commissioning the machine! Spare part no.: Never reach into the pick-up section when the tractor engine is running and the power take-off shaft is coupled. Spare part no.: Switch-off motor and take out the ignition key prior to maintenance- and repair works. Spare part no.: Switch-off motor and unplug the plug of the power supply prior to maintenance- and repair works. Spare part no.: Stay clear of tail gate swinging area while in operation. Spare part no.: WELGER RP 405 RP 435 RP 505 RP

24 Riding on the machine, on treads or on the platform is prohibited. Spare part no.: Handle cutting unit blades only with gloves and suitable tool Spare part no.: The accumulator is under gas and oil pressure. Depressurise hydraulic system prior to disassembling or repair. Spare part no.: Activate tail gate safeguard prior to enter the roll chamber. Spare part no.: WELGER RP 405 RP 435 RP 505 RP 535

25 2.9 Symbolised operating instructions The most important operating instructions are shown as symbols without text. The precise meaning is described in the following. Symbols Meaning / Spare part No. The two lift eyes at the upper traverse are indicated by this symbol. Other fastening points are not permitted for crane suspension. Spare part no.: Note on crane loading To ensure safe loading of the machine either a spreader must be used, or the transport chain must have a minimum length of 2.40 m. Spare part no.: Tail gate locking device If the lever is positioned at right angles to the flow direction, the tail gate is secured against lowering. Spare part no.: Maximum permissible hydraulic pressure The machine may only be connected to a hydraulic system providing a maximum oil pressure of 210 bar. Spare part no.: Adjusting the variable load valve For driving on the road, the variable load valve of the compressed-air brake must be set to "full brake force". Spare part no.: WELGER RP 405 RP 435 RP 505 RP

26 RP 405 / RP 435 Locking of the belt lever for maintenance purposes Spare part no.: RP 505 / RP 535 Locking of the belt lever for maintenance purposes Spare part no.: RP 405 / RP 435 Opening of the lateral guard casings Using a 13 mm spanner turn the hexagon head of the locking mechanism slightly in counterclockwise direction the casing engages in a safety catch. Push safety catch up. The casing opens fully. Ersatzteil-Nr.: (linke Schutzverkleidung) Ersatzteil-Nr.: (rechte Schutzverkleidung) RP 505 / RP 535 Opening of the lateral guard casings Using a 13 mm spanner turn the hexagon head of the locking mechanism slightly in counterclockwise direction the casing engages in a safety catch. Push safety catch down. The casing opens fully. Spare part no.: (l.h. side guard casings) Spare part no.: (r.h. side guard casings) 18 WELGER RP 405 RP 435 RP 505 RP 535

27 Guard lever for cutting unit blade To unlock the cutting unit blades the lever must be turned down through about 90. Spare part no.: and Setting of the bale density Spare part no.: Adjustment of the bale density for emergency operation Spare part no.: Lubrication! 1 x per day, check lubrication and relubricate if necessary. Spare part no.: Thread scheme for net tying Spare part no.: Thread scheme for twine tying Spare part no.: Spare part no.: WELGER RP 405 RP 435 RP 505 RP

28 Twine tying Distance between the individual windings Spare part no.: (on the right in travelling direction) Distance of the last winding from the bale edge Spare part no.: (on the left in travelling direction) Note on crane loading To ensure safe loading of the machine either a spreader must be used, or the transport chain must have a minimum length of 2.40 m. Spare part no.: Screw couplings on the drawbar head. Observe the required torques! Spare part no.: Required PTO speed Spare part no.: WELGER RP 405 RP 435 RP 505 RP 535

29 2.10 Proper use The machine is exclusively constructed for pressing bales from agricultural straw material lying on the floor (proper use). Using the machine for any other purposes does not constitute proper use. The manufacturer cannot be held liable for any damage resulting from such use; the risk of improper use lies entirely with the user. Operating the machine within the limits of its proper use also involves complying with the operating, maintenance and servicing conditions prescribed by the manufacturer. The bale weight must not exceed 1.5 t. I. e. the maximum bale size may not be available for silage bales (dependent on the quantity of moisture the bales must be smaller). Bale sizes: See chapter "Technical Data". The machine may only be used, serviced and repaired by persons who are familiar with such work and instructed on the dangers involved. Attachment of additional equipment other than at the positions provided by the factory is prohibited. Only additional equipment must be used that is allowed by the manufacturer. The relevant accident prevention regulations and all other generally accepted safety rules must be observed. Unauthorised modifications and installation of non-approved parts and equipment on the machine preclude any liability of the manufacturer for any damage resulting therefrom. Any changes to safety-relevant parts will invalidate the conformity declaration and the CE marking Electromagnetic compatibility The machine is equipped with electronic components and modules; the function of these electronic components and modules can be influenced by electromagnetic emissions of other equipment. Such influences can cause risks to persons, if the following safety instructions are not observed: In case of subsequent installation of electrical and electronic equipment and/or components into the machine, it is the user's responsibility to check whether the installation impairs the vehicle electronics or any other components. Ensure above all that the electrical and electronic components subsequently installed are in conformity with the EMC directive 89/336/EEC as amended, and that they are provided with the CE. WELGER RP 405 RP 435 RP 505 RP

30 2.12 To heed in the road traffic Attention! Prior to driving on the road the roll chamber must be completely emptied (acc. to road traffic regulations).... remove any crop material hanging loosely from the baler.... connect the drive shaft to the tractor power take-off shaft;... insert the spars of the bale ejector *.... the ladder of the maintenance platform must be turned up and locked.... connect the lighting set of the machine to the tractor and check function (also at daylight).... insert and secure the pick-up guide wheels* in upper position (pick-up width 2.25 m).... fully release the manually operated brake. Otherwise there is danger of fire by brakes running hot (e. g. in the field). Prior to operate the baler with connected machine (e.g. round bale wrapper), obtain information from the manufacturer. The wheel chocks (2 in number) which are part of the safety equipment are to be carried on the baler at all times. Permitted maximum speeds of individual assembly groups (e.g. drawbar or axis) do not count for the allowed maximum speed of the total machine. In this document only type relevant maximum speeds are listed. Any deviating national regulations must always be observed. The following regulation applies in Germany: Machine Equipment perm. maximum speed RP 405 with pneumatic brake system 40 km/h RP 435 brakeless 25 km/h RP 505 RP 535 with pneumatic brake system with pneumatic brake system with 500/ tire equipment 40 km/h 25 km/h 22 WELGER RP 405 RP 435 RP 505 RP 535

31 Pneumatic brake system*: Do not begin a journey with the baler attached unless both coupling heads (yellow and red) are connected to the tractor and the pressure gauge in the tractor cabin shows the required operating pressure. Attention, danger of accident! Prior to each journey pay attention to the lever position of the variable load valve of the pneumatic brake system. Wrong setting reduces the traffic safety (see chapter Adjust variable load valve*). Start driving on the road with connected baler only when the variable load valve is set to full load (see chapter Adjust variable load valve*) Hydraulic brake system*: Start driving on the road only when the according hydraulic tube is connected to the tractor Germany (StVZO road traffic regulations): Agricultural machines with permitted total weight of more than 3,000 kg need a type approval. (Technical changes such as attaching a trailer coupling will invalidate the type approval) Prior to changes at the machine it must be solved, if the changes are permitted or if they can added to the documents by an expert. Further heed the national regulations of the country where the machine is in use. WELGER RP 405 RP 435 RP 505 RP

32 Data plate specifications Figure 10 Item Meaning 1 Trade name of the machine 2 Ident no. individual machine number, please state in case of inquiries. 3 Machine type, machine version 4 Permissible total weight for operation on public roads. The actual weight can be less according to the equipment. Exception (only in field use): The actual weight of the machine plus bale in the chamber can be higher. 5 Maximum support load of the machine, that acts at maximum load of tying material* to the hitch. The open-type towing fixture of the tractor must be registered for this support load. 6 Permitted axle load for operation on public roads. 7 Year of construction of the machine 8 Internal batch number 9 Manufacturer's name and address 24 WELGER RP 405 RP 435 RP 505 RP 535

33 RP 405 / RP 435 only: Specifications on the data plate of the drawbar head Note! RP 505 and RP 535 have no data plates on the drawbar heads. Figure 11 Item Meaning 1 Drawbar type 2 official mark of conformity 3 Permitted maximum total weight of the machine 4 Permitted maximum support load WELGER RP 405 RP 435 RP 505 RP

34 2.13 Environment/Disposal Lubricants Dispose of lubricants properly and do not pollute the environment. Observe the safety data sheets of the lubricants used. Dispose of biodegradable lubricants separately. 1 litre of oil pollutes 1 million litres of water. 1 litre of oil pollutes 10 million cubic meters of soil Consumables Twines, nets, foils and machine parts thrown away pollute the environment. They endanger in particular the animal world. Therefore: dispose of twines, nets, foils and machine parts in a professional manner. 26 WELGER RP 405 RP 435 RP 505 RP 535

35 3 Assembly groups Figure 12 Item Assembly group Item Assembly group 1 E-LINK control box* 8 Bale ejector 2 BALERCONTROL E control box* 9 Guide roller 3 ELS ("Easy-Load-System" for net rolls) 10 Catch 4 Net tying or twine tying 11 Bottom door* 5 Belt 12 Pick-up 6 Rocker arm 13 Cutting device* 7 Tail gate WELGER RP 405 RP 435 RP 505 RP

36 4 Start Up Attention, danger of injury! During handling in the area of the drawbar ensure that the machine is secured against moving. Do not raise the support foot before the baler has been safely coupled to the tractor. Do not uncouple the baler, unless: the bottom for wheels and support foot is even and bearing. the baling chamber is empty and the tail gate closed. the wheels of the machine are blocked by means of wheel chocks. the hydraulic tubes have been depressurised. the hitch is released. Nobody must be between tractor and baler as long as the vehicles are not secured against moving by manually operated brake and/or wheel chocks! Always keep children away from the machine! 4.1 Coupling the baler Note! Dependent on the equipment variant, a rotary or a rigid hitch can be installed (observe national regulations!). For trouble-free operation of the baler correct coupling of the machine (with adjustment of the drive shaft) is of decisive importance. After coupling of the baler: fully retract the support foot using the crank handle. release the bolt. push support foot fully in and lock it with the bolt. 28 WELGER RP 405 RP 435 RP 505 RP 535

37 4.1.1 Manually operated brake (according to version) Attention, danger of burning! Do not begin a journey with the machine attached unless the manually operated brake [20] has been completely released. Otherwise there is danger of fire by brakes running hot (e. g. in the field). After coupling the machine to the tractor: Release manually operated brake [20] (turn crank to the left). Figure 13 Attention, danger of accident! Machines not coupled to the tractor must be secured against accidental rolling away by applying the manually operated brake [20] and by means of wheel chocks. Before uncoupling the machine from the tractor: Apply the manually operated brake [20] (turn crank to the right) Drawbar positions (all measures in [mm]) Figure 14 WELGER RP 405 RP 435 RP 505 RP

