Operating manual. RP 320 MASTER WELGER. from year of manufacture 2004

Transcription

1 RP 202 / RP 302 RP 220 / RP 320 WELGER RP 320 MASTER Operating manual from year of manufacture

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3 Contents 1. Model Overview Field Use Your Safety Wrapping Component Overview Overload protection / Reversing mechanism60 4. Putting Into Operation "BALERCONTROL"* Twine wrapping* Maintenance / Settings Net Wrapping* Technical Data Cutting Device*...35 The machine number is entered onto the data plate shown opposite and is located on the right hand side of the baler. Warranty claims and enquiries cannot be processed without this number. Please enter this number here below immediately after delivery:... Read the operating manual and safety instructions before putting the baler into operation. We have inserted a warning sign in this operating manual at points concerning your safety. Please also pass on all safety instructions to other users. The warning and instruction plates on the baler provide important information for safe operation. Paying attention to them is for your own safety! * Please note that the features marked with a [*] in this operating manual are fitted only to some models as standard or are only available for particular models as additional features. These features may also not be supplied to all export countries. Reproduction prohibited - all rights reserved. Design and construction subject to alterations. The illustrations shown are non-binding for model, form and equipment by 2004 by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany. Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 D Wolfenbüttel Phone: (+49) / Fax: (+49) / wmf@welger.com

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5 Handover Declaration Please fill in this form when the machine is handed over and return it to the distributor. No warranty applications can be processed until this form is received. Welger Maschinenfabrik GmbH Abteilung T.S. (Technical Support) Postfach 1965 D Wolfenbüttel (1) Handover Date (2) Type: RP... Machine No.: (see data plate: #) Equipment fitted: Pick-up unit 1.50 m Pick-up unit 2.00 m Pick-up unit 2.25 m Cutting unit Twine wrapping Net wrapping (3) Customer's address Name: Street: Postcode: Place: Country: Phone: (4) The baler entered in (2) was purchased/used by me. When the baler was handed over, I was given the operating instructions No.... including the EU Conformity Declaration. The safety, operating and maintenance regulations contained therein were explained to me. All safety features for the correct functioning and handling were demonstrated to me Date Customer s signature (5) Marketing partner s address Importer s address Company stamp/signature Company stamp/signature (6) The machine was handed over to the customer in accordance with the manufacturer's guidelines Date Customer service specialist's signature

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7 1. Model Overview This Operating Manual describes the models RP 202, RP 220, RP 302 and RP 320 RP 202 CLASSIC RP 302 CLASSIC RP 202 SPECIAL RP 302 SPECIAL RP 220 FARMER RP 320 FARMER RP 220 MASTER RP 320 MASTER RP 220 PROFI RP 320 PROFI 1,50 m Pick-up unit width 2,00 m 2,25 m MASTERCUT 12 blade Cutting device PROFICUT 23 blade PROFICUT 25 blade Conveyor bottom bolted HYDROFLEXCONTROL spring loaded a. hydr. actuated Wrapping VARIOTWIN Twine wrapping VARIONET Net wrapping Control BALERCONTROL E BALERCONTROL III Table 1 = Standard equipment = Special equipment WELGER RP 202 RP 220 RP 302 RP 320 3

8 2. Your Safety All the protective devices such as the safety covers, rubber aprons or safety brackets are provided for your safety! Never operate the baler with defective safety devices or if the safety devices have been removed! Always keep components which are relevant to safety in a suitable condition. All guards must be fitted and closed before putting the baler into operation! Never carry out adjustments, repairs or maintenance and service work on the baler while it is running. Always first stop the power take off (pto) shaft, detach the universal drive shaft from the pto shaft stub and disconnect the electrical connection between the tractor and the baler prior to working on any of the baler s moving parts. Never try to remove hay, straw or other harvested crop from the baler while it is running. Always first stop the pto shaft, and switch off the tractor engine. While work is in progress, only the driver should be on the tractor. Passengers are not allowed on the baler! Never step on the maintenance platform of the moving machine. Before you step on the maintenance platform: Stop the machine, switch off power take-off shaft and tractor engine and wait until the machine has stopped. Do not climb on the drawbar or other parts of the baler when it is in operation. Also, keep your distance from the pick-up unit. Do not reach into the working area of the transport units. Before threading in the binding material, switch off the baler drive and tractor engine and remove the ignition key All protective guards must be fitted to the baler and must be in sound condition. Before opening the guards, stop the pto shaft and the tractor engine, remove the ignition key and wait until the baler has stopped. Before detaching the baler from the tractor, secure it with the aid of the chocks to prevent it from rolling away. Carry the chocks with the baler when the baler is transported or used. Upon opening the tailgate, maintain at least 2 metres safety distance from the high voltage cables. Work on the magnets of the knife holders: The function of cardiac pacemakers may be impaired by magnetic fields. Work on the magnets of the knife holders: Danger of injury by splinter never strike the installed blades from the bottom with a striking tool. Magnets may be damaged! All maintenance and repair work beyond that described in the descriptions in these operating instructions must always be carried out by authorised persons. Wear parts of the brake system must always be replaced on both sides. Secure the baler from tipping backwards before detaching the complete pick up unit. Warning! The baler is inherently dangerous even if all the points listed above are followed exactly. Therefore always take care when working with the baler to avoid endangering yourself or other people! 4 WELGER RP 202 RP 220 RP 302 RP 320

9 2.1. Noise level of tractors and machines EU Guideline EEC concerning noise at the workplace instructs employers and employees to measure and control the noise level at the workplace. The noise level during normal field work is subject to various fluctuations which depend on the noise level of the tractor, and also on the conditions under which the baler is being used. The noise level generated by WELGER balers, measured at the driver's head height with the tractor window open, is less than 70 db(a) under normal working conditions. The combined noise level generated by the baler and tractor primarily depends on the level of tractor noise (radios are an additional source of noise). We recommend that the tractor be driven with the cabin windows closed. WELGER RP 202 RP 220 RP 302 RP 320 5

10 2.2. Fire prevention Crop materials are very combustible. Always keep the baler free of crop remnants and oil contamination. Should overheating of the baler components occur, determine the cause and resolve accordingly. Always keep the electrical circuits of the tractor and baler, as well as the tractor s exhaust system in perfect working order. The supplied cabling may not be used for purposes other than for factory installed or approved electrical equipment. Overloading the electrical cables leads to excessive heating. fig. 1 Smoking is forbidden in the vicinity of the baler. Always keep a suitable fire extinguisher within easy reach Tailgate safeguard If maintenance or installation/assembly work is performed with the tailgate open, it is essential to secure the tailgate to prevent it from falling. Use the cut-off valve on the right side of the baler for this purpose. The shut-off valve may only be actuated from the right side of the machine. Return the valve to its original position after completing maintenance and installation/assembly work (fig. 2). fig fig. 3 6 WELGER RP 202 RP 220 RP 302 RP 320

11 2.4. Hydraulic system Max. operating pressure of the hydraulic system 210 bar When carrying out assembly work on the hydraulic system, particularly when using accumulators (fig. 4): Depressurise the hydraulic system (control valve set to Lower ) Mechanically secure hydraulically operated components (pick-up device, cutting unit) to prevent uncontrolled movements. fig. 4 According to DIN 20066, the period of use of a hose line, including any storage period, should not exceed six years Protective guards In order to comply with European safety regulations EN 704, the manufacturer of machines is required since to supply fixed partitioned protective guards that are self locking but require the use of a tool to be opened. In order to open the protective guards on WELGER balers, turn the hexagon head of the lock anti-clockwise with a 13 mm spanner and pull the guard off the baler. fig. 5 Observe the following order: When opening:... first the upper cover (fig. 5). When closing:...first the side cover (fig. 6). To close, push the guard cover against the baler until the lock is heard engaging. The baler is never permitted to be operated with the protective guards open! fig Maintenance platform Danger of falling! Never step on the maintenance platform of the moving machine. Before you step on the maintenance platform: Stop the machine, switch off power-takeoff shaft and motor engine and wait until the machine has stopped. WELGER RP 202 RP 220 RP 302 RP 320 7

12 8 Warning symbol WELGER RP 202 RP 220 RP 302 RP 320 Spare part No.: Always switch off the engine and remove the ignition key before starting any maintenance and repair work. Spare part No.: Never reach into the baler pick-up area as long as the tractor engine is running with the pto shaft connected. Spare part No.: Close protective guards before putting baler into operation! Spare part No.: Read and adhere to the operating manual and safety notes before starting up for the first time. Description/Spare part No. The warning symbols must always be kept in a recognizable state. If there are no warning symbols on your baler or if they are damaged, replace them (see also Spare parts list, Section F) Explanation of the symbols Danger areas which cannot be made safe by design measures are identified by yellow warning symbols. Since these are signs without texts in most cases, their precise meaning is described below Warning symbols

13 Switch off the engine and pull out the plug from the power supply before starting any repair, maintenance and cleaning work. Spare part No.: Stay clear of tailgate swinging area while in operation. Spare part No.: Do not ride on platform or ladder. Spare part No.: Handle the cutting unit blades only if you are wearing gloves and using suitable tools. Spare part No.: The accumulator is under gas pressure or oil pressure. Depressurise the hydraulic system before removal and repairs. Spare part No.: Activate the tailgate safeguard before entering the roll chamber. Spare part No.: WELGER RP 202 RP 220 RP 302 RP 320 9

