RP 220 / RP 320 WELGER RP 220 MASTER

Transcription

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

2 Contents 1. Model Overview Your Safety Component Overview Putting Into Operation Twine wrapping* Net Wrapping* Cutting Device* Field Use Wrapping Overload protection "BALERCONTROL"* Maintenance / Settings Technical Data...78 The machine number is entered onto the data plate shown opposite and is located on the right hand side of the baler. Warranty claims and enquiries cannot be processed without this number. Please enter this number here below immediately after delivery: Ident - Nr. max. Ges. Gewicht/Gross Weight max. Achslast/Axle Load Typ Ausführung max. Stützlast/Imposed Load Höchstgeschw./max. Speed Baujahr/Year of Manufacture Lely Welger Maschinenfabrik GmbH Gebrüder - Welger-Str. 3 D Wolfenbüttel Made in Germany Read the operating manual and safety instructions before putting the baler into operation. We have inserted a warning sign in this operating manual at points concerning your safety. Please also pass on all safety instructions to other users. The warning and instruction plates on the baler provide important information for safe operation. Paying attention to them is for your own safety! * Please note that the features marked with a [*] in this operating manual are fitted only to some models as standard or are only available for particular models as additional features. These features may also not be supplied to all export countries. Reproduction prohibited - all rights reserved. Design and construction subject to alterations. The illustrations shown are non-binding for model, form and equipment by Lely Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany. Lely Welger Maschinenfabrik GmbH Postfach Wolfenbüttel / Germany Telephone: +49 (5331) Fax: +49 (5331) servex.lely-welger@t-online.de Manufacturer:

3 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. (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: Post code: City: (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. (5) Address of sales partner/importer Date Customer s signature Company stamp/signature Company stamp/signature if different to (5) (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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5 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 SPEEDMASTER RP 320 SPEEDMASTER Pick up unit width Cutting device Conveyor Bottom RP 220 PROFI RP 320 PROFI Wrapping RP 220 SPEEDPROFI RP 320 SPEEDPROFI Control Table 1 1,50 m 2,00 m (Feeder) 2,00 m (annular-tubed rotor) 2,25 m O O O MASTERCUT 12 blade PROFICUT 23 blade bolted HYDROFLEXCONTROL spring-loaded a. hydr. actuated VARIOTWIN Twine wrapping VARIONET Net wrapping = Standard equipment = Special equipment O O O O O O O O O O O O O O O O O O O O BALERCONTROL E BALERCONTROL III WELGER RP 202 RP 220 RP 302 RP 320 1

6 2. Your Safety All the protective devices such as the safety covers, rubber aprons or safety brackets are provided for your safety! Never operate the baler with defective safety devices or if the safety devices have been removed! Always keep components which are relevant to safety in a suitable condition. All guards must be fitted and closed before putting the baler into operation! Never carry out adjustments, repairs or maintenance and service work on the baler while it is running. Always first stop the power take off (pto) shaft, detach the universal drive shaft from the pto shaft stub and disconnect the electrical connection between the tractor and the baler prior to working on any of the baler s moving parts. Never try to remove hay, straw or other harvested crop from the baler while it is running. Always first stop the pto shaft, and switch off the tractor engine. While work is in progress, only the driver should be on the tractor. Passengers are not allowed on the baler! Do not climb on the drawbar or other parts of the baler when it is in operation. Also, keep your distance from the pick-up unit. Do not reach into the working area of the transport units. Before threading in the binding material, switch off the baler drive and tractor engine and remove the ignition key All protective guards must be fitted to the baler and must be in sound condition. Before opening the guards, stop the pto shaft and the tractor engine, remove the ignition key and wait until the baler has stopped. Before detaching the baler from the tractor, secure it with the aid of the chocks to prevent it from rolling away. Carry the chocks with the baler when the baler is transported or used. Upon opening the tailgate, maintain at least 2 metres safety distance from the high voltage cables. All maintenance and repair work beyond that described in the descriptions in these operating instructions must always be carried out by authorised persons. Wear parts of the brake system must always be replaced on both sides. Secure the baler from tipping backwards before detaching the complete pick up unit. Warning! The baler is inherently dangerous even if all the points listed above are followed exactly. Therefore always take care when working with the baler to avoid endangering yourself or other people! 2.1. 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. 2 WELGER RP 202 RP 220 RP 302 RP 320