38 4.1.3 Adjusting the drawbar Figure 15 Attention! The height adjustment and thus the adjustment of the hitch may be changed only by the manufacturer or an authorised special workshop. Place the baler on a horizontal ground. Turn out the support foot so far that the machine stands horizontally (axle plates horizontal, support foot vertical). Measure the height of the drawbar on the tractor. Measure the height of the hitch on the machine. Using the dimensions stated in Figure 14 adjust the drawbar to the pair of holes approximating the desired value most closely. After each loosening of the safety nuts these must be replaced. After alignment of the triangular draw system, position the hitch horizontally: loosen the fastening screws of the hitch and correct the position of the hitch by means of the threaded rod. Firmly tighten all fastening screws and nuts: Tow hitch version In case of tractor's tow hitch coupling of the baler the following dimensions must be observed, at all costs: (see Table 1). Attention! Other tow hitches than showed in Figure 16 or Table 1 are not permitted! Danger of breaking! Figure 16 Category in conformity with dimensions of the catch opening catch openingoutline layout max. permissible vertical support load ISO d B r 1) c 2) l F +1 min. max. min. ±10 kg ) Provided the outer radius r is adhered to, different designs of tow hitch are permissible (see Figure 16). 2) To adhere to the dimension c, the upper part of the tow hitch can possibly be removed. Dimensions in millimetres Table 1: Dimensions, position and support load of the tow hitch 30 WELGER RP 405 RP 435 RP 505 RP 535

39 4.2 Drive shaft Figure Coupling the cam-type cut-out clutch* Depending on the version, a drive shaft with automatic safety clutch (cam-type cut-out clutch) is installed. Clean and grease the profile of the machine sided connecting shaft prior to assembling. Loosen and turn out clamping cone [1]. Open maintenance hole in the guard cone on the machine side. Slide the clutch onto the connecting shaft so that the location hole [2] points towards the maintenance hole. Position the location hole for the clamping cone above the ring groove [3] of the connecting shaft. Turn clamping cone into location hole and tighten firmly (approx. 70 Nm) while moving the hub slightly to and fro in longitudinal direction. Check tight and firm seat of clutch hub by compression and tensioning movements. During work, check clutch for correct tightening at regular intervals. Figure Uncoupling of the cam-type cut-out clutch* Loosen and remove clamping cone from clutch hub. If this cannot be done by hand, drive out clamping cone from the opposite side by means of a pin punch. Figure 19 WELGER RP 405 RP 435 RP 505 RP

40 4.2.3 Adjusting the drive shaft (Figure 20) Pay attention to maximum operating length L max and minimum operating length L min! Aim at maximum overlap possible. a) Shortest operating length, i. e. complete overlap. b) During normal operation, the overlap of the sliding tubes should be a least 2/3 of the profile overlap L U. c) For a short time, the drive shaft can be operated with the length L max, i. e. the profile overlap is 1/3 L U. Figure 20 If necessary: adjust length. Hold the drive shaft halves next to each other in the shortest operating position and mark them. Shorten inner and outer tubes by equal amounts so that a sliding travel of 40 mm is retained in the shortest operating position. Secure the protective tubes of the drive shaft by retaining chain against revolving. Before the starting the drive shaft, check whether the locks have properly engaged. Figure 21 When driving through narrow bends ensure that the wide angle joint (on the tractor side) is not bent more than permitted by the manufacturer of the drive shaft. Heed the operating instructions of the drive shaft's manufacturer as well as national relevant signs with type approval for drive shaft protection. Only the drive shafts prescribed by the manufacturer may be used! Support drive shaft always with the drive shaft support when machine is uncoupled (Figure 22). In case of bottom coupling swivel up the support accordingly. Figure 22 Attention, danger of injury! Protective tube and guard cone of the drive shaft, and the power take-off shaft protection, must be fitted and be in proper condition. Ensure before switching on the power take-off shaft that the selected speed of the tractor is in conformity with the permissible speed and direction of rotation of the machine (540 rpm). Switch power take-off shaft only during idling! 32 WELGER RP 405 RP 435 RP 505 RP 535

41 4.3 Hydraulic System Hydraulic connections for machines with E-LINK Symbol on hydraulic tube Function Tractor connection Colour of marking Tail gate open and close single acting yellow Hydraulic switch with the functions open and close conveyor bottom raising and lowering the pick-up move cutting device in home- and in operating position double acting with floating position red WELGER RP 405 RP 435 RP 505 RP

42 4.3.2 Hydraulic connections for machines with BALERCONTROL E Symbol on hydraulic tube Function Tractor connection Colour of marking Tail gate open and close single acting yellow Pick-up lift and lower single acting red move bottom door in homeand in operating position (for machines without cutting device) double acting green move cutting device in home- and in operating position (for machines with fixed bottom door) double acting green 34 WELGER RP 405 RP 435 RP 505 RP 535

43 Note! For easier assignment of the correct oil connecting bushing in case of future coupling of the baler, transfer the colour marks of the hydraulic tubes to the connections of the tractor. Clean the coupling parts of the hydraulic hoses with clean cloth and plug them into the bushings at the tractor. Caution! Check hoses and tubing regularly for damage, ageing and operating reliability. Defective parts must immediately be replaced by original WELGER spare parts. Even in case of permissible stress, tubes and hoses are subject to natural ageing. They can therefore be used only for a limited period of time. The period of use for hydraulic tubing should not exceed six years! Prior to first commissioning: open hydraulic valve RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 For transportation the bottom door is hydraulically blocked in the factory, i. e. the bottom door valve on the hydraulic system control block is closed. (See also: chapter 7.4 Lock bottom door.) Figure 23 Prior to first commissioning: open hydraulic valve. Using appropriate tool: set the right ball valve 90 counterclockwise (Figure 23). WELGER RP 405 RP 435 RP 505 RP

44 4.4 Electrical system Lighting set To connect the lighting system, insert the 7-pin plug (ISO 1724) into the corresponding socket on the tractor. Before travelling on the roads, check that the lighting system functions correctly (also at daylight) Control electronics The machine will be delivered according to the version with the following control: "Balercontrol E" (with control box for "Balercontrol E" Figure 24) "Balercontrol III" (with control box for "E-LINK" Figure 25) Note! Read and heed the separate operating instruction "E-LINK for RP 435/535 MASTER". Figure 24 Figure 25 For attaching the corresponding control box a bracket is delivered with, that must be mounted nearby the tractor driver. The respective control box is equipped with a magnetic plate at the back and can be fixed onto a metallic surface into the tractor's cabin. Connecting the control box: To connect the control box to the control system plug the small 7-pole plug (with screw coupling) into the corresponding 7-pole socket on the machine. Connecting the power supply: A load socket according to DIN 9680 is required on the tractor for connecting the control electronics "Balercontrol". (Part of the delivery of the baler). Fuse protection must amount to 30 A. (For balers without twine tying a fuse protection of 16 A is sufficient.) Plug the 2- or 3-pole plug of the machine into the load socket (DIN 9680) of the tractor. After connecting the plug supply voltage is available and a short series of beeps can be heard from the control box (only if the load socket of the tractor is permanently connected or if the ignition of the tractor is actuated).. To equip another tractor the plug socket with connecting cable and fuse is available under the WELGER part no The correct polarity of the power supply of the tractor must not be changed, otherwise the electronic control could be damaged (Figure 26). Figure WELGER RP 405 RP 435 RP 505 RP 535

45 4.5 Compressed-air braking system Adjust variable load valve* Attention, danger of accident! Prior to each journey pay attention to the lever position of the variable load valve (Figure 27). A wrong setting reduces the traffic safety. Figure 27 Symbol Table 2 Brake power No brake power! Not for road driving! Not for field use! Low brake power! Not for road driving! Restricted for field use! Medium brake force! Not for road driving! Permitted for field use! Full brake force! Permitted for road driving! Permitted for field use! Brake released (no brake power) The machine has not sufficient braking power for driving on the road. This lever position may only be used for moving the uncoupled machine. This setting is not permitted for moving the machine with a tractor. Empty load (low brake power) The machine has not sufficient braking power for driving on the road. This lever position should not be used for field use of the machine. When using this setting the tractor must have sufficient brake power. For this heed the nature of the ground and of the site. Half load (medium brake power) The machine has not sufficient braking power for driving on the road. This lever position can be used for field use of the machine. When using this setting the tractor must have sufficient brake power. For this heed the nature of the ground and of the site. Full load (full brake power) This lever position must be set for driving on public roads. This lever position can be used for field use of the machine. WELGER RP 405 RP 435 RP 505 RP

46 4.5.2 Connecting the pneumatic system (pneumatic brake system) Attention, danger of injury! Pneumatic braking system: Before any work is carried out on the pneumatic system, the system must be depressurised. Caution, danger of injury! Do not begin a journey with the machine attached unless the pressure gauge in the tractor cabin shows 5.0 bar. Otherwise there is the risk of the brakes running hot. Remove dirt, if any, from the sealing washers of the coupling heads on the tractor and on the connecting tubes of the machine. Connect coupling heads for reservoir (red) and brake (yellow) with the corresponding connections of the tractor. Drain the compressed-air tank (left machine side) and check for damage and tight seat daily. To enable manoeuvring of the machine without connection to the compressed air system: lever of load apportioning regulator to: machine manoeuvring. Before the beginning of the next journey, or in order to brake the machine again: Set lever of load apportioning regulator according to demand or or (see chapter "Adjust variable load valve*"). 4.6 Hydraulic braking system Connect hydraulic system (hydraulic braking system) Attention, danger of injury! Hydraulic braking system: Before any work is carried out on the hydraulic system, the system must be depressurised. The machine can be equipped with a hydraulic brake according to the legal regulations of the delivery country. The corresponding hydraulic coupling is different from the other hydraulic couplings in that the sleeve of the quick-action coupling is fitted to the machine. Please observe in this context the national regulations of the country in which the machine is to be used. 38 WELGER RP 405 RP 435 RP 505 RP 535

47 5 Twine tying* 5.1 Threading the twine Attention, danger of injury! Prior to inserting of new spools of twine and threading the twine: stop machine, switch-off power take-off shaft and tractor motor, take out ignition key and wait for standstill of the machine. Make the control powerless (disconnect electrical connection to the tractor). Note! Optimum results in production during use of our machines depend of multiple factors. Therefore: The threaded twines must not contact each other or run crosswise. Use high-grade twines (recommendation: plastic twines). Place the twine spools upright side by side in the twine box. If the spools are inserted the wrong way round, the twine will tend to loop and break. Heed and follow the instructions given in the operating instructions. For working in extreme ambient conditions: request to our customer service. Heed the technical data at the end of this operating instruction. Twine A (Shown by continuous line in Figure 28 and Figure 29.) Twine B (Shown by dotted line in Figure 28 and Figure 29.) Twine A (Figure 28): Feed the beginning of the twine from spool A1 upwards through the guide eye and then out of the twine box. Knot end of twine of spool A1 with the beginning of the twine of spool A2. Important: The knot must be very small! Twine B (Figure 28): Feed the beginning of the twine of spool B1 upwards through the guide eye and then out of the twine box. Knot end of twine of spool B1 with the beginning of the twine of spool B2. Important: The knot must be very small! Thread the twines A and B each through the twine brake [1]. Wrap both twines around the guide rollers [2]. Thread in both twines upwards to the pair of eyes [3] on the binding bar. (Continued on the page after next.) WELGER RP 405 RP 435 RP 505 RP

48 Thread scheme: from the twine box to the variable diameter disc Figure 28 Thread scheme: from the variable diameter disc to the guide rollers Figure WELGER RP 405 RP 435 RP 505 RP 535

49 (Figure 29) Feed twines A and B through to the guide rollers [8]. Loop twine A anticlockwise once around the variable diameter disc [9]. Finally locate each twine at the entry to their respective guide roller. Turn the roller pair by hand until the thread has been securely grasped. Note! The clamping and cutting devices [10] have been factory set so that the driving twine (twine A) must be guided through the guide rollers on the left-hand side, as seen from the direction of travel. After threading: tighten the two twine ropes towards the twine spool. WELGER RP 405 RP 435 RP 505 RP