14 2.8. Symbols for the operation of the baler The most important operating instructions are shown as symbols for the purpose of clarity. The exact descriptions are given below. Symbol Description/Spare part No. The two lifting eyes in the upper part of the baler are identified by this symbol. No other fixing points may be used for hooking up a crane. Spare part No.: Locking lever for the cutter blades To unlock the cutter blades, the lever must be swivelled down by approx. 90. Spare part No.: and Tailgate safeguard If the lever is transverse with respect to the flow direction, the tailgate is secure against lowering. Spare part No.: Maximum permissible hydraulic pressure The machine may only be connected to a hydraulic system which supplies a maximum oil pressure of 210 bar. Spare part No.: WELGER RP 202 RP 220 RP 302 RP 320

15 2.9. Proper Use The baler has been built exclusively for producing bales compressed from agricultural straw material lying on the ground (proper use). Usage beyond this does not constitute proper use. The manufacturer is not liable for damage resulting from improper use; the user alone bears the risk. Proper use also includes compliance with the operating, maintenance and servicing conditions specified by the manufacturer. The baler may only be used, maintained and repaired by persons who are familiar with working with such machines and who have been informed of the dangers. The attachment of auxiliary equipment to the baler, other than at the factory pre-set positions, is prohibited. Only auxiliary units approved by the manufacturer may be used. The relevant accident prevention regulations, regional safety standards and other generally recognized safety regulations are to be observed. Unauthorized alterations and the installation of non-approved parts and equipment on the baler exclude the manufacturer from any liability or damage resulting from this. Alteration of any of the safety relevant components invalidates both the conformity declaration and the CE-symbol Electromagnetic compatibility (EMC) The baler is equipped with electronic constituents and component parts whose function can be influenced by electromagnetic radiation from other appliances. Such influences can generate hazards for persons if the following safety precautions are not taken into account. In the case of a supplementary installation of electrical and electronic appliances and/or constituents in the baler with a connection to the onboard system, the user has to verify whether the installation causes disturbances to the electronics of the vehicle or of other constituents. In particular, it has to be taken into account that any additionally installed electrical and electronic components comply with the EMC Directive 89/336/EEC in the respective current version and that they are CE labeled. WELGER RP 202 RP 220 RP 302 RP

16 2.11. Precautions for driving on the road Before driving on the road... the baling chamber must be completely emptied (in accordance with Road Traffic Vehicle Registration Regulations (RTVRR); the baler must be cleared of any harvested crop attached to it; the universal drive shaft must always be fitted to the tractor pto shaft; the tubes of the bale ejector* must be pushed in. the lighting equipment of the attached machinery must be connected to the tractor and its function checked (also in daylight); the support wheels of the pick-up unit must be detached (working width 2.25 m) and placed in the park position. the parking brake must be fully released. Otherwise there is danger of fire by brakes running hot (e. g. in the field). the power supply must be interrupted (pull plug), to prevent uninterrupted roller lubrication. Information shall be requested from the manufacturer before the baler is operated using attached machinery (e.g. bale wrapping device). The wheel chocks, which are part of the safety equipment (two in number), are to be carried on the baler at all times. The permissible maximum speeds for individual components (e.g. the drawbar or the axle) do not affect the maximum permitted speed limit for the entire baler (see Technical Data). Model-dependent maximum speeds limits have been exclusively specified in this operating manual. Current relevant national regulations, which may differ from manufacturers instructions, are always required to be observed. 12 WELGER RP 202 RP 220 RP 302 RP 320

17 Pneumatic braking system*: Do not start driving with an attached baler until both coupling heads (yellow and red) are connected to the tractor and the pressure gauge in the tractor cabin indicates the required operating pressure. Hydraulic braking system *: Do not start driving with the attached baler until the appropriate hydraulic hose is connected to the tractor. Germany (StVZO): Agricultural equipment with a permissible total weight more than 3000 kg are required to have an operating permit. (Technical changes, e.g. fitting a trailer hook, result in the operating permit becoming void). Before making intended changes to the attached working unit, it is essential to clarify whether the change is permissible without further requirements and can be entered in the vehicle s documents following approval by an officially recognised expert. Furthermore, the national regulations from the country of use are to be observed. WELGER RP 202 RP 220 RP 302 RP

18 Details on the rating plate fig. 7 Item Meaning 1 ID number individual machine number. Always quote in the event of queries 2 Permissible total weight for operation on public roads. The machine s actual weight can be less. Exception (for field use only): The actual weight of the machine plus bale in the chamber may be higher. 3 Permissible axle load for operation on public roads 4 Machine s year of construction 5 No applicable 6 Trade designation of the machine 7 Details of the systematic structure of the general operating permit (ABE) 8 Max. imposed load on the drawbar eye. The open-type hitch on the tractor must be approved for this imposed load. 9 Permissible type-related maximum speed of the machine. National regulations can specify a lower speed! 10 Internal control number 14 WELGER RP 202 RP 220 RP 302 RP 320

19 Details on the rating plate of the drawbar fig. 8 Item Meaning 1 Drawbar type (designation): D7 or D8 2 Official mark of conformity 3 Permissible, maximum total weight of the machine 4 Permissible maximum imposed load (D7: 400 kg; D8: 800 kg) WELGER RP 202 RP 220 RP 302 RP

20 3. Component Overview V fig. 9 No. Component No. Component 1 Pick up unit 7 Net wrapping* 2 BALERCONTROL III - Control panel* 8 Bale ejector* 3 BALERCONTROL E - Control panel* 9 Tailgate 4 Cutting device* 10 Lock 5 Floor flap* 11 Chain wheels for roller drive 6 Twine wrapping* 16 WELGER RP 202 RP 220 RP 302 RP 320

21 4. Putting Into Operation When handling parts of the machine in the area of the drawbar, make sure that the machine is safeguarded from rolling away. Do not crank up the support foot until the baler is securely coupled to the tractor. Do not disconnect the baler until: The surface is level and supports the road wheels and the support foot The baler chamber is empty and the tailgate is closed The machine s road wheels are blocked by chocks The hydraulic hoses are depressurised There is no load applied to the drawbar eye Do not step between the tractor and baler until the vehicles are safeguarded from rolling away by means of the parking brake and/or the wheel chocks! Children must be kept away from the baler at all times! 4.1. Attaching the baler Correct baler attachment and drive shaft set up to the tractor is important to ensure trouble-free operation of the baler. After attaching the baler, screw in the support foot with the hand crank until there is sufficient clearance from the ground. Caution, danger of fire! Do not start driving with the machine attached unless the parking brake has been fully released. Otherwise there is danger of fire by brakes running hot (e.g. in the field). After attaching the machine to the tractor release the parking brake (turn crank counterclockwise). Caution, danger of accident! Any machines standing free, detached from the tractor, must be secured against accidental rolling away by applying the parking brake and by means of chocks. Apply the parking brake before detaching the machine from the tractor (turn crank clockwise). WELGER RP 202 RP 220 RP 302 RP

22 Drawbar configuration (all dimensions in [mm]) fig. 10 fig WELGER RP 202 RP 220 RP 302 RP 320

23 RP 202 CLASSIC Adjusting the trailer hitch Any adjustment in the height set-up, and therefore a displacement in the drawbar eye position, shall only be carried out by the manufacturer or an approved specialist workshop. Position the baler on even ground. Screw out the support foot until the baler is standing level. Use the flange plate on the stand as a reference. fig. 12 Measure the height of the tractor towing hitch; Measure the height of the baler drawbar eye. RP 202 SPECIAL RP 220 RP 302 RP 320 With reference to fig. 10 and fig. 11 align the drawbar with the hole configuration that gives the closest fit to the desired dimension. The locking nuts must be replaced by new ones each time they are undone. After aligning the trailor hitch, the drawbar eye needs to be brought into a horizontal position. Do this by undoing the fastening screws of the drawbar eye and correct the alignment of the drawbar eye with the help of the threaded pin. Firmly tighten all fastening screws and nuts. fig. 13 WELGER RP 202 RP 220 RP 302 RP

24 RP 202 CLASSIC Important: Depending on the equipment configuration, a rigid or rotatable drawbar eye can be fitted. (observe local regulations!) The drawbar eye [3] can be rotated about its longitudinal axis, but has to be locked for a open-type hitch attachment D7 3 1 For open-type hitch (high hitch) attachment, prevent drawbar eye [3] from turning by fitting parts 4, 5 and fig For tow hitch (low hitch) attachment, do not prevent drawbar eye [3] from moving, i.e., parts 4-6 not be fitted. Parts 4 6 are included loose with the delivery of balers having rotating drawbar eyes. The horizontal protective bracket underneath the drawbar must be set for a minimum ground clearance of 50 cm. Note: All fastening screws and nuts must be done up tightly: Component see Tension moment Bracket RP 202 CLASSIC Bracket RP 202 SPECIAL RP 220 RP 302 RP 320 fig Nm fig Nm Drawbar eye fig. 14, item Nm Table 2: Tension moment 20 WELGER RP 202 RP 220 RP 302 RP 320

25 Configuration of the tow hitch If the baler is attached to the tractor tow hitch, compliance with the following dimensions is necessary: (Table 3). Tow hitches other than as shown in fig. 15 and Table 3 are not permitted! Danger of breakage! fig. 15 Corresponding category Catch opening dimensions Catch opening outer radius Position Vertical support load ISO d b r 1) c 2) l F +1 min. max. min. ±10 kg ) Various configurations for the tow hitch are permissible if the external radius r is complied with. (see fig. 11) 2) The upper part of the tow hitch can be dismantled to comply with dimension c. Dimensions are in millimetres Table 3: Dimensions, location and support load of the tow hitch WELGER RP 202 RP 220 RP 302 RP