7 fig 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. 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. fig. 2 Return the valve to its original position after completing maintenance and installation/assembly work (fig. 2). fig WELGER RP 202 RP 220 RP 302 RP 320 3

8 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. 6 4 WELGER RP 202 RP 220 RP 302 RP 320

9 2.6. Warning symbols Explanation of the symbols Danger areas which cannot be made safe by design measures are identified by yellow warning symbols. Since these are signs without texts in most cases, their precise meaning is described below. The warning symbols must always be kept in a recognizable state. If there are no warning symbols on your baler or if they are damaged, replace them (see also Spare parts list, Section F). Warning symbol Description/Spare part No. Read and adhere to the operating manual and safety notes before starting up for the first time. Spare part No.: Close protective guards before putting baler into operation! Spare part No.: Never reach into the baler pick-up area as long as the tractor engine is running with the pto shaft connected. Spare part No.: Always switch off the engine and remove the ignition key before starting any maintenance and repair work. Spare part No.: WELGER RP 202 RP 220 RP 302 RP 320 5

10 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

11 Where to locate the warning signs fig WELGER RP 202 RP 220 RP 302 RP 320 7

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

13 2.8. Proper Use The baler has been built exclusively for producing bales compressed from agricultural straw material lying on the ground (proper use). Usage beyond this does not constitute proper use. The manufacturer is not liable for damage resulting from improper use; the user alone bears the risk. Proper use also includes compliance with the operating, maintenance and servicing conditions specified by the manufacturer. The baler may only be used, maintained and repaired by persons who are familiar with working with such machines and who have been informed of the dangers. The attachment of auxiliary equipment to the baler, other than at the factory pre-set positions, is prohibited. Only auxiliary units approved by the manufacturer may be used. The relevant accident prevention regulations, regional safety standards and other generally recognized safety regulations are to be observed. Unauthorized alterations and the installation of non-approved parts and equipment on the baler exclude the manufacturer from any liability 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 320 9

14 2.10. Precautions for driving on the road Before driving on the road... the baling chamber must be completely emptied (in accordance with Road Traffic Vehicle Registration Regulations (RTVRR); the baler must be cleared of any harvested crop attached to it; the universal drive shaft must always be fitted to the tractor pto shaft; the tubes of the bale ejector* must be pushed in. the lighting equipment of the attached machinery must be connected to the tractor and its function checked (also in daylight); the support wheels of the pick-up unit must be detached (working width 2.25 m) and placed in the park position. Information shall be requested from the manufacturer before the baler is operated using attached machinery (e.g. bale wrapping device). The wheel chocks, which are part of the safety equipment (two in number), are to be carried on the baler at all times. The permissible maximum speeds for individual components (e.g. the drawbar or the axle) do not affect the maximum permitted speed limit for the entire baler (see 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. 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. 10 WELGER RP 202 RP 220 RP 302 RP 320

15 Details on the rating plate 6 1 Ident - Nr. Typ Ausführung 7 2 max. Ges. Gewicht/Gross Weight max. Stützlast/Imposed Load 8 3 max. Achslast/Axle Load Höchstgeschw./max. Speed 9 4 Baujahr/Year of Manufacture 10 5 Lely Welger Maschinenfabrik GmbH Gebrüder-Welger-Str. 3 D Wolfenbüttel Made in Germany fig. 8 Item Meaning 1 ID number individual machine number. Always quote in the event of queries 2 Permissible total weight for operation on public roads. The machine s actual weight can be less. 3 Permissible axle load for operation on public roads 4 Machine s year of construction 5 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 WELGER RP 202 RP 220 RP 302 RP

16 12 V 3. Component Overview 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* 12 WELGER RP 202 RP 220 RP 302 RP 320

17 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. WELGER RP 202 RP 220 RP 302 RP