50 5.2 Adjusting the twine brake The twine brakes [1] (Figure 28) must hold the twines as taut as possible for the twines to be tight around the bales. (Figure 30) Adjust dimension "X" of the twine brake according to the following table. Basic setting Twine A Twine B Length "X" of the spring (Figure 30) 39 mm 37 mm Note! The permitted thread tension is exceeded when the twine breaks in the vicinity of the guide rollers [8] (Figure 30). The dimension "X" is measured between: washer bottom edge and the bottom surface of the cranked plate. Figure WELGER RP 405 RP 435 RP 505 RP 535

51 5.3 Setting the edge clearances For lateral limitation of the twine wrapping at the ends of the bale: adjust the left and right range spacer [1] (only the right machine side is shown in Figure 31 and Figure 32). With very dry and brittle crop materials select the retainers in the middle of the baler. Figure 31 Figure Adjusting the wrapping distance The distance between the wrappings is given by the diameter used for the variable diameter disc [9] (Figure 29). The smaller the effective diameter of the disc, the greater the distance between the wrappings. A lever [2] used to adjust the wrapping distance is located on the far right-hand end (in travelling direction) of the binding bar [2] (Figure 31 and Figure 33). Swivelling the lever towards the machine centre will move the two halves of the variable diameter disc apart, reduce the effective diameter of the variable diameter disc and result thus in a larger twine distance. Setting: Figure 33 Position 1: maximum wrapping distance Position 7: minimum wrapping distance WELGER RP 405 RP 435 RP 505 RP

52 5.5 Edge wrapping adjustment In order to ensure that the high density bales remain well compressed, the twine wrappings are automatically laid closer together near the edge of bales. In order to achieve this, the right-hand shuttle [4] presses the variable diameter disc closer together when reaching the end zone. The working diameter of the variable diameter disc increases and the distance between wrappings is reduced towards the edges. Figure 34 A switching angle [3] (Figure 34) is installed in the right-hand shuttle, which is attached by two screws in a unit with a set of holes. Four different installation positions are available. By displacing the angle towards the variable diameter disc, the variable diameter disc is pressed closer together for the area of the edge wrappings. The effective diameter increases and more edge wrappings are applied to the edge of the bale. Setting: Displace switching angle (3) towards the variable diameter disk: more end windings on the edge of the bale. Or: Displace switching angle (3) towards the machine centre: less end windings on the edge of the bale. 44 WELGER RP 405 RP 435 RP 505 RP 535

53 6 Net tying* 6.1 Inserting the net Attention, danger of injury! Prior to inserting new net rolls and threading the net: stop machine, switch-off power take-off shaft and tractor motor, take out ignition key and wait for standstill of the machine. Make the control powerless (disconnect electrical connection to the tractor). In order to handle the net roll safely, insert it together with the help of a second person! Attention, danger of injury by cutting! There is danger of injury by cutting during work on the net knife (Figure 48, item 10). Wear protective gloves. Open left-hand side cover. Attention, danger of injury by net knife turning down automatically! Only if the last wrapping process has not been completely executed (e. g. because the net roll depleted during the wrapping process): (Figure 35) Pull the handle of the knife carrier hard to the front against the spring tension (the triangular counting segment for the net length returns to its starting position). This prevents unexpected activation and automatic drop-down of the net knife during threading of the net. Figure 35 WELGER RP 405 RP 435 RP 505 RP

54 (Figure 36) Open safety chain [1]. 1 Figure 36 (Figure 37) Pull out handle [5] of the crank handle. Crank back the tensioning spindle [4] until the lock plate with the crank handle. 5 4 Figure 37 8 Open upper hood. (Figure 38) Slide net tightener [8] back and secure with cotter pin. Figure WELGER RP 405 RP 435 RP 505 RP 535

55 10 (Figure 39) Depending on the diameter of the net rolls in use the height of the net roll plate [10] must be set accordingly: Net roll with net length 3,000 m: Mount net roll plate in lower position (bottom thrill hole in Figure 40). Net roll with net length 2,000 m: Mount net roll plate in medium or upper position (centre or top thrill hole in Figure 40). Figure 39 Figure (Figure 41) Dependent on the width of the net rolls used an extension tensioning spindle (16) can be mounted on the original tensioning spindle (15): Width of the net roll more than 1.23 m: extension tensioning spindle not necessary. Width of the net roll 1.23 m or smaller: Unscrew extension tensioning spindle (16) and attach to the tensioning spindle [15]. 16 Figure 41 WELGER RP 405 RP 435 RP 505 RP

56 Figure (Figure 42) Depending on the width of the net rolls in use the complete net holder [21] must be moved horizontally and fasten again: Width of the net roll 1.23 m: move complete net holder [21] in the slotted holes to the left until the lock plate and fasten it. Width of the net roll 1.30 m: move complete net holder [21] in the slotted holes [20] to the right until the lock plate and fasten it. According to the width of the net rolls a position between the left and the right lock plate can be selected for the net holder. (Figure 43) Slide net roll until the lock plate into the tiltable auxiliary net holder. Note! Watch wind-off direction of the net roll! The net must enter the machine beneath the net roll (see Figure 48). Figure 43 (Figure 44) Tilt net roll into the net holder. Figure 44 Note! (Figure 45) The tips of both tensioning spindles must point into the sleeve of the net roll. If the tips of the two tensioning spindles do not point into the sleeve but onto the net material the height of the net roll plate must be corrected accordingly (Figure 39 and Figure 40). Figure WELGER RP 405 RP 435 RP 505 RP 535

57 (Figure 46) Pull out handle of the crank handle. Crank tensioning spindle with crank handle into the sleeve of the net roll. Figure (Figure 47) Crank tensioning spindle so far until between the bushing (25) and the crank handle (26) is only a gap of approx. 2 mm left. Fold back the crank handle again. 25 Note! Before closing the side cover: Turn crank back into machine. Fold back the crank handle. Figure 47 The net roll must rotate free and easy. If not: Check and repeat the setting described in this chapter "6.1 Inserting the net", if necessary. WELGER RP 405 RP 435 RP 505 RP

58 Figure 48 Figure 49 (Figure 48) Feed the net from the roll (11) around the upper guide tube [4] and subsequently around the net tightener [3]. (Figure 48 and Figure 49) Feed the net across the expanding device [5] and place its front end between rubber roller [6] and steel roller [7]. (Figure 50) Turn the rubber roller [6] by hand until the net is grasped. To prevent the net from getting into the roll chamber too early during the baling process, the front end of the net must not project more than approx. 10 cm beyond the rubber roller. (Figure 38) Remove cotter pin from the net tightener and swivel net tightener to the front. (Figure 43) Insert an auxiliary net roll into auxiliary net holder. (Figure 36) Close safety chain. Figure WELGER RP 405 RP 435 RP 505 RP 535

59 6.2 Tightening the net knife Normal case: the net knife is tensioned automatically whenever the tail gate is opened. Special case: if, while the baling chamber is filled, new net tying is necessary without opening of the tail gate (e. g. because of a net roll change or a fault), the net knife can be tensioned by hand: (Figure 51) Pull the knife carrier against the spring tension to the front. Triggering is effected as described in the chapter "Operation / Tying". Figure 51 WELGER RP 405 RP 435 RP 505 RP

60 6.3 Adjusting the net length BALERCONTROL E Using the scale (Figure 52) the net length (i.e. the number of net wraps around the bale) can be adjusted continuously: Slacken the wing nut. Displace the wing nut in the slotted hole to adjust the desired net length. Retighten the wing nut. Figure 52 Note! First select a setting in the middle of the slotted hole. To save net material change the setting step by step towards ( ) for subsequent bales. Do not use too little net material: The bale must still be held together. For very smooth bales and high baling densities a larger amount of net material must be adjusted. Note! If the bale diameter changes the net length must be adjusted accordingly E-LINK Via the E-LINK control system the net length can be adjusted in increments of 0.5 from 1.5 to 5 net layers (net layers are the number of net wraps around the bale). Note! In case of E-LINK machines the wing nut must be installed in the separate square hole of the scale (Figure 52) (not in the slotted hole). Note! Read and observe the separate operating manual: E-LINK for RP 435 MASTER / RP 535 MASTER. 52 WELGER RP 405 RP 435 RP 505 RP 535

61 7 Cutting device* The cutting device (Figure 53) can be used for silage, hay and straw. The knifes of the cutting device are swivelled in and out hydraulically. Attention, danger of injury! Prior to any work on the cutting device of the machine: Switch off power take-off shaft, switch off tractor engine, remove ignition key and disconnect drive shaft from power take-off shaft end. Make the control powerless (disconnect electrical connection to the tractor). 7.1 Equipment The machines can be equipped as follows: machine with control box: can be equipped with: Figure 53 BALERCONTROL E without cutting device MasterCut (13 knives) XtraCut 17 (17 knives) Balercontrol E E-LINK E-LINK without cutting device MasterCut (13 knives) XtraCut 17 (17 knives) XtraCut 25 (25 knives) 7.2 Knife groups To change the cut length of the material to be pressed, knife groups can be selected (that means, not all knives of the cutting device are in use): The cutting device XtraCut 17 (17 knives) contains an 8- knife group and a 9-knife group (8 + 9 = 17). Both knife groups can be used in the following combinations: 0 knives 8 knives 9 knives 17 knives The cutting device XtraCut 25 (25 knives) contains a 12- knife group and a 13-knife group ( = 25). Both knife groups can be used in the following combinations: 0 knives 12 knives 13 knives 25 knives WELGER RP 405 RP 435 RP 505 RP

62 7.2.1 Select knife group (E-LINK) Note! Read and heed the separate operating instruction "E-LINK for RP 435 MASTER / RP 535 MASTER". Caution! Before a knife group can be selected, all knives that can be in cutting position must be totally moved into home position. see chapter 7.3 Moving in and out the cutting device. To move a knife group by means of the tractor's distribution valve it must have been selected: In the menu "MONITOR": Repeat pressing the centre key until the symbol for the selected knife group appears in the display (above the centre key). For example: for a machine with 17-knife cutting device the following selection is possible: (8-knife group) (9-knife group) (8- and 9-knife group together) The selected knives can be moved now: see chapter 7.3 Moving in and out the cutting device. 54 WELGER RP 405 RP 435 RP 505 RP 535

63 7.2.2 Select knife group (Balercontrol E) Caution! Before a knife group can be selected, all knives that can be in cutting position must be totally moved into home position. see chapter 7.3 Moving in and out the cutting device. To move a knife group by means of the tractor's distribution valve it must have been selected by means of the hydraulic valves [1] and [2] (Figure 54 and Figure 55). The hydraulic valves are located on the left machine side, seen driving direction. 1 2 Figure 54 2 Attention, danger of injury! The hydraulic valves are located in the range of action of the pick-up and of the cutting device. Prior to operate the hydraulic valves: Switch off the power take-off shaft, switch off the tractor engine, remove the ignition key. Desired knife group Adjust hydraulic valves (according to Figure 54) no knives Valve 1 Position 0 Valve 2 Position 0 8 Knife Valve 1 Position "I" Valve 2 Position Knife Valve 1 Position 0 Valve 2 Position "I" Figure Knife Valve 1 Valve 2 Position "I" Position "I" Adjust hydraulic valves according to the table. The knives can be moved, now: see chapter 7.3Moving in and out the cutting device. WELGER RP 405 RP 435 RP 505 RP