26 4.2. Universal drive shaft Connecting the cam-type cut-out clutch* Depending on the model, the universal drive shaft is fitted with an automatic overload safety cut out (cam-type cut-out clutch). Clean and grease the splines of the connecting shaft before installation. Grease Undo and pull out the clamping cone [1] Gra i sse fig Open the maintenance hole in the protective cone. Push the clutch unit onto the connecting shaft until the locator hole [2] points to the maintenance hole. Position the locator hole for the clamping cone above the snap ring groove [3] of the connecting shaft Turn the clamping cone within the locator hole and gently move the hub backwards and forwards lengthways to seat it securely (approx. 70 Nm). 1 Check that the clutch hub is properly located and securely fixed by pushing and pulling on it. During this process, the proper location of the clutch should be checked at regular intervals. 2 3 fig Removing the cam-type cut-out clutch* Undo the clamping cone and pull it out of the clutch hub. If that cannot be done by hand, the clamping cone can also be driven out from the other side with the help of a pin punch fig WELGER RP 202 RP 220 RP 302 RP 320

27 a) b) Lmin LU 2/3 LU Adjusting the universal drive shaft Pay attention to the maximum operating length Lmax and minimum operating length Lmin! Aim for the greatest possible overlap. a) Shortest operating length, i.e., fully covered b) During normal operation, the overlap of the tube section should be at least 2/3 of the overlap LU. c) Lmax fig. 19 1/3 LU 40 mm c) The universal drive shaft can be operated with length Lmax for short periods, i.e., with a tube section overlap of 1/3 LU. If necessary, adjust the length. To do this, hold the drive shaft tubes next to each other in the shortest operating position and mark them. Saw off the inner and outer tubes by equal amounts so that a sliding travel of 40 mm is retained in the shortest operating position. Prevent the protective tube of the universal drive shaft from rotating by fastening the retaining chain. Check the universal drive shaft each time before start-up to ensure that the locks are properly engaged fig. 20 Important: When turning around sharp bends, ensure that the angle at the wide-angle joint (at the tractor) does not exceed the maximum value quoted by the manufacturer of the universal drive shaft. Pay attention to the operating instructions from the universal drive shaft manufacturer as well as to country-specific approved product labels for the protection of universal drive shafts. Warning: Only universal drive shafts approved by the manufacturer may be used. A wedge-type freewheel device that is an integral part of the universal drive shaft protects the machine drive against follow-on weights. When the machine is disconnected, always deposit the universal drive shaft on the universal drive shaft support (Fig. 23). In the case of attachment below, swivel the support upwards as appropriate. fig. 21 The protective tube and cone of the universal drive shaft and the pto protection device must be fitted and must be in sound working order. Before starting the pto shaft, ensure that the selected rpm of the tractor is in accordance with the permissible rpm and direction of rotation of the machine (540 min -1 ). Only start the pto shaft at idling speed! WELGER RP 202 RP 220 RP 302 RP

28 4.3. Hydraulic hoses Symbol on hydraulic hose Baler Function Tractor connection Colour identification RP 202 RP 220 RP 302 RP 320 Open and close tailgate single-acting yellow RP 202 RP 220 FARMER RP 302 RP 320 FARMER Raise and lower pick up single-acting red OIL RP 220 FARMER RP 320 FARMER Activate floor flap and cutting knife double-acting green OIL OIL RP 220 w. CD RP 320 w. CD Hydraulic switch with the functions floor flap* pick up unit cutting device* double-acting red OIL CD = Cutting Device* 24 WELGER RP 202 RP 220 RP 302 RP 320

29 Note: In order to find the correct oil coupling sleeves quickly when hooking up the baler on later occasions, it is advisable to transfer the colour identification used for the hydraulic hoses to the couplings at the tractor end. Clean the coupling parts of the hydraulic pipes with a clean cloth and plug in to the sockets at the tractor. Check hoses and pipelines regularly for damage, deterioration and safe functioning. Defective parts are to be replaced immediately by original WELGER replacement parts. Hoses and hose lines are subject to natural deterioration even under normal operating loads. As a result, the useful service life is limited. According to the "Safety Regulations for Hydraulic Hoses", a service life of six years should not be exceeded! WELGER RP 202 RP 220 RP 302 RP

30 4.4. Electrical system Lighting To connect the lighting system, insert the 7-pin plug into the corresponding socket on the tractor. Before travelling on the road check that the lighting system functions correctly (also in daylight) "Balercontrol" Electronic Controller Balercontrol E RP 202 RP 302 RP 220 FARMER RP 320 FARMER fig V Read and follow the separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320. The control panel is provided with a plate which should be fastened within easy reach of the tractor driver. The control panel of the Balercontrol control system is also provided with a magnetic plate on the rear and can be attached to a metallic surface within easy reach of the driver. Once the plug is inserted in the socket, power is supplied to the unit and a short sequence of beeps is heard. Note: When connecting the Balercontrol electronic controller, a power socket conforming to DIN 9680 must be fitted on the tractor. (Supplied with the baler.) The fuse rating must be 30 A. (For baling without twine wrapping a fuse rating of 16 A is sufficient.) The socket with connecting cable and fuse can be supplied under WELGER part No as a retrofit part for an additional tractor. fig. 23 The correct polarity of the power supply on the tractor must not be changed, since otherwise the electronic control unit might be damaged (fig. 24). fig WELGER RP 202 RP 220 RP 302 RP 320

31 5. Twine wrapping* 5.1. Threading the baling twine Insert and thread new twine spools only when the baler is switched off. Remove the ignition key Use good quality baler twine. Refer to technical data at the end of this operating manual. The use of plastic twine is recommended. Place the spools upright into the twine box. If the spools are inserted the wrong way up, the twine tends to form loops and leads to breakage. Twine A (Shown as a continuous line in fig. 26 to fig. 28) Guide the start of the twine from the inside of spool A1 (inner diameter) upwards to the guide eye and then out of the twine box. Tie the end of the twine (outer diameter) of spool A1 to the start of the twine of spool A2. Twine B (Shown as a dashed line in fig. 26 to fig. 28) Guide the start of the twine of spool B1 similarly upwards through the guide eye and then out of the twine box. 1. Guide the twines A and B through the twine brake (1). 2. Only in the case of Balercontrol E : Wrap both twines around the deflection rollers (2). 3. Thread in both twines upwards to the pair of eyes (3) on the binding bar. 4. Only in the case of RP 302 / RP 320 with Balercontrol E : Use the additional guide eyes between the deflection rollers (2) and the pair of eyes (3). 5. The twines shall not touch each other. 6. For continuation go to fig. 27. WELGER RP 202 RP 220 RP 302 RP

32 Threading-in diagram for machines with BALERCONTROL E RP 202 / RP 302 CLASSIC and SPECIAL RP 220 / RP 320 FARMER A = B = fig. 25 Threading-in diagram for machines with BALERCONTROL III RP 220 / RP 320 MASTER / PROFI A = B = fig WELGER RP 202 RP 220 RP 302 RP 320

33 Cross Support 1. Guide twines A and B through to the guide rollers [8] as shown in fig Loop twine A anticlockwise once around the variable diameter disc [9]. 3. Finally locate each twine at the entry to their respective guide roller. 4. Turn the guide roller 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 (shown as a continuous line ) must be guided through the guide roller on the left-hand side, as seen from the direction of travel. 5. Tension both sets of twine once they have been threaded. A = B = fig. 27 WELGER RP 202 RP 220 RP 302 RP

34 Setting the twine brake Basic set up Spring length at the twine brake (fig. 28) BALERCONTROL E BALERCONTROL III (fig. 25) (fig. 27) Twine A (shown as continuous line ) 39 mm 33 mm Twine B (shown as dashed line ) 37 mm 28 mm The twines brakes [1] (fig. 25 and fig. 27) must hold the twines as taut as possible for the twine to be tight around the bales. Note: The permitted thread tension is exceeded when the twine breaks in the vicinity of the guide rollers [8] (fig. 27). fig WELGER RP 202 RP 220 RP 302 RP 320

35 Setting the edge clearances In order to limit the twine wrapping on the ends of the roll bale, the edge clearance retainers [1] are adjustable (the right side of the baler is shown in fig 30 and fig. 31, but the same applies to the left side):with very dry and brittle crops it is better if the retainers are located more towards the middle of the baler. fig Setting the distance between twine wrappings The distance between the wrappings is given by the diameter used for the variable diameter disc [9] (fig. 27). The smaller the effective diameter of the disc, the greater the distance between the wrappings. On the far right-hand edge of the cross-support is a lever [2] (fig. 29 and fig. 31), which is used to set the distance between the wrappings. Setting Position 1...greatest winding distance Position 7... smallest winding distance Setting the edge wrappings 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. fig. 30 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. An adjustable arm [3] (fig. 29) is installed in the right-hand shuttle, which is attached by two screws in a unit with a set of holes. There are four different installation settings available. Setting Switching angle (3) towards the variator disk more end windings on the edge of the bale Switching angle (3) towards the machine centre less end windings on the edge of the bale fig. 31 WELGER RP 202 RP 220 RP 302 RP

36 6. Net Wrapping* 6.1. Inserting the net In order to handle the net roll safely, insert it together with the help of a second person! Open all protective covers. fig. 32 If a wrapping process has not been completely executed (e. g. because the net roll depleted during the wrapping process): pull the grip of the knife carrier strongly forward against the spring tension (fig. 32). The counting segment for the net length is reset to its starting position. Release the handwheel [1] on the disk brake in counterclockwise direction Withdraw support pipe [2] from the holder. Remove empty hard paper core. Push net tensioner [3] to the rear and secure with cotter pin. Insert the net roll at first angularly above the two net roll grooves from the left side in the direction of motion (fig. 33). Slide the net roll onto the mandrel (on the right in the direction of motion) (fig. 34). fig. 33 Lift net roll on the left in direction of motion, push in and lock support pipe [2] (fig. 34). Align net roll laterally to the effect that it is positioned centrally to the roll chamber. Remove cotter pin from net tensioner and pull net tensioner to the front again. Tighten handwheel [1]. fig. 34 fig WELGER RP 202 RP 220 RP 302 RP 320

37 fig. 36 Guide the net from the roll around the upper deflection roller [4] and finally around the net tensioner [3]. Place the beginning of the net over the sideways tensioner [5] and then between the rubber roller [6] and steel roller [7]. Turn the rubber roller manually until the net is caught. So that the net does not prematurely enter the roll chamber during baling operation, the start of the net must not project more than approx. 10 cm. Move the net tensioner [3] forward into its working position. fig. 37 fig. 38 WELGER RP 202 RP 220 RP 302 RP

38 6.2. Tensioning the net cutting knife The net cutting knife is automatically tensioned (reset) each time the tailgate is opened. If a new net wrapping is required without opening the tailgate while the bale chamber is full, due to a net changeover or fault, the tensioning process can be done manually. This is done by pulling the knife holder forwards against the spring (fig. 39). It can be released as described in the Section Wrapping. fig Setting the net wraps With help from the scale (fig. 40), a variable number of net wraps around the roll bales can be set. After loosening the wing nut, the net length can be set by moving the nut within the slot. Tip: First, select the setting in the centre of the slot. To save binding material, adjust stepwise in the ( - ) direction for the following bales. fig. 40 However, the bales must still be held together securely. With very smooth material and a high pressing density, a greater amount of net may be needed. 34 WELGER RP 202 RP 220 RP 302 RP 320

39 7. Cutting Device* RP 220 RP 320 Depending on the model, the baler can be fitted with a 12-blade cutting device (MASTERCUT) or with a 23-blade cutting device (PROFICUT) or with a 25-blade cutting device. It can be used for silage, hay and straw. The cutting device is hydraulically moved in and out Cutting device operation fig RP 220 RP 320 MASTER / PROFI Read and observe the separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP Press the button on the BALERCONTROL panel. The symbol cutting device appears in the display field of the control panel (fig.43). 2. Activate the attached tractor control valve. (The actuating direction can be changed by swapping the connected hydraulic hoses.) fig When the blades are in the cutting position, the symbol cutting device also appears in the display field of the control panel. Or: When the blades are not in cutting position, the symbol cutting device crossed out appears in the display field of the control panel (fig.44). 4. In order to fill the hydraulic accumulators, operate the control valve for at least another 2 seconds. 5. In order to ensure free movement of the individual blades, it is recommended to move the cutting device in and out several times each day. fig.43 Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This activates at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked. fig.44 WELGER RP 202 RP 220 RP 302 RP

40 Remedy: 1. Keep the button depressed, while at the same time: 2. Activate the control valve for at least 3-4 seconds. 3. Repeat points 1 and 2 as needed until the blades are in the cutting position. Warning: The common protection for the cutter blades has been disabled by pressing the button! Finally, the blades must definitely be once again moved completely in and out without having to depress the cutting device button. Otherwise, the machine overload will result in a cancellation of the warranty! 36 WELGER RP 202 RP 220 RP 302 RP 320

41 RP 220 FARMER - RP 320 FARMER with cutting unit, with swivel floor Pick-up unit width 2.0 metres Activating the cutting device: 1. Open the shut-off valve on the left side of the baler (fig. 45), i.e. move the lever into the vertical position. 2. Activate the "raise" function on the connected tractor valve until the cutting device moves into its working position. (If the swivel floor (HYDROFLEXCONTROL) was open, it will also move upwards. 3. In order for the hydraulic accumulators to fill, continue to activate the control valve for another 5 seconds after the cutter blades have moved in. fig Close the shut-off valve (fig. 45), i.e. move the lever into the horizontal position. I Deactivating the cutting device: 1. Open the shut-off valve on the left side of the baler (fig. 45), i.e. move the lever into the vertical position. 2. Activate the "raise" function on the connected tractor control valve for about 5 seconds. Blades and conveyor channel floor will move downwards one after the other. 3. Close the shut-off valve (fig. 45), i.e. move the lever into the horizontal position Activate the "raise" function on the connected tractor control valve until the conveyor channel floor is completely closed. fig Tip: In order to ensure free movement of the individual blades, move the cutting device in and out several times each day. The shut-off valve (fig. 45) is only opened for moving the blades in and out. During normal operation the shut-off valve must always remain closed (position 0 in fig. 46). WELGER RP 202 RP 220 RP 302 RP

42 Hydraulic protection of the cutter blades Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure valve serving the cutter blades. This activates at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked. Remedy: 1. Move the ball valve under the left protective guard towards the back (shown in fig. 47 without the protective guards). fig Move the shut-off valve, on the left side of the baler, into a vertical position (fig. 48). 3. Activate the "raise" function on the connected tractor valve until the cutting device moves into its working position. 4. Once again activate the "lower" function on the connected tractor control valve until the cutting device and the conveyor channel floor are located in the lowest position. 5. Repeat points 3 and 4 as needed until the blades are operating smoothly. 6. Move the ball valve again towards the middle of the baler (fig. 47 and fig. 49). fig Activate the "raise" function on the tractor control valve until the cutting device is in its working position. 8. Close the shut-off valve (fig. 48), i.e. move the lever into the horizontal position. o. k. Warning: If the ball valve lever (fig. 47) is pointing towards the back, the common protection of the cutter blades is deactivated! After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler! (fig. 49) After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty! fig WELGER RP 202 RP 220 RP 302 RP 320

43 RP 220 FARMER RP 320 FARMER with cutting unit, with swivel floor Pick-up unit width 2.25 meters Attention: For daily operation the two ball valves must be positioned in parallel (see fig. 50)! Switching the cutting device on: 1. (Left machine side, fig. 50 and fig. 51:) Left ball valve of the hydraulic block must be set to position 35 bar. Right ball valve of the hydraulic block must point towards the machine. 2. Set the connected tractor control valve to Raise and leave it in this position until the cutting device moves to working position. 3. To enable the hydro accumulators to fill: continue to actuate the control valve for another 5 s approx. after the cutter blades have moved in. fig. 50 Switching the cutting device off: 1. (Left machine side, fig. 50 and fig. 51:) Left ball valve of the hydraulic block must be set to position 35 bar. Right ball valve must point towards the machine. 2. Set the connected tractor control valve to Lower for 5 10 s approx.. Tip: In order to ensure free movement of the individual blades, switch the cutting device on and off several times each day. fig. 51 WELGER RP 202 RP 220 RP 302 RP

44 Hydraulic protection of the cutter blades: Note: To safeguard the cutting device from overload the cutter blades are protected in common by a hydraulic pressure valve. This pressure valve responds when a factory-set pressure is reached.. I. e. this is also the only pressure which is available for switching on the blades. Depending on the conditions, the hydraulic pressure may be insufficient if the blade slots are clogged. Attention: For daily operation the two ball valves must be positioned in parallel (see fig. 52)! Remedy: 1. (Left machine side, fig. 52 and fig. 53:) Left ball valve must be set to position 180 bar. Right ball valve of the hydraulic block must point towards the machine. fig Set the connected tractor control valve to Raise and leave it in this position until the cutting device moves to working position. 3. Set the connected tractor control valve to Lower and leave it in this position until the cutting device disappears again in the swivel floor. 4. Repeat points 2 and 3 as needed until the blades are operating smoothly. 5. (Left machine side, fig. 52 and fig. 53:) Reset left ball valve of the hydraulic block to position 35 bar. fig Set the connected tractor control valve to Raise and leave it in this position until the cutting device moves to working position. 7. Set the connected tractor control valve to Lower and leave it in this position until the cutting device disappears again in the swivel floor. Attention: If the ball valve lever (fig. 54) points to the position 180 bar, the common protection of the cutter blades is deactivated! After raising of the cutter blades, the lever of the ball valve must be reset to the 35 bar position! It is absolutely necessary that finally the cutting device is once again lowered and raised (see points 2 and 3). Otherwise machine overload will result in cancellation of the warranty! fig WELGER RP 202 RP 220 RP 302 RP 320

45 RP 220 FARMER RP 320 FARMER with cutting unit, without swivel floor The cutting device is directly actuated with the double-acting tractor control valve. (The actuating direction can be changed by swapping the connected hydraulic hoses.) In order to ensure free movement of the individual blades, it is recommended to move the cutting device in and out several times each day. Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure valve serving the cutter blades. This responds at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked. Remedy: fig Move the ball valve under the left protective guard towards the back (fig. 55). 2. Activate the control valve until the blades are in the cutting position. 3. Move the ball valve once again towards the middle of the baler. 4. Move the blades once more in and out. Only after this process can the baler be brought into normal operation. o. k. Warning: If the ball valve lever (fig. 55) is pointing towards the back, the common protection of the cutter blades is deactivated! After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler! (fig. 56) After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty! fig. 56 WELGER RP 202 RP 220 RP 302 RP

46 7.2. Brittle crops It is recommended when baling brittle crops to hydraulically move the cutting device out of the cutting position before wrapping. The bales are then enclosed by long material and crumbling losses are avoided to a large extent Installation and removal of the cutter blades The cutting length for the pressed material can be adjusted by removing individual blades. All of the blades can be removed if the cutting function is not needed for a longer period of time: fig. 57 Warning: Danger of injury! Wear protective gloves when handling blades. If maintenance or assembly work is to be performed when the tailgate is open, then for safety reasons it is absolutely necessary that the tailgate be secured from lowering. Move the cutting device into the cutting position. Lower the HYDROFLEXCONTROL bottom flap* approximately halfway (fig. 57). Open the tailgate and secure it by using the cut-off valve (see chapter 2.3. Tailgate safeguard). Pull down the blade lock lever on the conveyor housing on the right-hand side (in the driving direction) by approx. 90 until it stops. From the roll chamber, pull out the blades using pliers diagonally up from the blade axle and remove it from the slot. Once removed, the blades can be stored behind the right door panel and secured in place with a plug-in split pin and a lever. (fig. 58). fig. 58 Note: Removed blades should be replaced by dummy blades* in order to prevent the slots from becoming blocked. (Part no ) 42 WELGER RP 202 RP 220 RP 302 RP 320