64 7.3 Moving in and out the cutting device General On the following pages the conditions "Knives in cutting position" and Knives in home position" are mentioned. Now, the definition of the states: "Knives in cutting position" means: The knives are totally moved out of the knife bottom plate (Figure 56). Straw conveyed through the machine is cut by the moved out knives. "Knives in home position" means: The knives are totally inserted into the knife bottom plate (Figure 57). Straw conveyed through the machine is not cut by the inserted knives. Figure 56 (Pictures from open bottom door) Figure 57 Knives in cutting position Knives in home position Prior to first commissioning: open hydraulic valve RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 For transportation the bottom door is hydraulically blocked in the factory, i. e. the bottom door valve on the hydraulic system control block is closed. (See also: chapter 7.4 Lock bottom door.) Figure 58 Prior to first commissioning: open hydraulic valve. Using appropriate tool: Set the right ball valve 90 counterclockwise (Figure 58). 56 WELGER RP 405 RP 435 RP 505 RP 535

65 7.3.3 E-LINK control box 13-knife cutting device 17-knife cutting device 25-knife cutting device HYDROFLEXCONTROL bottom door Note! Read and heed the separate operating instruction "E-LINK for RP 405/435". Caution! Before a knife group can be moved into cutting position, all knives that can be in cutting position must be totally moved into home position. Only those knife groups are displayed that can be moved in or out for the actual moment, e.g. (here: 8-knife group). Move cutting device into cutting position In the menu "MONITOR": Press centre key so many times until the symbol "Cutting device" (with the number of knives) is displayed (above the centre key), e.g.. Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). If the hydraulic bottom door was open (HYDROFLEXCONTROL) this, too, swivels up. That the hydraulic accumulators can be filled: After the knives have reached the cutting position, the tractor's distribution valve must be operated for another 5 sec. Move cutting device into home position In the menu "MONITOR": Press centre key so many times until the symbol "Cutting device" (with the number of knives) is displayed (above the centre key), e.g.. Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). That the hydraulic accumulators can be emptied: After the knives have reached the home position, the tractor's distribution valve must be operated for another 5 sec. Note! To prevent jamming the knife slots and to keep the knives movable: Move in and out the cutting device multiple times a day. WELGER RP 405 RP 435 RP 505 RP

66 Cutting device protection Caution! Special function for fault clearance. Not permissible for production! Normal production only permitted with 40 bar. To protect the cutting device against mechanical overload (e.g. large stones or hard wood parts come into the cutting device), the knives of the cutting device are protected via a hydraulic circuit (cutting device protection). This hydraulic circuit limits the hydraulic pressure available to the cutting device knives to a standard pressure of 40 bar. Only this standard pressure is available for swivelling the cutting device knives out to cutting position. If the knife slots are clogged, this standard pressure may not be sufficient. A by-pass function is therefore available which permits putting cutting device protection out of operation. This means, the cutting device knives move out of the knife bottom plate with the full hydraulic pressure of the tractor and can thus better remove jams at the knife slots. Attention, danger of injury! In the following the cutting device knives are moved without cutting device protection. In the menu "MONITOR": Press centre key so many times until the symbol "Cutting device" (with the number of knives) is displayed (above the centre key),. Important: Do not release the button! (If the button was released: Press centre button so many times that the symbol "Cutting device" is displayed again. Important: Do not release the button! At still pressed centre button: Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). At still pressed centre button: Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). Repeat the two working steps above so long until the jamming of the knife sots is removed and the knives move free and easy. 58 WELGER RP 405 RP 435 RP 505 RP 535

67 Attention! The knives must finally moved in and out with 40 bar. Otherwise: Lost of guarantee possible when machine was overload! Important: Release centre key. Move knives again into home position and then back to cutting position by means of the tractor's distribution valve. Just now the normal production can be continued. WELGER RP 405 RP 435 RP 505 RP

68 7.3.4 Balercontrol E control box 13-knife cutting device fixed bottom plate (no bottom door) Note! For normal production the ball valve must point away from the machine (see Figure 59 and Figure 60)! Figure 59 Move cutting device into cutting position Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). That the hydraulic accumulators can be filled: After the knives have reached the cutting position, the tractor's distribution valve must be operated for another 5 sec. Move cutting device into home position Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). That the hydraulic accumulators can be emptied: After the knives have reached the home position, the tractor's distribution valve must be operated for another 5 sec. Note! To prevent jamming the knife slots and to keep the knives movable: Move in and out the cutting device multiple times a day. Cutting device protection Caution! Special function for fault clearance. Not permissible for production! Normal production only permitted with 40 bar. To protect the cutting device against mechanical overload (e.g. large stones or hard wood parts come into the cutting device), the knives of the cutting device are protected via a hydraulic circuit (cutting device protection). This hydraulic circuit limits the hydraulic pressure available to the cutting device knives to a standard pressure of 40 bar. Only this standard pressure is available for swivelling the cutting device knives out to cutting position. If the knife slots are clogged, this standard pressure may not be sufficient. A by-pass function is therefore available which permits putting the pressure valve out of operation. This means, the cutting device knives move out of the knife bottom plate with the full hydraulic pressure of the tractor and can thus better remove jams at the knife slots. 60 WELGER RP 405 RP 435 RP 505 RP 535

69 Attention, danger of injury! In the following the cutting device knives are moved without cutting device protection. Figure 60 Swivel ball valve (Figure 60) beneath the left side cover to the front: 180 bar (Figure 61). Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). Repeat the two working steps above (tractor's distribution valve to "Lift" and "Lower") so many times until the jamming of the knife slots is removed and the knives move free and easy. Turn the ball valve (Figure 60) again away from the machine: 40 bar (Figure 61). Attention! The knives must finally moved in and out with 40 bar. Otherwise: Lost of guarantee possible when machine was overload! Move knives again into home position and then back to cutting position by means of the tractor's distribution valve. Just now the normal production can be continued. Figure 61 WELGER RP 405 RP 435 RP 505 RP

70 7.3.5 Balercontrol E control box 13-knife cutting device HYDROFLEXCONTROL bottom door Note! For normal production both ball valves must point away from the machine (see Figure 62)! Figure 62 Move cutting device into cutting position Left machine side: Adjust ball valves of the hydraulic block according to Figure 62. Set the tractor's distribution valve so long to "Lower", until the cutting device is moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate) and until the bottom door is completely opened (moved down). Set the tractor's distribution valve so long to "Lift", until the cutting device is moved completely to cutting position (i.e. until the knives are moved completely out of the knife bottom plate) and until the bottom door is completely closed (moved up). That the hydraulic accumulators can be filled: After the knives have reached the cutting position, the tractor's distribution valve must be operated for another 5 sec. Move cutting device into home position Left machine side: Adjust ball valves of the hydraulic block according to Figure 62. Set the tractor's distribution valve so long to "Lower", until the cutting device is moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate) and until the bottom door is completely opened (moved down). That the hydraulic accumulators can be emptied: After the knives have reached the home position, the tractor's distribution valve must be operated for another 5 sec. For working without cutting device: Left machine side: Adjust ball valves of the hydraulic block according to Figure 63. Thus the cutting device is locked hydraulically. Set the tractor's distribution valve so long to "Lift" until the bottom door is closed completely (moved up). The cutting device rests completely in home position (the knives do not move out of the knife bottom plate). Figure 63 Note! To prevent jamming the knife slots and to keep the knives movable: Move in and out the cutting device multiple times a day. 62 WELGER RP 405 RP 435 RP 505 RP 535

71 Cutting device protection Caution! Special function for fault clearance. Not permissible for production! Normal production only permitted with 40 bar. To protect the cutting device against mechanical overload (e.g. large stones or hard wood parts come into the cutting device), the knives of the cutting device are protected via a hydraulic circuit (cutting device protection). This hydraulic circuit limits the hydraulic pressure available to the cutting device knives to a standard pressure of 40 bar. Only this standard pressure is available for swivelling the cutting device knives out to cutting position. If the knife slots are clogged, this standard pressure may not be sufficient. A by-pass function is therefore available which enables moving the knives of the cutting device out of the knife bottom plate and into working position by means of the full hydraulic pressure of the tractor. By this clogging of the knife slots can be removed. Attention, danger of injury! In the following the cutting device knives are moved without cutting device protection. Figure 64 Left machine side: set left ball valve of the hydraulic block according to Figure 64: 180 bar. set right ball valve of the hydraulic block according to Figure 64: this releases the knives. Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). Repeat the two working steps above ("Lift" and "Lower") so many times until the jamming of the knife slots is removed and the knives move free and easy. Set left ball valve (Figure 64) back to 40 bar. Attention! The knives must finally moved in and out with 40 bar. Otherwise: Lost of guarantee possible when machine was overload! WELGER RP 405 RP 435 RP 505 RP

72 Move knives again into home position and then back to cutting position by means of the tractor's distribution valve. Just now the normal production can be continued. Special function: lock bottom door The HYDROFLEXCONTROL bottom door (bottom door can be opened and closed hydraulically) can be if desired locked hydraulically. see chapter 7.4 Lock bottom door. 64 WELGER RP 405 RP 435 RP 505 RP 535

73 7.3.6 Balercontrol E control box 17-knife cutting device fixed bottom plate (no bottom door) Note! For normal production the ball valve must point away from the machine (see Figure 65 and Figure 66)! Figure 65 Caution! Before a knife group can be moved into cutting position, all knives that can be in cutting position must be totally moved into home position. Move cutting device into cutting position Select 8-knife group or 9-knife group or all of the 17 knives by means of the hydraulic valves (see 7.2.2Select knife group (Balercontrol E). Set the tractor's distribution valve so long to "Lift" as it takes to move the desired knife group totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). That the hydraulic accumulators can be filled: After the knives have reached the cutting position, the tractor's distribution valve must be operated for another 5 sec. Move cutting device into home position Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). That the hydraulic accumulators can be emptied: After the knives have reached the home position, the tractor's distribution valve must be operated for another 5 sec. Note! To prevent jamming the knife slots and to keep the knives movable: Move in and out the cutting device multiple times a day. WELGER RP 405 RP 435 RP 505 RP

74 Cutting device protection Caution! Special function for fault clearance. Not permissible for production! Normal production only permitted with 40 bar. To protect the cutting device against mechanical overload (e.g. large stones or hard wood parts come into the cutting device), the knives of the cutting device are protected via a hydraulic circuit (cutting device protection). This hydraulic circuit limits the hydraulic pressure available to the cutting device knives to a standard pressure of 40 bar. Only this standard pressure is available for swivelling the cutting device knives out to cutting position. If the knife slots are clogged, this standard pressure may not be sufficient. A by-pass function is therefore available which permits putting the pressure valve out of operation. This means, the cutting device knives move out of the knife bottom plate with the full hydraulic pressure of the tractor and can thus better remove jams at the knife slots. Attention, danger of injury! In the following the cutting device knives are moved without cutting device protection. Figure 66 Select 8-knife group or 9-knife group or all of the 17 knives by means of the hydraulic valves (see 7.2.2Select knife group (Balercontrol E). Swivel ball valve (Figure 66) beneath the left side cover to the front: 180 bar (Figure 67). Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). Repeat the two working steps above (tractor's distribution valve to "Lift" and "Lower") so many times until the jamming of the knife slots is removed and the knives move free and easy. Swivel ball valve (Figure 66) back to the machine: 40 bar (Figure 67). 66 WELGER RP 405 RP 435 RP 505 RP 535

75 Attention! The knives must finally moved in and out with 40 bar. Otherwise: Lost of guarantee possible when machine was overload! Figure 67 Move knives again into home position and then back to cutting position by means of the tractor's distribution valve. Just now the normal production can be continued. WELGER RP 405 RP 435 RP 505 RP