47 7.4. Sharpening the cutter blades In order to ensure an optimum throughput of crops, it is recommended that the cutter blades be sharpened after 500 bales have been cut at the latest. Depending on the operating conditions, sharpening may also be required sooner. Attention, danger of injury during work on the magnets of the knife holders! The function of cardiac pacemakers can be impaired by magnetic fields. Danger of injury by splinter: Never strike the installed blades from the bottom with a striking tool - magnets may be damaged! As described above, remove the blades and grind the cutting edge from the smooth side. Pay attention that the hardened cutting edges are not drawn when grinding. A grinder is available as a spare part. (Part no ) WELGER RP 202 RP 220 RP 302 RP

48 8. Field Use The roll baler is safeguarded against foreseeable accidents. In spite of this, necessary precautions must still be taken when working. Each time before use, check that all safety devices on the roll baler are in proper working order. Never attempt to correct malfunctions while the machine is in operation. Take special care when opening and closing the tailgate. Stay clear of swing area of the tailgate at all times. Before entering the bale chamber, lock the tailgate (fig. 3) Driving on the road Lift the pick-up unit to its highest position. Close the shut-off valve on the hydraulic hoses for the pick-up unit. The pick-up unit is now hydraulically secured in the transport position. For pick-up units with 2.25 m* width: Also move the pick-up unit support wheels into the park position (fig. 59). In order to avoid any danger to other road users, both rectangular tubes of the bale ejector must be pushed in and secured (fig. 60). fig Bale ejector* In order to prevent bales that have already been tied from remaining within the swing area of the tailgate, a bale ejector is mounted underneath the baling chamber. Prior to field use, both rectangular tubes should be pulled out from the parking position and secured with bolts and split pins. When working on a sloped surface the bale ejectors should remain in the park position Windrowing fig. 60 The full capacity of the baler and good bale formation can be only achieved by careful windrow preparation. Therefore the windrows should be laid down uniformly. The windrow width should be as follows: Pick-up unit width 1.50 m 2.00 m 2.25 m Optimal windrow width (approx.) 1.30 m 1.40 m 1.50 m 44 WELGER RP 202 RP 220 RP 302 RP 320

49 8.4. Pick-up unit RP 202 RP 302 CLASSIC / SPECIAL RP 220 RP 320 FARMER The pick-up unit is raised and lowered by operating the tractor control valve. Read and observe the separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320. RP 220 RP 320 MASTER / PROFI An electro-hydraulic manifold block (Hydraulic switch*) makes it possible to operate a number of different hydraulic functions with a single control valve. In order to raise or lower the pick-up unit, press the button (shown opposite) on the Balercontrol control panel (fig. 61). The symbol Pick-up appears in the display field of the control panel (fig. 62). The connected tractor control valve can now be used to actuate the pick-up lifting mechanism fig. 61 fig Support wheels* When on the field, set the pick-up unit support wheels to give the tines a ground clearance of at least 2 cm. To set the support wheels, raise the pick-up unit. Pull out the spring retainer [1] and align the bracket [2] with the desired hole (fig. 63); secure the support wheels once again with the spring retainer. Provide the same setting on both sides. fig. 63 WELGER RP 202 RP 220 RP 302 RP

50 Hold-down device / Pick-up unit short crop guard* For all types of pick-up unit, the hold-down device is movable and hangs over the pick-up drum. The height of the hold-down device rake can be adjusted by using the chain to allow for various windrow thickness. The upper end of the chain must always be hung on the hook in order to prevent it from being caught up in the pick-up unit Special Notes: RP 202 CLASSIC / RP 302 CLASSIC Pick-up unit width 1.50 m (fig. 64) As an optional feature, a pick-up unit short crop guard can be supplied (not shown). It prevents short baling crops from falling away ahead of the pick-up unit. fig. 64 For installation, locate both brackets of the pick-up short crop guard onto the inside of the hold-down device and secure on each side by using a spring pin. Adjust the setting by using the chain with swivel hooks. Set high or remove the pick-up unit short crop guard for long crops RP 202 SPECIAL / RP 302 SPECIAL Pick-up unit width 2.00 m (fig. 65) The hold-down device rods [1] should be parallel to the pick-up unit bottom plate. For adjustment, use the connecting bar [2] on the left side of the baler. 1 2 fig. 65 RP 220 and RP 320 Pick-up unit width 2.00 m and 2.25 m (fig. 66) For pick-up units with pick-up width of 2.25 m, both support wheels cover the sides of the rotating tines and therefore also form part of the installed safety equipment. When using the baler, both support wheels must be installed at all times. fig WELGER RP 202 RP 220 RP 302 RP 320

51 8.5. Feed guide plate The streamlined feed guide plate [1] is factory installed in the roll chamber. 1 Should material become jammed due to unusual crop conditions, then the feed guide plate may be removed. To do this, take out screws (arrow in fig. 67) on the right side (in the driving direction) and remove the plate from the roll chamber. fig Pto shaft speed Operate the baler with a standard pto shaft speed of 540 min -1. For extremely short or brittle crops, the baler can also work at lower pto shaft speeds ( min -1 ). Only universal drive shafts approved by the manufacturer may be used. The protective tube and cone of the universal drive shaft and the pto shaft protection device must be fitted and must be in sound working order Always check that the universal drive shaft is correctly installed and well secured! Secure the universal drive shaft guard by attaching the chain to prevent it from turning! Before starting the pto shaft, ensure that no person is within the danger zone of the machine! m 8.7. Driving with the baler To obtain high output and well-shaped round bales, an appropriate driving style is required so that the roll chamber is evenly fed with material over the entire baler width m For narrow windrows - i.e. the width of the windrow is narrower than the pick-up unit width - uniform feeding of the bale chamber can be achieved by driving into the left and right side of the windrow in an alternating fashion (fig. 68). When turning around sharp bends, ensure that the angle at the wide-angle joint (at the tractor) does not exceed 80. Otherwise there is a danger of breakage during operation and at rest. richtig correct correct fig. 68 falsch wrong faux WELGER RP 202 RP 220 RP 302 RP

52 8.8. Setting the bale density RP 202 RP 302 CLASSIC / SPECIAL RP 220 RP 320 FARMER There is a lever on the right-hand side of the baler to set the density. 1. With the side panel open, loosen the wing nut. 2. Shift the pointer to set the desired baling density within the range between + and Finally, screw on the wing nut once again. fig. 69 RP 220 RP 320 MASTER / PROFI (See separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320 ) 48 WELGER RP 202 RP 220 RP 302 RP 320

53 8.9. Locking the tailgate Before picking up the crop and after each bale ejection, the tailgate must be locked properly. To do this, keep the tractor control valve for tailgate actuation in the "lower" position. This will automatically lock the tailgate. For balers with net wrapping, the tractor control valve must be kept in the "lower" position for a further few seconds after the locking of the tailgate. This will reactivate the net wrapping. Note: So as not to place any unnecessary load on the hydraulic pump, leave the control valve in the floating position during pressing. RP 202 RP 302 RP 220 FARMER RP 220 FARMER The white pilot lamp (right front side of the machine) lights for as long as the tailgate is not locked. RP 220 RP 320 MASTER / PROFI A short signal tone informs the tractor driver that the tailgate is fully locked. WELGER RP 202 RP 220 RP 302 RP

54 9. Wrapping The following wrapping modes* can be selected manual wrapping (twine and net) automatic twine wrapping automatic net wrapping automatic combined wrapping (only for MASTER and PROFI) 9.1. "BALERCONTROL E Control Panel RP 202 RP 302 CLASSIC and SPECIAL RP 220 RP 320 FARMER The BALERCONTROL E control panel contains the following functions and displays. (fig. 70): No. Component Function V Green LED Correct power supply 2 Red LED Set bale density reached 3 Yellow LED Automatic net wrapping selected. (Flashes when the net clutch is in operation) 4 Yellow LED Automatic twine wrapping selected. (Flashes when the twine motor is in operation) 5 Button Changes between manual and automatic wrapping (manual: lights [3] and [4] go out). Depress for 5 seconds: resets the bale counter (DLC 1 ) to zero. 6 Button Trigger the net wrapping by hand 7 Button Trigger the twine wrapping by hand fig Display Top row: non-resetting life time counter (LTC 2 ); Bottom row: daily counter (DLC) can be reset; 9 buzzer Pre-selected bale density reached (on back side) 1 DLC = Daily Counter 2 LTC = Life Time Counter 50 WELGER RP 202 RP 220 RP 302 RP 320

55 Triggering the wrapping (BALERCONTROL E) When the pre-selected bale density is reached, the tractor driver is notified by the red LED [2] and the buzzer [9]. Depending on the selected wrapping mode, the wrapping is triggered either automatically or manually from the appropriate button (net [6] or twine [7]) Manual twine wrapping Selection: Depress button [5] several times until both yellow LED's go out. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds. While driving, depress the twine button [7]; the corresponding yellow LED flashes simultaneously. fig. 71 Stop driving the tractor approx. 5 to 10 seconds after depressing the twine button [7]. With normal P.T.O speed, allow the twine to wrap the bale. Check the twine is running by the detection pulleys (fig. 71). As soon as the detection pulleys stop, the wrapping process is finished Open the tailgate and eject the bale. Manual net wrapping Selection: Depress button [5] several times until both yellow LED's go out. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds. Stop driving the tractor and allow the pick up unit to clear. Depress the net button [6] for approx. 5 seconds; The corresponding yellow LED flashes. fig With normal P.T.O. speed allow the net to wrap the bale Check the net is running by the detection pulley (fig. 72). As soon as the detection pulley stops the wrapping process is finished. Open the tailgate and eject the bale. WELGER RP 202 RP 220 RP 302 RP

56 Automatic twine wrapping Selection: Depress button [5] (fig. 70) several times until the right yellow LED lights up. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The twine is automatically guided into the roll chamber. The corresponding yellow LED flashes simultaneously. The buzzer sounds about 4 seconds after triggering the twine wrapping. Stop driving the tractor at this point. With normal speed, allow the twine to wrap the bale. Check the twine is running by the detection pulleys (fig. 71). As soon as the detection pulleys stop, the wrapping process is finished. Open the tailgate and eject the bale. Automatic net wrapping Selection: Depress button [5] (fig. 70) several times until the left yellow LED lights up. Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds. Immediately stop driving the tractor and allow the pick up unit to run clear. About 4 seconds after the sounding of the buzzer, the net is automatically driven into the roll chamber. The corresponding yellow LED flashes simultaneously. With normal P.T.O. speed allow the net to wrap the bale. Check the net is running by the detection pulley (fig. 72). As soon as the detection pulley stops, the wrapping process is finished. Open the tailgate and eject the bale. Note: Should very brittle crops be wrapped with twine, the following procedures have shown to be advantageous: In order to tightly bind the start of the twine, quickly supply extra crop shortly after the wrapping process begins. After finishing the wrapping process, eject the bales at normal speed. 52 WELGER RP 202 RP 220 RP 302 RP 320

57 Combined net / twine wrapping In order to minimise crumbling losses and keep net consumption low, it is possible to use both types of wrapping simultaneously. Activate the baler for automatic twine wrapping (see page 44). Allow the twine wrapping to be triggered automatically. As soon as the yellow LED stops flashing, depress the net wrapping button. For combined wrapping it is sufficient to select a lower number of net wrappings and a larger distance between twine wrappings "BALERCONTROL III" Control Panel RP 220 RP 320 MASTER / PROFI 1 Read and observe the separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320. For wrapping operations, the BALERCONTROL III control panel contains the following functions and displays (fig. 73): No. Component Function 1 Display Display: Wrapping type, bale density, a.s.o Button <AUTO/MAN> Alternate between various wrapping types Button <NET> Trigger the net wrapping by hand 4 Button <TWINE> Trigger the twine wrapping by hand fig Buzzer (on back side) Pre-selected bale density reached WELGER RP 202 RP 220 RP 302 RP

58 Wrapping the bale Repeatedly depress the button <AUTO/MAN> on the control panel until the desired wrapping type is selected. The following sequence appears: fig. 74 Set to: manual wrapping (twine and net possible) Set to: automatic twine wrapping Set to: automatic net wrapping Set to: automatic combined wrapping Set to: manual wrapping (start setting) The selected setting is stored and will be used again automatically when the electronics are switched on. The following two pages show the relevant operating steps and the associated display on the control panel for each type of wrapping: 54 WELGER RP 202 RP 220 RP 302 RP 320

59 Twine wrapping, manually triggered: As soon as lock opens: Audible (3 sec.) signal when reaching the preselected baling density (visual: bar graph display of bale density raised to preset level). After bale ejection: Close tailgate again using the tractor control valve. After locking of the tailgate a signal sounds. While driving depress button <TWINE> : The bar graph display for the bale density has dropped to 0. Twine motor is switched on for 8 sec. after depressing button. Stop driving tractor After completion of the twine wrapping (twine movement sensors indicate stoppage): More crop can be once again added. A signal sounds. Then: Open tailgate with tractor control valve. WELGER RP 202 RP 220 RP 302 RP

60 Net wrapping, manually triggered: As soon as lock opens: Audible (3 sec.) signal when reaching the selected baling density (visual: Bar graph display for bale density raised to preset level). Stop driving the tractor and allow the pick up unit to operate freely. Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. The net cutting knife is automatically tensioned (reset) again when the tailgate is closed. Depress button <NET> until the net is grasped by the bale. The bar graph display for the bale density has dropped to 0. More crop can be once again added. After completion of the net wrapping (net cutting knife was operated): A signal sounds, Then: Open the tailgate using the tractor control valve. 56 WELGER RP 202 RP 220 RP 302 RP 320

61 Twine wrapping, automatically triggered: Wrapping starts without any action from the driver on reaching the pre-selected baling density. The driver will be signalled to stop driving by a continuous tone lasting for 3 seconds. This signal begins 2.5 sec. or 5 sec. after the start of wrapping. The delay can be adjusted in the set-up menu. After completion of the twine wrapping (twine movement sensors indicate stoppage): Net wrapping, automatically triggered: Wrapping starts without any action from the driver on reaching the pre-selected baling density. The driver will be signalled to stop driving by a continuous tone lasting for 3 seconds. This signal begins 2.5 sec. or 5 sec. before the start of wrapping. The delay can be adjusted in the set-up menu. The net clutch is activated for a period of 5 seconds. After completion of the net wrapping (net cutting knife was operated): A signal sounds. Then: Open tailgate with tractor control valve. As soon as lock opens: A signal sounds. Then: Open tailgate. As soon as lock opens: Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. Activate the control valve for a further 5 sec. so that the net cutting knife* is fully tensioned. The bar graph display for the bale density has dropped to 0. More crop can be once again added. The bar graph display for the bale density has dropped to 0. More crop can be once again added. WELGER RP 202 RP 220 RP 302 RP

62 Combined wrapping, automatically triggered: The "automatic twine wrapping" and the "automatic net wrapping" are started within 3 sec. of one another. (Twine wrapping first). Stop driving the tractor after the tone ("density reached") Multiple triggering of the wrapping: Automatic wrapping can only be triggered once. To reactivate, the tailgate must be once again opened. Manual wrapping can be triggered as often as desired without having to open the tailgate. When net wrapping is manually triggered for the second time, the following query appears Net cutting knife tensioned? If the button <NET> is depressed once more, wrapping starts again. Before beginning a new wrapping, check whether the net cutting knife has been reset. 58 WELGER RP 202 RP 220 RP 302 RP 320

63 9.3. Ejecting the bale After completing the wrapping process, open the tailgate hydraulically so that the bale rolls out. Keep the tractor control valve on "raise" until the tailgate has completely opened. If no bale ejector* (see fig. 9, No. 8) is fitted, then reverse by approx. 3 m before ejecting and then drive forward again up to the windrow before closing the tailgate. To close the tailgate, keep the tractor control valve on "lower" until the tailgate has been securely locked and when required, until the net wrapping* is once again tensioned. If possible move the tractor control valve into the floating position after actuation (only if floating position is available). For balers fitted with BALERCONTROL III there is also an audible confirmation tone. The control panel display again shows the initial start-up condition. The tailgate is now locked on both sides and collecting the crop can begin again for the next bale. Take special care when opening and closing the tailgate. Stay clear of swing area of the tailgate at all times. If the ground is uneven, the bale may start to roll or tip over onto its side. Employ suitable measure to eliminate this risk. All persons must move away from the bale s possible movement area. WELGER RP 202 RP 220 RP 302 RP

64 1 10. Overload protection / Reversing mechanism Universal drive shaft with shearing bolt clutch* A shearing bolt clutch is installed in the universal drive shaft on the baler side. In the event of overloading, the bolt [1] will shear and must be subsequently replaced by a new one. Only put the machine into operation again when the cause for the overload has been resolved Use original replacement parts only: fig. 75 Shearing bolt with nut Universal drive shaft with cam-type cut-out clutch* The cam-type cut out clutch limits the drive torque in the event of overload. Switch off the pto shaft and remedy the cause of the overload. After switching on the pto shaft, the torque increases once again, so that the baler can be put into operation. fig Avoid long and frequent overloading. Ensure that only the appropriate universal drive shaft is used Reversing the main drive RP 220 / RP 320 without HYDROFLEXCONTROL* Should the inlet section become blocked for balers without hydraulic bottom flaps (HYDROFLEXCONTROL), the main drive can be manually rotated backwards (fig. 77): Switch off the pto shaft Switch off engine and remove the ignition key fig. 77 Apply the crank lever delivered with the baler (46 mm jaw width) and rotate the drive backwards far enough so that the blockage in the inlet section can be removed; Before restarting the baler, remove the crank lever and close up all protective guards! 60 WELGER RP 202 RP 220 RP 302 RP 320

65 10.4. Hydraulic bottom flap* (HYDROFLEXCONTROL)* The hydraulically hinged conveyor channel floor has two hydraulic cylinders which help in extending the conveyor channel through to the roll chamber. Any congested material is thereby easily pulled through, grasped by the lower pressing roller and transported into the roll chamber. fig.78 What to do if material jams: RP 220 RP 320 MASTER / PROFI Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed! Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves! 1. Stop driving and switch off pto shaft. 2. If the cutting device was used, first press the button <CUTTING DEVICE> (fig. 79) and use the tractor control valve to swing the cutter blades away from the conveyor channel. The symbol for cutting device inactive appears in the display. 3. Press the button <BOTTOM FLAP> (fig. 80) and use the tractor control valve to open the conveyor channel floor. The fig. 79 flashing symbol for bottom flap open appears in the display. 4. Engage the universal drive shaft. 5. Return the bottom flap to the working position once the blockage has been removed (symbol bottom flap open disappears). 6. If the cutting function is required, the blades must be swung in once again. The symbol for cutting device active appears in the display. fig. 80 WELGER RP 202 RP 220 RP 302 RP