76 7.3.7 Balercontrol E control box 17-knife cutting device HYDROFLEXCONTROL bottom door Note! For normal production both ball valves must point away from the machine (see Figure 68)! Caution! Before a knife group can be moved into cutting position, all knives that can be in cutting position must be totally moved into home position. Figure 68 Figure 69 Move cutting device into cutting position Left machine side: Adjust ball valves of the hydraulic block according to Figure 68. Set the tractor's distribution valve so long to "Lower", until the cutting device is moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate) and until the bottom door is completely opened (moved down). Select 8-knife group or 9-knife group or all of the 17 knives by means of the hydraulic valves (see 7.2.2Select knife group (Balercontrol E). Set the tractor's distribution valve so long to "Lift", until the cutting device is moved completely to cutting position (i.e. until the knives are moved completely out of the knife bottom plate) and until the bottom door is completely closed (moved up). That the hydraulic accumulators can be filled: After the knives have reached the cutting position, the tractor's distribution valve must be operated for another 5 sec. Move cutting device into home position Left machine side: Adjust ball valves of the hydraulic block according to Figure 68. Set the tractor's distribution valve so long to "Lower", until the cutting device is moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate) and until the bottom door is completely opened (moved down). That the hydraulic accumulators can be emptied: After the knives have reached the home position, the tractor's distribution valve must be operated for another 5 sec. For working without cutting device: Left machine side: Adjust ball valves of the hydraulic block according to Figure 69. Thus the cutting device is locked hydraulically. Set the tractor's distribution valve so long to "Lift" until the bottom door is closed completely (moved up). The cutting device rests completely in home position (the knives do not move out of the knife bottom plate). 68 WELGER RP 405 RP 435 RP 505 RP 535

77 Note! To prevent jamming the knife slots and to keep the knives movable: Move in and out the cutting device multiple times a day. Cutting device protection Caution! Special function for fault clearance. Not permissible for production! Normal production only permitted with 40 bar. To protect the cutting device against mechanical overload (e.g. large stones or hard wood parts come into the cutting device), the knives of the cutting device are protected via a hydraulic circuit (cutting device protection). This hydraulic circuit limits the hydraulic pressure available to the cutting device knives to a standard pressure of 40 bar. Only this standard pressure is available for swivelling the cutting device knives out to cutting position. If the knife slots are clogged, this standard pressure may not be sufficient. A by-pass function is therefore available which enables moving the knives of the cutting device out of the knife bottom plate and into working position by means of the full hydraulic pressure of the tractor. By this clogging of the knife slots can be removed. Attention, danger of injury! In the following the cutting device knives are moved without cutting device protection. Figure 70 Left machine side: set left ball valve of the hydraulic block according to Figure 70: 180 bar. set right ball valve of the hydraulic block according to Figure 70: this releases the knives. Set the tractor's distribution valve so long to "Lower" as it takes to move the cutting device totally into home position (that means until the knives are totally moved into the knife bottom plate). Set the tractor's distribution valve so long to "Lift" as it takes to move the cutting device totally into cutting position (that means until the knives are totally moved out of the knife bottom plate). Repeat the two working steps above ("Lift" and "Lower") so many times until the jamming of the knife slots is removed and the knives move free and easy. Set left ball valve (Figure 70) back to 40 bar. WELGER RP 405 RP 435 RP 505 RP

78 Attention! The knives must finally moved in and out with 40 bar. Otherwise: Lost of guarantee possible when machine was overload! Move knives again into home position and then back to cutting position by means of the tractor's distribution valve. Just now the normal production can be continued. Special function: lock bottom door The HYDROFLEXCONTROL bottom door (bottom door can be opened and closed hydraulically) can be if desired locked hydraulically. see chapter 7.4 Lock bottom door. 70 WELGER RP 405 RP 435 RP 505 RP 535

79 7.4 Lock bottom door The HYDROFLEXCONTROL bottom door (bottom door can be opened and closed hydraulically) can be if desired locked hydraulically. It acts then as a fixed bottom door, i.e. it cannot be opened as long it is locked. Advantage: The knives can be retracted and extended by means of the tractor distribution valve WITHOUT the HYDROFLEXCONTROL bottom door opening as well in each case Lock bottom door Set lever to home position (according to Figure 71). Figure 71 Remove lever from centre shaft and apply it to the right shaft according to Figure 72. Figure 72 Set right lever to locking position (according to Figure 73). The bottom door is locked now. I.e.: only the cutting device but not the bottom door can be moved by means of the tractor's distribution valve. Figure Release bottom door Set the right ball valve according to Figure 74. The bottom door is released. I.e.: the cutting device as well as the bottom door can be moved by means of the tractor's distribution valve. Figure 74 WELGER RP 405 RP 435 RP 505 RP

80 7.5 Brittle crop material While pressing brittle crop material it is recommended to move the cutting device into home position short before wrapping process. In this way the bale is finally wrapped with long material and crop losses are minimised. 7.6 Assembly and disassembly of the cutting device knives Note! By removing individual knives the cut length of the baling material can be changed. (This counts mainly for the 13-knife cutting device. At the 17-knife cutting device and the 25-knife cutting device the same effect can be got by selecting knife groups). If no cutting function is desired for a longer period of time, all knives can be removed. Figure knife cutting device: to optimise material flow in the conveying elements and to stabilise the side faces of the bales (in case of dry straw), the two outer knives of the cutting device should be removed. Attention, danger of injury! Wear protective gloves while working with the knives. If any maintenance or assembly work is carried out with the tail gate open, the tail gate must be hydraulically secured against lowering for safety reasons: For the following working steps: see chapter 7.3 Moving in and out the cutting device. Figure 76 Move cutting device to cutting position. Swivel the bottom door* about half way down. Open and secure tail gate (see chapter 9.3 Eject bales). Figure 75: Swivel lever of the knife axle on the feeder housing (on the right in driving direction) down through about 90 as far as the stop. Using tongs withdraw the knives diagonally upwards from the knife axle and remove them from the slot proceeding from the roll chamber. 72 WELGER RP 405 RP 435 RP 505 RP 535

81 Note! Removed blades should be replaced by blind blades* to prevent soiling of the knife slots (part no ) Blind blades (Figure 76) and any blades removed can be "parked and secured with a cotter pin behind the left casing door (Figure 77). Figure Regrinding the cutting device knives To provide the best crop throughput it is recommended to regrind the cutting device blades at least after cutting of 500 bales. Dependent on the working conditions sharpening may be necessary earlier: Note! In case of cutting devices with knife groups (see chapter 7.2 Knife groups) the knife groups can be used one after the other That means e. g. first 500 bales are produced with the 12-knife group and subsequently another 500 bales are produced with the 13-knife group. This duplicates the operation time of the cutting device. Attention, danger of injury when working on the magnets of the knife holders! the function of cardiac pacemakers can be interrupted by magnetic fields. Danger of injury by splinters: Never strike against the installed knives from the bottom with a striking tool - this may damage the magnets! Remove knives, see chapter 7.6 Assembly and disassembly of the cutting device knives. Regrind knives from the smooth side. The temper of the blades must not be drawn when grinding. A grinder is available as special tool. (Part no ) WELGER RP 405 RP 435 RP 505 RP

82 8 Field use Attention! The machine may only be operated by persons who are familiar with the operating instructions and the safety instructions. Never remove any malfunctions while the drive is running. Never remove any harvested crop material from the machine while the drive is running. Prior to work: Switch off power takeoff shaft, switch off tractor engine, remove ignition key and disconnect drive shaft from power take-off shaft end. During operation: do not climb the machine. Keep sufficient distance to the range of action of the machine (pick-up, running gear, tail gate, bale unloading area). As a matter of principle: Riding on the machine is prohibited for the entire machine! Keep children away from the machine! Prior to first start: Make yourself with the control box and the functions of this machine. Nobody must stay between tractor and machine while the tractor engine is running. Never operate the machine with defective or removed protective devices (e. g. casing sheets and distance brackets)! Before opening the protections: Switch off power take-off shaft, switch off tractor engine, remove ignition key and disconnect drive shaft from power take-off shaft end. Prior to enter the baling chamber: close tail gate locking device (Figure 3). Machines not coupled to the tractor must be secured against accidental rolling away by applying the manually operated brake (if available) and by means of wheel chocks. Do not begin a journey with the machine attached unless the manually operated brake has been completely released. Otherwise there is a risk of fire due to brakes running hot. 74 WELGER RP 405 RP 435 RP 505 RP 535

83 8.1 Locking the tail gate Before picking up of crop material is started and after every ejection of a bale, the tail gate must be correctly locked: Hold the tractor control valve for tail gate actuation in "Lower" position. This will lock the tail gate automatically RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 Extinguishing of the lamp [3] signals complete closing of the tail gate. Figure RP 435 MASTER and RP 535 MASTER Complete closing of the tail gate is signalled by: a single beep of the E-Link control box. (Figure 79) The tail gate is displayed closed on the display. (Figure 79) The swath on the display moves towards the machine. Figure 79 Note! To avoid unnecessary load on the hydraulic pump of the tractor: leave the control valve in "floating position" during the baling process. The upper lamp [3] should only light up when the tail gate is unlocked. Should the lamp be on also during the baling process, the sensor setting must be checked. The lower lamp [4] should light up only for a short time, when the bale rolls over the bale ejector. The tail gate must not be closed as long as the lower lamp [4] is on. WELGER RP 405 RP 435 RP 505 RP

84 8.2 Adjusting the bale diameter Attention! The bale diameter must be selected so that the bale weight does not exceed 1.5 tons. So the bale diameter values must - of necessary - be selected lower than specified in the following table. Machine RP 405 / RP 435 RP 505 / RP 535 Crop material Silage Straw Silage Straw Bale diameter 0.90 m 1.55 m 0.90 m 1.60 m 1.10 m (max. 1.5 tons) 1.10 m 2.00 m RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 (Figure 80) Slacken the wing nut and adjust the desired bale diameter with the pointer. The obtainable diameters are between about 0.90 and 1.55 m for silage and 0.90 and 1.60 m for straw. (Figure 84) Read the bale diameter currently reached on display 2. Figure RP 435 MASTER and RP 535 MASTER Actuate the right function key repeatedly until the symbol for "Bale diameter" appears in the display of the control box (Figure 81). Figure 81 Using the keys and set the desired bale diameter. The obtainable diameters are between about 0.90 and 1.55 m for silage and 0.90 and 1.60 m for straw. (Figure 82) The arrow in the bar graph shows the selected diameter value. Figure WELGER RP 405 RP 435 RP 505 RP 535

85 8.3 Setting the bale density Note! Reduction of the bale density is recommended: for hey, if an airy bale core is desired. for extremely short and dry material, if material jams in the feed area occur. Figure RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 Basic setup: Turn handwheel (Figure 83) clockwise up to the stop. Turn handwheel a full rotation back. Bale test bale and assess quality. If required: readjust bale density. The preset bale density (i. e. the baling pressure) is indicated on the pressure gauge [1] (Figure 84): Interrupt power supply to BALERCONTROL control box (pull plug). Open the tail gate. The tail gate now opens slowly and does not reach its highest position. Read preset bale density (i. e. the baling pressure) on the pressure gauge [1]. Figure RP 435 MASTER und RP 535 MASTER Actuate the right function key repeatedly until the symbol for "Bale density" appears in the display of the control box (Figure 85). Using the keys and select the desired bale density in 1-digit increments from 1 to 10. Figure 85 WELGER RP 405 RP 435 RP 505 RP