66 What to do if material jams: RP 220 FARMER / RP 320 FARMER Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed! Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves! If the cutting device was used: 1. Stop driving and switch off the pto shaft. 2. (Left machine side, fig. 81 and fig. 82:) The right ball valve of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine. fig Set the connected tractor control valve to Lower and leave it in this position until the blades move into the bottom flap. 4. Reengage the pto shaft. The material jam is automatically removed by the running conveying elements. If the material jam has been removed, see work steps 5 and 6. If swivelling-back of the cutting device is not sufficient to remove a material jam: open and close the bottom flap (please continue on the next page now). 5. Set the connected tractor control valve to Raise and leave it in this position until the blades move to working position. fig To enable the hydro accumulators to fill: actuate the control valve for another 5 s. approx. after the blades have moved in. 62 WELGER RP 202 RP 220 RP 302 RP 320

67 Opening the bottom flap: 1. Stop driving and switch off the pto shaft. 2. (Left machine side, fig. 81 and fig. 82:) The right ball valve of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine. 3. Set the connected tractor control valve to Lower and leave it in this position until the bottom flap moves down and opens completely. 4. Engage the pto shaft: The material jam is automatically removed by the running conveying elements. Then close the bottom flap. Closing the bottom flap: 1. Set the connected tractor control valve to Raise and leave it in this position until the bottom flap moves up and closes completely. 2. To enable the hydro accumulators to fill: actuate the control valve for another 5 s. approx. after the bottom flap has closed. Attention: For daily operation the two ball valves must be positioned in parallel (see fig. 81)! 3. (Left machine side, fig. 81 and fig. 82:) The right ball valve of the hydraulic block must point again towards the machine. The left ball valve of the hydraulic block must point towards the machine. Attention: When the bottom flap is being closed, the blades move automatically to working position. If you want to work without blades, they must subsequently be moved to home position again: see chapter 7. Cutting Device! WELGER RP 202 RP 220 RP 302 RP

68 11. "BALERCONTROL"* Not only the control unit (only with BALERCONTROL III), but also the operating control panel, as well as the associated program, all have their own serial numbers. In order to process future enquiries, it is necessary to state the serial / version numbers. Therefore please enter these numbers below upon delivery: BALERCONTROL E Component Version number How do I find the version number? Control panel program (Software)... By switching on the power supply before the counters are displayed. BALERCONTROL III Component Serial number How do I find the serial number? Control panel (hand set) SW.Rev... dd... By switching on the power supply while keeping any control panel buttondepressed. Control unit Serial No.... SW version... SW date... Memory... Press button several times until "Systeminfo" appears in the display. 64 WELGER RP 202 RP 220 RP 302 RP 320

69 11.1. Your Safety The "Balercontrol" control system was designed and manufactured with utmost attention to details and maximum precision. Each unit has been checked and tested for correct functioning before delivery. Despite all the precautions, a malfunction can still occur. Therefore, the "Balercontrol" control system and associated baler should be always operated in such a manner that prevents damage to person or property. Never carry out adjustments, repairs, maintenance and service work on the "Balercontrol" while the machinery is running. Always first stop the pto shaft and detach the universal drive shaft from the power take off stub before working on the baler or near moving baler components. A safety clearance from the machine must be maintained during baler control diagnosis Protection of the electronic control system All assembly and maintenance work (connection and disconnection of sensors, valves, control panels etc., replacing of fuses) must be carried out with the power supply disconnected. "Balercontrol" is designed to operate with a 12 volt power supply. The system must not be connected to other on-board power supplies! The "Balercontrol" control panel should at all time be in a position where it is protected from water spray (tractor cab or the baler twine compartment, with the cable outlet pointing downwards). When welding on the baler: - Do not allow the welding current to pass through the control unit. - Disconnect the power supply between the tractor and baler. - Be careful of heat generated at welding points; detach any potentially sensitive components (cables, sensors etc) before welding. WELGER RP 202 RP 220 RP 302 RP

70 The "BALERCONTROL III" Control Panel RP 220 RP 320 MASTER / PROFI Important baler functions can be controlled and monitored with the control panel remotely from the tractor. Read and observe the separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320. The control panel (fig. 83) consists of: LCD graphic display Keypad with 9 buttons Audible buzzer on the back side of the panel After connecting the power supply the signal sounds and various information about the system appears on the display one after the other. After approx. 4 seconds the final display appears. fig Menu structure (See separate operating manual BALERCONTROL III with Graphic Display for RP 220/RP 320 ) 66 WELGER RP 202 RP 220 RP 302 RP 320

71 12. Maintenance / Settings General instructions After about the first 20 operating hours: tighten all fastening screws, wheel nuts, drawbar screws and nuts, including those inside the machine. When doing so, do not change adjustment screws, e.g. on the twine guide or the net brake. Danger of falling! Never step on the maintenance platform of the moving machine. Before you step on the maintenance platform: Stop the machine, switch off power-takeoff shaft and motor engine and wait until the machine has stopped Environment/Disposal Lubricants Always dispose of lubricants properly and do not allow them to pollute the environment. Observe the safety data sheets of the lubricants used. Biologically degradable lubricants must be disposed of separately. 1 litre of oil contaminates 1 million litres of water. 1 litre of oil contaminates 10 cubic metres of soil. Consumables Any twines, nets, foils and machine parts thrown away are polluting. They particularly endanger the animal world. Therefore: Dispose of twines, nets, foils and machine parts properly! Clamping elements (fig. 84) The gear wheels [2] of the main drive roller [1] are installed on the roller end by means of clamping elements. Any work on the clamping elements [3] may only be carried out by instructed expert personnel. fig. 84 WELGER RP 202 RP 220 RP 302 RP

72 12.4. Maintenance of the net wrapping system* Setting the disc brakes In order to prevent the net roll from running on, the disc brake must be set such that the brake disc can no longer be turned by hand when the lever [1] is vertical In order to do this, undo screw [2] on the lever [1], tighten up knurled nut [3] until the brake linings lie snugly on the disc. Tighten up screw [2] once again fig. 85 If there is excessive wear on one side of the brake disc lining [4], undo the lock nut [5], turn the screw [6] until the brake linings are parallel again and re-apply the lock nut [6] fig WELGER RP 202 RP 220 RP 302 RP 320

73 Setting the oscillation damper The motion of the net tensioner [12] is braked with an oscillation damper on the left side of the baler. Two wing nuts (arrows in fig. 87) press the friction pads against the net tensioner from both sides. To set the net tensioner, first of all move it into its highest position and do up the wing nut "finger-tight". Do the same for the lowest position. The setting is correct when the net tensioner can still just be moved up and down by hand between the two limiting positions. 12 When operating the net wrapping system, the net tensioner should move slowly enough between the two end positions so that the net always remains tensioned fig. 87 Danger of injury! Never reach into the cutting knife area Standby wrapping operation In the event of a defect in the electronic control system, the twine or net wrapping unit can be operated using the electric lighting system. The plug-in connection [1] that protrudes from the cable harness on the right side of the baler is used for this Emergency operation of the net wrapping unit (BC III and BC E)* The black connection plug [1] of the electrical net clutch is simply plugged into the free white plug connection [2]. To trigger the net wrapping process, briefly switch on the parking light (or the passing beam or full beam) until the net is caught by the bale (recognisable by the faster rotation of the net roll). fig Emergency operation of the twine wrapping unit (BC III only)* The red connection plug [3] for twine wrapping is simply plugged into the free white plug connection [2]. To trigger the twine wrapping process, briefly switch on the parking light (or the passing beam or full beam) until the twine is caught by the bale. This emergency operation requires that the main power supply system between tractor and machine works properly. Note: Interrupt the provisional electrical connection for the net or twine wrapping unit if the vehicle lighting is to be switched on for a long duration, e.g. when driving on the road. WELGER RP 202 RP 220 RP 302 RP

74 12.6. Balercontrol components RP 220 RP 320 MASTER / PROFI fig.89 No. No. 1 Control unit 10 Magnet, net wrapping* (N) 2 Sensor cutting device (S) 1) 11 Motor, twine wrapping* (G) 3 Pressure switch (D) 1), opener at 35 bar 12 Hydraulic switch 1) A (0) 4 Sensor, right lock (R) Ø 30 mm 13 Hydraulic switch 1) A1 (1) 5 Sensor, left lock (L) Ø 30 mm 14 Hydraulic switch 1) A2 (2) 6 Sensor, bottom flap (G) 15 Hydraulic switch 1) A4 (4) 7 Sensor, right twine run (1) 16 Left clearance sensor, yellow (L) 8 Sensor, left twine run (2) 17 Right clearance sensor, yellow (R) 9 Sensor, net cutting knife (N) 1) Only for models with a cutting device 70 WELGER RP 202 RP 220 RP 302 RP 320

75 12.7. Hydraulic diagrams RP 220 RP 320 MASTER / PROFI P2 P2 Hydraulic switch P 0,7 mm P Screw valves must be closed A4 A2 A1 A A B Release valve opens at 35 bar Pick up BALER- CONTROL Bottom flap closed open 2x bar Cutting device Cutting position Rest position Circuit Logic fig. 90 Solenoid valve Control valve Blade Bottom Switch position A A1 A2 A4 P P2 Cutting Pressure switch closed device Pressure switch open open closed closed open closed closed closed open Cutting position Rest position closed Bottom flap closed closed open open Rest position open closed Pick-up unit closed open closed closed Symbol: = voltage at solenoid valve = line is pressurised WELGER RP 202 RP 220 RP 302 RP