86 8.4 Raising / lowering the pick-up RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 Raising and lowering of the pick-up are effected directly via the connected tractor control valve RP 435 MASTER and RP 535 MASTER Actuate the central function key repeatedly until the symbol for "Lift/lower pick-up" appears in the display of the control box (Figure 86). Actuate the connected tractor control valve. (The actuating direction can be reversed by reversing the two connected hydraulic tubes.) Figure Pick-up guide wheels Tine distance from ground in field use: min. 2 cm Lift the pick-up (see chapter 8.4 Raising / lowering the pickup ). Draw out spring clip [1]. Hook the plate [2] into the required hole. Secure the pick-up guide wheels again with the spring clips. Select the same adjustment on both sides. Figure WELGER RP 405 RP 435 RP 505 RP 535

87 8.6 Windguard / Pick-up shield* In case of all pick-up models (Figure 89 and Figure 90) the windguard is mounted movably hanging above the pick-up. Adjust the height of the windguard rake to the swath thickness using the chain. (Figure 88) To avoid that the pick-up grasps the chain the upper end of the chain must always be fastened to the hook. Figure 88 Caution! On the pick-up with a pick-up width of: 2.25, both pick-up guide wheels cover the circular path of the tines laterally and are therefore also part of the safety equipment. That is why both guide wheels must always be attached when the baler is used. Figure 89 Figure 90 WELGER RP 405 RP 435 RP 505 RP

88 8.7 Feed guide plate The tear-shaped feed guide plate [1] is installed in the roll chamber in the factory. If a material jam occurs in case of an extraordinary crop structure, the feed guide plate can be removed: unscrew the right screw, seen in driving direction (arrow in Figure 91) and remove profile from the roll chamber. Figure PTO speed Operate baler at power take-off shaft nominal speed of 540 rpm. Caution! Only the drive shafts prescribed by the manufacturer may be used! Protective tube and guard cone of the drive shaft, and the power take-off shaft protection, must be fitted and be in proper condition. Always ensure that the drive shaft is installed and secured correctly: Secure the drive shaft safeguard against revolving by fitting the chain. Ensure before switching on the power take-off shaft that nobody is within the range of danger of the device! 80 WELGER RP 405 RP 435 RP 505 RP 535

89 8.9 Driving style Large swath Drive speedily at nominal speed (hand throttle). Let the swath centrally run into the pick-up. If a small amount of baling material is in the baling chamber and no pressure has built up yet (see pressure gauge), we recommend to switch off the power take-off shaft during empty runs (e.g. during turning round on the headland) Small swath Drive speedily at nominal speed (hand throttle). The baling chamber must be evenly filled with material across its entire width rapidly and without interruption. At the beginning of each bale, change immediately between left and right swath side and vice versa (Figure 92) until the set working pressure is reached (see pressure gauge, Figure 93). Figure 93 Figure 92 WELGER RP 405 RP 435 RP 505 RP

90 (Figure 94) Frequent visual checks through belt window. Figure 94 (Figure 95) If the belts begin to leave their normal position and drift apart, and/or if material escapes at such points between the belts, the respective side of the baling chamber is not sufficiently filled. In this case drive the machine immediately across the swath with the side concerned. Figure 95 (Figure 92) When the set working pressure is reached (see pressure gaugefigure 93): change regularly between left and right swath side. If a small amount of baling material is in the baling chamber and no pressure has built up yet (see pressure gauge, Figure 93), we recommend to switch off the power take-off shaft during empty runs (e.g. during turning round on the headland). Operation at slopes For baling at slopes we recommend to begin with the filling of the higher side of the baling chamber. Then continue as shown in Figure 92. Visual check: after a bale has been ejected from the machine, do not close the tail gate unless the belts run again. Dry, brittle, smooth crop material If no material is taken up, the power take-off shaft should always be switched off after 10 seconds at the latest. Reconnect the power take-off shaftonly then, just before material is picked up again. 82 WELGER RP 405 RP 435 RP 505 RP 535

91 8.10 Safety clutch Attention, danger of injury! Causes of overload may only be removed after disconnection of the control system from power supply (interrupt electric connection to tractor), when the tractor motor has been stopped and the ignition key removed! Drive shaft with shear bolt yoke* A shear bolt yoke is inserted at the machine side into the drive shaft. The bolt [1] shears off at overload and must be replaced by a new one. Do not restart the machine unless the source of the overload is removed. Figure 96 Use only original spare parts: Shear bolt with nut Drive shaft with cam-type cut-out clutch* In the event of overload the cam-type cut-out clutch interrupts the driving torque. Switch off power take-off shaft and remove cause of overload. After switching on the power take-off shaft, the torque builds up again so that the machine can be put into operation. Figure 97 Avoid long and frequent overloads. Make sure, that only the corresponding drive shaft is used. WELGER RP 405 RP 435 RP 505 RP

92 9 Operation / Tying 9.1 BALERCONTROL E control box The control box The BALERCONTROL E control box has the following functions and displays (Figure 98): Item Part Meaning 1 LED, green Power supply correct 2 LED, red Preset bale diameter reached or exceeded 3 LED, yellow automatic net tying selected. (flashes when net coupling is in operation) 4 LED, yellow Automatic twine tying selected. (Flashes when twine motor is in operation) 5 Button Toggling between manual and automatic tying (see chapter Trigger tying (BALERCONTROL E)) hold for 5 sec: resetting the bale counter (TAZ) 6 Button Manual activation of net tying 7 Button Manual activation of twine tying 8 Display, illuminated 9 acoustic buzzer (back side) Top line: Cumulative counter cannot be deleted Bottom line: Day counter, can be deleted Preset bale diameter reached Figure 98 The following tying modes can be selected dependent on the type and version of the machine: Manual net tying Automatic net tying manual twine tying automatic twine tying 84 WELGER RP 405 RP 435 RP 505 RP 535

93 9.1.2 Trigger tying (BALERCONTROL E) (Figure 98) When the preset bale diameter is reached, this is indicated to the tractor driver by the red LED [2] and the buzzer [9]. According to the selected tying mode the tying process is triggered either manually or automatically: manually, i.e. the operator presses the corresponding button (button "Net" [6] or button "Twine" [7]). automatically, i.e. triggered by the control. Figure 99 Manual net tying Select manual net tying mode: press button [5] several times until none of the yellow LED's is lighting. When the preset bale diameter is reached, the red LED [2] will first flash and then light continuously. A signal sounds. Stop tractor and let pick-up run empty. Press button Net [6] for approx. 2 sec. The yellow LED [3] flashes simultaneously. Let the tying process run at power take-off shaft standard speed (540 min-1). Check net run on the net roll. When the net knife drops down (acoustic shock) and the net roll has stopped again, the wrapping process is finished. Open tail gate and eject bale (see 9.3 Eject bales). Note! Tying can also be triggered when the preselected bale diameter has not yet been reached. Such a bale is not taken into account by the vale counter. Automatic net tying Select automatic net tying: Press button [5] several times until the left yellow LED [3] lights. When the preset bale diameter is reached, the red LED [2] will first flash and then light continuously. A signal sounds. Stop tractor and let pick-up run empty. Approx. 2,5 s after the signal was triggered the net is automatically inserted into the roll chamber. The yellow LED [3] flashes simultaneously. Let the tying process run at power take-off shaft standard speed (540 min-1). Check net run on the net roll. When the net knife drops down (acoustic shock) and the net roll has stopped again, the wrapping process is finished. Open tail gate and eject bale (see 9.3 Eject bales). WELGER RP 405 RP 435 RP 505 RP

94 Figure 100 Manual twine tying Select manual twine tying: Press button [5] for several times until none of the yellow LED's is lighting. When the preset bale diameter is reached, the red LED [2] will first flash and then light continuously. A signal sounds. During drive: Press button Twine [7] for a short time. The yellow LED [4] flashes simultaneously. Stop the tractor after about 5 sec. after pressing the Twine button [7]. Let the tying process run at power take-off shaft standard speed (540 min-1). Check twine run at the twine guide rollers (Figure 100). Tying is finished as soon as the guide rollers stop. Open tail gate and eject bale (see 9.3 Eject bales). Automatic twine tying Select automatic twine tying: Press button [5] several times until the right yellow LED [4] lights. When the preset bale diameter is reached, the red LED [2] will first flash and then light continuously. The twine is inserted automatically in the roll chamber. The yellow LED [4] flashes simultaneously. A signal sounds approx. 2.5 sec. after automatic triggering of twine tying. This is the time for stopping the tractor. Let the tying process run at power take-off shaft standard speed (540 min-1). Check twine run at the twine guide rollers (Figure 100). Tying is finished as soon as both guide rollers stop. Open tail gate and eject bale (see 9.3 Eject bales). 86 WELGER RP 405 RP 435 RP 505 RP 535

95 9.2 E-LINK control box The control box Note! Read and heed the separate operating instruction "E-LINK for RP 435 MASTER / RP 535 MASTER". The following tying modes can be selected dependent on the type and version of the machine: Manual net tying Automatic net tying manual twine tying automatic twine tying Figure 101 WELGER RP 405 RP 435 RP 505 RP

96 9.2.2 Select tying mode Actuate the left function key repeatedly until the symbol for the desired tying mode appears in the display of the control box: Note! Dependent on the SETUP setting one of the tying modes is visible only in each case: "Net tying Automatic and "Net tying Manual or "Twine tying Automatic" and "Twine tying Manual "Net tying Automatic (Figure 102) or Figure 102 "Net tying Manual (Figure 103) or Figure 103 "Twine tying Automatic" (Figure 104) or Figure 104 "Twine tying Manual" (Figure 105). Figure WELGER RP 405 RP 435 RP 505 RP 535

97 9.2.3 Trigger tying (E-LINK) Figure 106 Manual net tying Select tying mode: "Manual net tying" (see Select tying mode). When the preselected bale diameter is reached, an acoustic and an optical signal are output: The arrow in the bar graph rises to the preset value (Figure 106). Stop tractor and let pick-up run empty. Press START/STOP button for about 3 sec. The symbol for "Tying in progress" appears in the display (Figure 107). Let the tying process run at power take-off shaft standard speed (540 min-1). Should the net roll stop after release of the START/STOP button: press START/STOP button once again for about 3 sec. (Figure 108) Acoustic signal at the end of the tying process. Subsequently: Open tail gate and eject bale (see 9.3 Eject bales). Figure 107 Note! When the power take-off shaft is running, tying can always be started manually. Figure 108 Automatic net tying Select tying mode: "Automatic net tying" (see Select tying mode). Tying is started when the preselected bale diameter is reached, without the driver's action. An interrupted signal tone taking 3 seconds requests the driver to stop the tractor. (This signal begins optionally 0 or 2.5 or 5 sec. before net tying is started. The delay can be entered in the Setup ). After tying has been triggered, the symbol for Tying in progress appears in the display (Figure 107). Let the tying process run at power take-off shaft standard speed (540 min-1). (Figure 108) Acoustic signal at the end of the tying process. Subsequently: Open tail gate and eject bale (see 9.3 Eject bales). WELGER RP 405 RP 435 RP 505 RP

98 Figure 109 Manual twine tying When the preselected bale diameter is reached, an acoustic and an optical signal are output: The arrow in the bar graph rises to the preset value (Figure 109). Press START-STOP key shortly: the twine motor starts. The symbol for "Tying in progress" appears in the display (Figure 110). Stop the tractor after about 5 sec. after pressing the START/STOP button. Let the tying process run at power take-off shaft standard speed (540 min-1). (Figure 111) Acoustic signal at the end of the tying process. Subsequently: Open tail gate and eject bale (see 9.3 Eject bales). Figure 110 Figure 111 Automatic twine tying Tying is started when the preselected bale diameter is reached, without the driver's action. An acoustic signal requests the driver to stop the tractor. (This signal begins optionally 0 or 2.5 or 5 sec. after tying is started. The delay can be entered in the Setup ). After tying has been triggered, the symbol for Tying in progress appears in the display (Figure 110). Let the tying process run at power take-off shaft standard speed (540 min-1). (Figure 111) Acoustic signal at the end of the tying process. Subsequently: Open tail gate and eject bale. (see 9.3Eject bales). 90 WELGER RP 405 RP 435 RP 505 RP 535