76 RP 220 FARMER RP 320 FARMER with cutting unit and without swivel floor fig. 91 Note: During baler operation, the changeover valve "U" must always point towards the machine centre. 72 WELGER RP 202 RP 220 RP 302 RP 320

77 RP 220 FARMER RP 320 FARMER with cutting unit and swivel floor 2.00 m pick-up unit only (see Table 1) fig. 92 Note: During operation, the shut-off valve [1] must be closed, otherwise the floor may lower itself. During baler operation, the changeover valve "U" must always point towards the machine centre. WELGER RP 202 RP 220 RP 302 RP

78 RP 220 RP 320 FARMER / MASTER / PROFI with cutting unit and swivel floor 2.25 m pick-up unit only (see Table 1) fig. 93 Note: During baler operation, the changeover valve "U" must always point towards the machine centre. 74 WELGER RP 202 RP 220 RP 302 RP 320

79 12.8. Sensor settings* There are three types of sensors installed: No. Designation Application RP 220 RP 320 RP 202 RP 302 Setting 1 Sensor M mm Cutting Device* Bottom flap* Right twine run Left twine run MASTER PROFI - 0,5-2,0 mm 2 Sensor M mm Lock, right Lock, left Net cutting knife* MASTER PROFI - 5 mm Basic density setting FARMER CLASSIC SPECIAL only possible using special tools Part No.: and: Clearance sensor (yellow) 20 mm Tailgate clearance, right Tailgate clearance, left MASTER PROFI - only possible using special tools Part No.: and: WELGER RP 202 RP 220 RP 302 RP

80 12.9. BALERCONTROL III - Quick check RP 220 RP 320 MASTER / PROFI Step 1 Plug in the power supply connector;... The control panel sounds a bleeps Display lights up The start-up message appears on the display Monitoring display appears Does the BALERCONTROL accept commands, e.g. density selection?... Step 2 Mode: Start SETUP Check the settings: Dialog language... Baler type... Delay 2.5 or 5 seconds... Step 3 Mode: Start SYSTEMINFO View hardware and software and note as required... Step 4 Mode: Start DIAGNOSIS (alternatively: AUTO DIAGNOSIS) In DIAGNOSIS / SENSOR, activate/deactivate each sensor, i.e. hold metal in front of sensor and away from sensor; check for function, setting and correct position in the display;... In DIAGNOSIS / ANALOG, check the electrical values Set values: a) unloaded: (0), approx.100 to 160, max. total of b) at maximum load: approx. 244 (10) DIAGNOSIS / ACTUATOR, check all actuators for -/- and +/+... In DIAGNOSIS / VOLTAGE, check the operating voltage Voltage drop not greater than 1-2 Volts... Voltage under load not less than 11 volts WELGER RP 202 RP 220 RP 302 RP 320

81 Pin-outs of control unit RP 220 RP 320 MASTER / PROFI WELGER RP 202 RP 220 RP 302 RP

82 Chain lubrication (oil lubrication) The mechanical chain lubrication system supplies the drive chains of the machine with oil. Check the oil level in the lubrication oil tank daily (visual inspection). Never let the lubrication oil tank run completely empty. Warning! Check oil level daily. Avoid complete emptying. Otherwise air may enter the distribution system and the pump may possibly reach its full capacity only after some time. Oil type: see chapter Lubrication chart. If required: refill oil: fig. 94 Unscrew tank lid. Refill oil up to the Max mark. Screw down tank lid again. Check sieve in the lubrication oil tank for soiling or blockage (visual inspection). If necessary: clean tank sieve: Unscrew tank lid. Remove tank sieve. Thoroughly clean the tank sieve using exclusively benzine or paraffin oil. Insert tank sieve and screw tank lid down again. Subsequently: Check oil level in oil tank. Warning! Never use for cleaning: Tri, Per, Methanol, Acetone or other polar, organic solvents. 78 WELGER RP 202 RP 220 RP 302 RP 320

83 Roller lubrication (grease lubrication) The electrical roller lubrication system supplies the baling rollers of the machine with grease. The electrical roller lubrication system runs continuously as long as the machine is connected to power supply. Therefore: When the machine is not in use (e. g. longer downtimes,, driving on the road, power supply must be interrupted (pull plug). Please observe the separate operating instructions for the roller lubrication system (attached to the lubricant tank). Check filling level in the lubricant tank daily (visual inspection). Do not allow the level to drop below the minimum mark. Warning! Do not allow the level to drop below the minimum mark. Otherwise air may enter the distribution system, and deairing may become necessary. Grease type: see chapter Lubrication chart. If necessary: Refill grease: Clean filling nipple on lubricant tank. fig. 95 Fill lubricant tank via the filling nipple using a lever-type grease gun. WELGER RP 202 RP 220 RP 302 RP

84 Lubrication chart after every 500 bales (or daily) Item (fig. 96) Baler component Lubricant (Table 4) 1 Universal drive shaft A Remark 2 Chain lubrication B Right side of baler (fig. 94 and fig. 96) 3 Tailgate hinge1) A Both sides 4 Lubricating manifold*, left front A 2) Lubricating manifold*, right front A 2) not shown in fig Lubricating manifold*, left rear A 2) Lubricating manifold*, right rear A 2) not shown in fig Locking hook 1) A Both sides 7 Locking roller A Both sides 8 Cutting rotor* 1) A Both sides 9 Swivel wheels* A Both sides 10 Tailgate guide dome A On right side of baler: grease 11 Pick-up unit 2.00 m (SPECIAL): bearing of actuator (1x) bearing of rake shaft (2x) Sliding bearing of rake (2x) A not shown in fig Roller lubrication F Right side of baler (fig. 95 and fig. 96) 1) depending on the fitted equipment, already served by central lubricating manifold 2) Supply the lubricant distributor with 1-2 cautious strokes from a hand lever grease gun do not use a compressed air grease gun. yearly after the end of season (weekly under extreme operating conditions) Item (fig. 96) Baler component Lubricant Remark 12 Star ratchet in the pick-up unit drive A For 1.50 m pick-up, only installed outside the EU 13 Main gear box RP 202 / RP 302 RP 220 / RP 320 RP 220 / RP 320 ( V V ) 3) C / 1,65 l C / 1,50 l C / 2,00 l Oil change Check oil level with dipstick or overflow hole 14 Moveable parts of the net wrapping system* D Keep running smoothly 15 Moveable parts of the twine wrapping system* D Keep running smoothly 16 Locking hook disc spring E Dismantle, clean and grease; Warning: do not change sensor settings! 17 Twine guide eyes A Lightly grease chafe mark 3) Gearbox is labelled on the top side with the letters "V V" 80 WELGER RP 202 RP 220 RP 302 RP 320

85 Schematic diagram of the lubricating positions fig. 96 Lubricant Trade name, e. g. A Multi-pupose 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 Oil according ISO VG 68 ISO VG 220 (non thickening) B Chain-adhesive oil Optimol Non Fluid 150 C Gear oil SAE 90 D Machine oil E Multi-pupose grease Gleitmo 810 F Multi-pupose grease Multi-pupose grease according NLGI-Class 2, with high-pressure additive, without solids Table 4: Specification of lubricants WELGER RP 202 RP 220 RP 302 RP

86 Never carry out adjustments and repairs, or maintenance and service work on the baler while it is running. Switch off engine and remove the ignition key Wait for the baler to stop. Switch off the pto shaft and disconnect the universal drive shaft from the pto shaft before working on the moving parts of the baler. If maintenance or installation/assembly work is performed with the tailgate open, it is essential to secure the tailgate to prevent it from falling. Use the cut-off valve on the right side of the baler for this purpose. When it is in a locked state, the operating lever is at right angles to the direction of flow (fig. 3). The shut-off valve may only be actuated from the open right hand side guard door Setting the dividing plates In order to prevent binding material from coming out of the roll chamber, two dividing plates [1] were built into the area near the front rollers (fig. 97). Upon loosening the fastening screws in the side walls, the dividing plate clearance to the rollers can be set. For correct setting, the longitudinal section of the operating rollers should just about gently strike the dividing plates. Finally tighten the screws once again fig WELGER RP 202 RP 220 RP 302 RP 320

87 fig Roller drive chains The chains of the roller drives must be tensioned so far that the spring plates are approximately flush with the measuring angles (fig. 99 and fig. 100). WELGER RP 202 RP 220 RP 302 RP 320 fig. 99 fig. 98 Rotor drive chain The double chain of the rotor drive must be tensioned so far that the distance between the two pulleys is about 70 mm (fig. 98). Note: New chains will lengthen shortly after placing them into operation. Therefore these can be tensioned a little more than usual. Proper chain tensioning reduces wearing of chains, chain wheels and bearings on rollers. The tension of the chain should be checked at the latest every 500 bales and re-adjusted as required Tensioning the roller chain

88 Main drive chain The main drive chain must be tensioned so far that the distance between the upper and the lower pulley is about 90 mm (fig. 101). fig. 101 Worm and pick-up drive chain Chain tensioning of the worm and pick-up drive chain is effected by a silentbloc chain tensioner and two tensioning blocks (fig. 102). After loosening of the screw on the square block the silentbloc must be turned to the effect that the arrow reaches 15 on the scale. Then retighten the screw. After loosening the screw connection, tension the tensioning blocks (one each on the left and on the right machine side) so far that the upper strand of the chain (above the tensioning block) can still be depressed by about 10 mm. fig Winter break Before a winter break: Remove all crop residues from the machine. Thoroughly lubricate all bearings. Remove, grind and reinstall cutter blades. Grease wrapping unit. Check and if necessary adjust air pressure. 84 WELGER RP 202 RP 220 RP 302 RP 320