99 9.3 Eject bales Attention, danger of injury! Proceed with particular care when opening and closing the tail gate. No persons may stay in the swivelling range of the tail gate and in the bale unloading area. When opening the tail gate keep a minimum distance of 2 m from electrical high-voltage lines. In case of locations on a slope: place the round bales always so that they cannot move automatically. Figure 112 Figure RP 405 SPECIAL and RP 435 RP 505 SPECIAL and RP 535 After tying has been finished: open the tail gate hydraulically by means of the tractor control valve so that the bale rolls out. Hold tractor control valve in "Lift" position until tail gate is fully open. The upper white lamp [3] (Figure 113) (on the RP 505 SPECIAL and RP 535 it is the left white lamp) will be on as long as the tail gate is not locked. The lower white lamp [4] (on the RP 505 SPECIAL and RP 535 it is the right white lamp) will light up only for a short time, when the bale rolls over the bale ejector. When the white lamp [4] has gone out (not earlier, because the bale is still in the swivelling range of the tail gate): close the tail gate hydraulically by means of the tractor control valve. Hold tractor control valve in "Lower" position until the tail gate is definitely locked. As soon as the tail gate is closed, the white lamp [3] goes out and crop pick-up for the next bale can be started. Set tractor control valve to floating position after actuation ("Neutral" position). WELGER RP 405 RP 435 RP 505 RP

100 Figure RP 435 MASTER and RP 535 MASTER After tying has been finished: open the tail gate hydraulically by means of the tractor control valve so that the bale rolls out. Hold tractor control valve in "Lift" position until tail gate is fully open. The request to close the tail gate appears in the display after the bale has passed the bale ejector (Figure 114). close the tail gate hydraulically by means of the tractor control valve. Hold tractor control valve in "Lower" position until the tail gate is definitely locked. As soon as the tail gate is locked on both sides, the normal display Bale (Figure 115) appears and crop pick-up for the next bale can be started. Set tractor control valve to floating position after actuation. Figure WELGER RP 405 RP 435 RP 505 RP 535

101 9.4 Emergency operation Even in case of failure of the electronic control system the most important machine functions can still be executed. Note! Emergency operation must not be used for daily production. It is intended only for finishing the work started Emergency operation: bale diameter reading RP 405 SPECIAL / RP 435 / RP 435 MASTER RP 505 SPECIAL / RP 535 / RP 535 MASTER The current bale diameter can always be followed by observing the bale diameter display [2] (Figure 116) on the machine front. For triggering tying: see following chapters. Figure Emergency operation: Net tying RP 405 SPECIAL / RP 435 RP 505 SPECIAL / RP 535 Net tying can be triggered by means of the electric lighting system. The plug connection [1] projecting from the cable harness on the right side of the machine serves for this purpose (Figure 117). The black attachment plug [2] of the electric net coupling is simply plugged into the empty white socket [1]. To trigger net tying, actuate the parking light of the tractor until the bale has grasped the net. Figure 117 Note! If the lighting system is permanently switched on (e.g. for driving on the road), it is essential that the provisional connection of the net tying unit is interrupted. WELGER RP 405 RP 435 RP 505 RP

102 9.4.3 Emergency operation: Net tying RP 435 MASTER and RP 535 MASTER Net tying can be triggered by means of the electric lighting system. Interrupt electrical connection between tractor and machine. (Figure 118) Move the net knife by hand to severing position: pull the knife carrier slightly to the front against the spring tension, so that the segment does not rest any longer on the roller. Press the segment to the rear and place the knife carrier slowly on the anvil. Figure 118 (Figure 119) Move net position sensor as far as possible up in the sensor support since otherwise the rod head will damage the sensor. (see also point 6) Figure Remove connecting rod [1] (length 105 mm) from the square hole of the control lever [2]. Figure Remove connecting rod [1] (length 105 mm) from the cam [3] of the rubber roller. 1 Figure WELGER RP 405 RP 435 RP 505 RP 535

103 (Figure 122) Remove stop plate. Figure 122 (Figure 123) Attach the longer connecting rod [1] (length 145 mm) included in the delivery to the slotted hole of the control lever [2] and the cam [3] of the rubber roller. Setting of the net layers (+/-): shift the wing nut of the connecting rod [1] in the slotted hole. 1 3 Caution! The control lever [2] must point downwards to prevent the connecting rod [1] from dragging along the motor or the sensor support. 2 Figure (Figure 124) Action on the plug connection [11] (projecting from the cable harness on the right side of the machine): The black attachment plug [10] of the electric net coupling is simply plugged into the empty white socket [11]. To trigger net tying, actuate the parking light of the tractor until the bale has grasped the net. 11 Note! If the lighting system is permanently switched on (e.g. for driving on the road), it is essential that the provisional connection of the net tying unit is interrupted. Figure 124 WELGER RP 405 RP 435 RP 505 RP

104 Finishing emergency operation of net tying unit RP 435 MASTER and RP 535 MASTER: Restore original state (install short connecting rod). (Figure 119) Adjust the net position sensor shifted upwards to a distance of 1-2 mm from the cam (rubber roller). (Figure 122) Attach stop plate to angle bar and adjust a gap of 2 mm to the knurled wheel. In the "Diagnosis" menu: Check the net coupling / knife triggering function and the function of the net run (net layer) sensor. (See separate operating manual E-LINK for RP 435 MASTER.) Emergency operation: TWINE TYING RP 405 SPECIAL / RP 435 RP 505 SPECIAL / RP 535 No emergency operation possible. RP 435 MASTER and RP 535 MASTER This emergency operation requires an intact main power supply between tractor and machine. (Figure 125) Unplug the two plugs [5] and [6] from the control unit [7] and fasten them so that they do not collide with the running machine. (Figure 117) Open the red plug connection. Then simply plug the red attachment plug into the free white socket [1]. To trigger twine tying switch on the parking light (or the low beam or the high beam) of the for a short time until the twine is grasped by the bale. Note! If the lighting system is permanently switched on (e.g. for driving on the road), it is essential that the provisional connection of the net tying unit is interrupted. Figure WELGER RP 405 RP 435 RP 505 RP 535

105 9.4.5 Emergency operation: Bale density RP 435 MASTER and RP 535 MASTER A hydraulic block is located on the rear side of the machine (Figure 126). Adjust the lever to vertical position Turn the handwheel attached to the side of the machine clockwise up to the stop. In this position maximum pressure (maximum bale density) is set. If a lower bale density is desired, the handwheel can be turned back in counterclockwise direction. The preset bale density (i. e. the baling pressure) is indicated on the pressure gauge [1] (Figure 116). Figure 126 WELGER RP 405 RP 435 RP 505 RP

106 10 Removing a material jam Attention, danger of injury! Malfunctions on the draw-in elements (e. g. pick-up, draw-in screws and tine rotor) may only be remedied after disconnection of the control system from power supply (interrupt electric connection to tractor), when the tractor motor has been stopped and the ignition key removed! On machines with cutting device* there is danger of injury by knives when working in the feed channel. Wear always protective gloves! 10.1 Main drive reversing RP 405 SPECIAL / RP 435 without HYDROFLEXCONTROL* RP 505 SPECIAL / RP 535 without HYDROFLEXCONTROL* If the feed channel jams on machines without hydraulic bottom door (without HYDROFLEXCONTROL) the main drive can be reversed manually (Figure 127): Switch off power take-off shaft. Stop the tractor engine and take out the ignition key. Attach turning handle (wrench size 46 mm) and reverse machine until the feed channel can be emptied. Figure 127 Attention, danger of injury! Prior to restart the machine: dismount turning handle and close all guard casings! 98 WELGER RP 405 RP 435 RP 505 RP 535

107 10.2 Hydraulic bottom door* The bottom door (HYDROFLEXCONTROL) can be opened hydraulically. The empty space beneath the rotor is clearly increased. In this way, jammed material is drawn through easier, grasped by the bottom baling roller and conveyed into the roll chamber. Figure Behaviour during material jam (E-LINK) Stop driving and switch off power take-off shaft. In the menu "MONITOR": Press centre key repeatedly until the symbol "Bottom door" is displayed (above the centre key). Operate the tractor's distribution valve so long until the bottom door is completely opened and until the knives are moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate). The window "Bottom door open" is displayed (with flashing exclamation mark, Figure 129) when the bottom door is open. The symbol "Cutting device" disappears when the knives are inserted into the knife bottom plate (in Figure 129 still displayed). Switch on PTO shaft again. Figure 129 After material jam has been removed by itself: In the menu "MONITOR": Press centre key so many times until the symbol "Cutting device" (with the desired number of knives) is displayed (above the centre key). Operate the tractor's distribution valve so long, until the cutting device is moved completely to cutting position (i.e. until the knives are moved completely out of the knife bottom plate) and until the bottom door is completely closed (window "Bottom door open" disappears). That the hydraulic accumulators can be filled: Operate tractor's distribution vale for another 5 sec. WELGER RP 405 RP 435 RP 505 RP

108 Behaviour during material jam (BALERCONTROL E) Stop driving and switch off power take-off shaft. Actuate the connected tractor distribution valve until the bottom door is completely opened and until the knives are moved completely to home position (i.e. until the knives are moved completely into the knife bottom plate). Switch on PTO shaft again. The material jam is removed by the running conveying devices. Figure 130 After the material jam is removed: Operate the tractor's distribution valve so long, until the cutting device is moved completely to cutting position (i.e. until the knives are moved completely out of the knife bottom plate) and until the bottom door is completely closed. That the hydraulic accumulators can be filled: Operate distribution valve after moving the knives for another 5 sec. 100 WELGER RP 405 RP 435 RP 505 RP 535

109 Special case: Behaviour in case of material jam (BALERCONTROL E) in case of operation with BLOCKED bottom door See chapter 7.4 Lock bottom door. Stop driving and switch off power take-off shaft. Operate the connected the tractor's distribution valve so long as it takes to move the knives totally into home position (that means until the knives are totally moved into the knife bottom plate). Switch on PTO shaft again. The material jam is removed by the running conveying devices. Figure 131 Figure 132 If the material jam is removed: Operate the connected the tractor's distribution valve so long as it takes to move the knives into cutting position (that means until the knives are moved out of the knife bottom plate). That the hydraulic accumulators can be filled: Operate distribution valve after moving the knives for another 5 sec. If the material jam is not removed: Switch off power take-off shaft. (Left machine side, Figure 132:) Turn right ball valve through 90 counterclockwise. The right ball valve of the hydraulic block must point to the tail end of the machine. The left ball valve of the hydraulic block must point away from the machine. Operate the connected tractor's distribution valve until the bottom door is completely opened. Switch on PTO shaft again. The material jam is removed by the running conveying devices. Close bottom door: Operate the tractor's distribution valve so long, until the cutting device is moved completely to cutting position (i.e. until the knives are moved completely out of the knife bottom plate) and until the bottom door is completely closed. That the hydraulic accumulators can be filled: Operate distribution valve after closing the bottom door for another 5 sec. (Left machine side, Figure 133:) Turn right ball valve through 90 clockwise. The right ball valve of the hydraulic block must point away from the machine again. The left ball valve of the hydraulic block must point away from the machine. Figure 133 Attention! The knives move automatically into working position when closing the bottom door. If it must be worked without knives the knives must then be moved back to home position: see chapter "7 Cutting device". WELGER RP 405 RP 435 RP 505 RP

110 11 Maintenance / Setting Attention, danger of injury! Never perform maintenance- and repair works during machine is in operation. stop the tractor engine and take out the ignition key, wait until the machine has stopped, switch off PTO shaft and pull drive shaft from the PTO shaft before start working at movable parts of the machine. Never step onto the maintenance platform during machine is in motion. Before stepping onto the maintenance platform: stop machine, switch-off power take-off shaft and tractor motor and wait for standstill of the machine. If any maintenance or assembly work is carried out with the tail gate open, the tail gate must be hydraulically secured against lowering for safety reasons: For this use the shut-off valve located at the maintenance platform. When the valve is shut off, the actuating lever is at right angles to the flow direction (Figure 2) General notes After the first 20 running hours: Retighten all fastening screws, wheel nuts, drawbar screws and nuts also inside the machine. Exception: Do not change adjusting screws, e.g. on the twine guiding or the net brake Grease knife lever Only machines with cutting device XtraCut 17 and XtraCut 25: Nonrecurring 3 weeks after first commissioning: Grease the knife levers [1] (grease nipple at the bottom side of each knife lever). Nonrecurring 3 weeks after first commissioning: Grease the knife lever [2] (grease nipple at the bottom side of the knife lever). After set regrease once per season. Figure WELGER RP 405 RP 435 RP 505 RP 535

111 11.3 Tensioners Caution! (Figure 135) The gears [2] of the main drive shaft [1] are mounted with tensioners to the shaft end. Working at the tensioners [3] must only performed by instructed technical staff. Figure Maintenance of the net tying unit Figure Adjusting the disk brake of the net tying unit (Figure 136 and Figure 137) To prevent coasting of the net roll the disk brake must be adjusted in such a way that the brake disk can no more be turned by hand when the lever [1] points upwards. Slacken screw [2] on the lever [1], tighten milled nut [3] so far that the brake linings are fully attached to the brake disk. Retighten screw [2]. When brake lining [4] is worn only one-sided slacken lock nut [5] and slightly insert screw [6] until brake linings are parallel again, lock screw [6] again. Figure 137 WELGER RP 405 RP 435 RP 505 RP

112 Adjusting the shock absorbers (Figure 138) On the left machine side, the movements of the net tensioner [12] are braked by a shock absorber. Two wing nuts (arrows in Figure 138) press the friction linings against the net tensioner from both sides. For adjustment first move the net tensioner to the top end position and tighten the wing nut "hand-tight". Proceed analogously in the bottom end position. The adjustment is correct, if the net tensioner can just still be moved to and fro between the two end positions by hand. Figure 138 During net tying the net tensioner may move between the two end positions only in such a way that the net always remains properly tensioned. Attention, danger of injury by cutting! Do not reach into the area of the net knife! Wear protective gloves Tensioning the roller chains Chain tensioning has to be checked and/or retightened at least after 500 bales. On pick-up or cutting device drive*: loosen and readjust chain tensioning blocks in the slotted holes. Subsequently tighten the tensioning blocks properly. The other drive chains are tensioned flexibly by springs (arrow in Figure 139). Lock the nut again after adjustment. If chain tensioning is no more possible, shorten the chain by removing a chain link. If necessary insert a cranked chain link. Figure 139 Note! New chains elongate already after a short time of operation. They can therefore be tensioned a little bit stronger. 104 WELGER RP 405 RP 435 RP 505 RP 535

113 11.6 Hydraulic layouts Hydraulic layout Machines with E-LINK with HYDROFLEXCONTROL bottom door with 13-, 17- or 25-knife cutting device Figure 140 Figure 141 WELGER RP 405 RP 435 RP 505 RP

114 Hydraulic layout BALERCONTROL E Machines with fixed bottom door with cutting device Figure WELGER RP 405 RP 435 RP 505 RP 535

115 Hydraulic layout BALERCONTROL E Machines with HYDROFLEXCONTROL bottom door with cutting device Figure 143 WELGER RP 405 RP 435 RP 505 RP

116 11.7 Tire air pressure RP 405 / RP 435 Tire size max. speed Pressure 15.0/55-17 (NOT for RP 435 MASTER) 40 km/h 2.75bar 19.0/ km/h 1.5 bar 380/55-17 (NOT for RP 435 MASTER) 40 km/h 2.0 bar 425/55-R17 40 km/h 2.0 bar 500/ km/h 1.5 bar Tightening torque for wheel nuts: 460 Nm 170/60-8 (pick-up guide wheel) 2.0 bar 11.8 Tire air pressure RP 505 / RP 535 Tire size max. speed Pressure 15.0/55-17 (NOT for RP 435 MASTER) 40 km/h 3,0 bar 19.0/ km/h 2,0 bar 380/55-17 (NOT for RP 435 MASTER) 40 km/h 2,4 bar 425/55-R17 40 km/h 2,0 bar 480/ km/h 2,0 bar 500/50R17 40 km/h 1,75 bar 500/ km/h 1,5 bar 500/ km/h 2,4 bar Tightening torque for wheel nuts: 460 Nm 170/60-8 (pick-up guide wheel) 2.0 bar 108 WELGER RP 405 RP 435 RP 505 RP 535

117 11.9 Chain lubrication (oil lubrication) (Figure 144) The mechanical chain lubrication system with oil reservoir supplies the drive chains of the machine with lubricating oil. Caution! Check oil level daily. Oil reservoir must never run completely empty! Otherwise the lubricating pump and the roller chains may be damaged. Figure 144 Check oil level in oil reservoir daily (visual check). Never let the oil reservoir run completely empty If nevertheless the oil reservoir runs empty: Fill with oil (see chapter Fill with oil). Deaerate the system (see chapter Deaerating the system) Fill with oil To prevent dirt from getting into the lubrication system proceed as follows before opening the tank cover: Clean the surroundings thoroughly. Unscrew tank cover. Fill the oil reservoir with clean lubricating medium via the filling filters! Observe the lubricant specifications by the machine manufacturer! Observe the safety data sheet by the lubricant manufacturer! The viscosity range of the lubricant changes with the operating temperature. Check the oil level several times at equal intervals during the first hours of operation. If required refill clean lubricating medium. Refill oil up to the max. mark. Oil type: see chapter Lubrication chart. Caution! To avoid damage to the lubricating pump and the roller chains or to the machine: use exclusively clean and fresh oil. Check tank screen in the oil reservoir for dirt or blockage (visual check). Screw cover down again. WELGER RP 405 RP 435 RP 505 RP

118 Deaerating the system Deaerate the system during first commissioning and whenever the oil reservoir has been emptied completely! Deaeration is effected by unpressurized operation with all system outlets opened. Detach lubricating lines from the lubrication points. Start and run the pump until the lubricating medium flows from every lubricating line without air bubbles. Collect lubricating medium at the end of the line in suitable vessel (pollution control; safety at work). Dispose of the collected lubricating medium properly. Reconnect the lubricating lines to the lubrication points. Perform visual inspection of the connections for tightness. If required refill clean lubricating medium If required: clean screen Unscrew tank cover. Remove screen. Clean the screen thoroughly using exclusively petroleum benzine or petroleum. Insert screen and screw cover on again. Subsequently: Check oil level in oil reservoir daily Once per year: clean complete lubricating pump Detach the pump from the machine. Disconnect all lubricating lines from the plug-type connections. Empty the pump completely. Dispose of the lubricant residues properly! Loosen cap nuts on the cover of the oil reservoir. Remove cover and oil reservoir. Wash pump thoroughly with benzene, petroleum or suitable cleaning agent and rinse. Wash oil reservoir thoroughly with benzene, petroleum or suitable cleaning agent. Reassemble the pump and attach it to the machine. Fill oil (see chapter Fill with oil). Deaerate the system (see chapter Deaerating the system). 110 WELGER RP 405 RP 435 RP 505 RP 535

119 Regulating the flow rate: Caution! To avoid damage to the lubricating pump and the roller chains or to the machine: The flow rate of the lubricating pump correctly set in the factory must not be changed. If certain cases require adjustment of the flow rate: such work may be carried out only by trained and instructed service personnel on the basis of the service information provided by Welger Winter pause Prior to a winter pause: Place the machine on an even surface. Unthread twine, unthread net. Remove twine, net and straw remains from the machine. Disconnect control box from the machine (pull plug). Keep control box dry and at room temperature. Remove, grind and reinstall cutting device knives. Grease tying mechanism. Thoroughly lubricate all bearings. Slightly grease the surface of the baling chamber by means of a lubricant degrading neither the environment nor the fodder ( e.g. rape oil). Check and if necessary adjust air pressure of tires (11.7 Tire air pressure RP 405 / RP 435 or 11.8 Tire air pressure RP 505 / RP 535). WELGER RP 405 RP 435 RP 505 RP

120 11.11 Lubrication chart 3 weeks after first commissioning Item in (Figure 145) Machine part Lubricant (Table 3) Note 14 Only machines with cutting device XtraCut 17 and XtraCut 25: grease knife lever (see 11.2Grease knife lever) A 3 weeks after first commissioning, then once per season After each 500 bales (or daily) Item in (Figure 145) Machine part Lubricant (Table 3) Note 4 Lubricant metering device (roller lubrication) A 2) Left machine side After each 500 bales (or daily) Item in (Figure 145) Machine part Lubricant (Table 3) Note 1 Drive shaft A 2 Autom. chain lubrication system B Right machine side (Figure 144) see 11.9 Chain lubrication (oil lubrication) 3 Hinge of tail gate A 1) 5 Locking hook A on both sides 6 Roller on locking device A on both sides 7 Cutting rotor A on both sides 8 Castors* A on both sides 1) Depending on version, already supplied by central metering device. 2) Supply metering device by means of 2 strokes from the manual grease gun - do not use compressed air grease gun. 112 WELGER RP 405 RP 435 RP 505 RP 535

121 Annually after the end of the season (in case of special operating conditions also weekly) Item in (Figure 145) Machine part Lubricant (Table 3) Note 6 Belleville springs of the locking hooks E Dismantle, clean and grease; Attention: do not change sensor setting! 9 Main gear unit C / 1.7 l Oil change Check filling level with dip stick or overflow hole 10 Movable parts of the net tying unit* or movable parts of the twine tying unit* 11 Hydraulic cylinder on tail gate locking mechanism d A provide for smooth motion on both sides 12 Star ratchet in pick-up drive A Left machine side 13 Twine eyes A grease chafe marks slightly 14 Only machines with cutting device XtraCut 17 and XtraCut 25: grease knife lever (see 11.2Grease knife lever) A 3 weeks after first commissioning, then once per season Annually Item in (Figure 145) Machine part Lubricant (Table 3) Note 15 Brake A on both sides WELGER RP 405 RP 435 RP 505 RP

122 11.12 Lubrication points Figure 145 Lubricant Trade name, e. g. A Multipurpose grease Fuchs Renolit FEP 2 Bechem High-Lub LM 2 EP BP Energrease LS-EP2 Elf Epexa 2 Esso Beacon EP 2 B Chain lubrication Lubricant according to ISO VG 68 ISO VG 220 (not thickening) C Gear oil SAE 90 API GL - 5 D Machine oil E Multipurpose grease Gleitmo 810 F Multipurpose grease Multipurpose grease according to NLGI-class 2, with high pressure additive, without solid parts Table 3: Specification of the lubricants 114 WELGER RP 405 RP 435 RP 505 RP 535