18 Drawbar configuration (all dimensions in [mm]) A 130 C - 5 A CB B - 5 A - 2 RP B - 6 A - 3 B - 7 A - 4 B - 8 fig A C A CB B - 5 A B - 6 RP A - 3 B - 7 A - 4 B - 8 fig WELGER RP 202 RP 220 RP 302 RP 320

19 RP 220 RP fig Adjusting the trailer hitch Any adjustment in the height set-up, and therefore a displacement in the drawbar eye position, shall only be carried out by the manufacturer or an approved specialist workshop. fig. 13 fig. 14 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. Measure the height of the tractor towing hitch; Measure the height of the baler drawbar eye. With reference to Figure 10 to Figure 12 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. WELGER RP 202 RP 220 RP 302 RP

20 D7 1 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 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 blacket 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: D8 Component see Tension moment 3 1 Bracket, (RP 202 / RP 302) Fig Nm fig. 16 Bracket, strengthened Fig Nm Drawbar eye Fig. 15 and Fig 16, Pos. 1 Table 2: Tension moment 350 Nm 16 WELGER RP 202 RP 220 RP 302 RP 320

21 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 Figure 17 and Table 3. are not permitted!danger of breakage! fig. 17 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 Figure 13) 2) The upper part of the tow hitch can be dismantled to comply with dimension c. Dimensions are in millimeters Table 3: Dimensions, location and support load of the tow hitch WELGER RP 202 RP 220 RP 302 RP

22 4.2. Universal drive shaft Grease Graisse Connecting the cam-type cut-out clutch* Depending on the model, the universal drive shaft is fitted with an automatic overload safety cut out (cam-type cut-out clutch). Clean and grease the splines of the connecting shaft before installation. Undo and pull out the clamping cone [1] fig 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

23 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) Lmin LU a) Shortest operating length, i.e., fully covered b) 2/3 LU b) During normal operation, the overlap of the tube section should be at least 2/3 of the overlap LU. c) Lmax fig. 21 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. 22 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. 23 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

24 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 w/o CD RP 302 RP 320 w/o CD Raise and lower pick up single-acting red OIL RP 220 Activate floor flap and RP 320 (only FARMER) cutting knife doubleacting green OIL OIL OIL RP 220 w. CD RP 320 w. CD Hydraulic switch with the functions floor flap* double- red pick up unit acting cutting device* CD = Cutting Device* 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 color identification used for the hydraulic hoses to the couplings at the tractor end. 20 WELGER RP 202 RP 220 RP 302 RP 320

25 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! 4.4. Electrical system Lighting To connect the lighting system, insert the 7-pin plug into the corresponding socket on the tractor. Before travelling on the road check that the lighting system functions correctly (also in daylight). Balercontrol E RP 202 RP 302 RP 220 FARMER RP 320 FARMER 12 V "Balercontrol" Electronic Controller The control panel is provided with a plate which should be fastened within easy reach of the tractor driver. The control panel of the Balercontrol control system is also provided with a magnetic plate on the rear and can be attached to a metallic surface within easy reach of the driver. Once the plug is inserted in the socket, power is supplied to the unit and a short sequence of beeps is heard Balercontrol III fig. 24 Note: When connecting the Balercontrol electronic controller, a power socket conforming to DIN 9680 must be fitted on the tractor. (Supplied with the baler.) The fuse rating must be 16 A. The socket with connecting cable and fuse can be supplied under WELGER part No as a retrofit part for an additional tractor. RP 220 RP 320 MASTER PROFI SPEEDMASTER SPEEDPROFI fig. 25 WELGER RP 202 RP 220 RP 302 RP

26 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 WELGER RP 202 RP 220 RP 302 RP 320

27 Threading-in diagram for machines with BALERCONTROL E RP 202 / RP 302 CLASSIC and SPECIAL RP 220 / RP 320 FARMER A = B = fig. 26 Threading-in diagram for machines with BALERCONTROL III RP 220 / RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI A = B = fig. 27 WELGER RP 202 RP 220 RP 302 RP

28 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 WELGER RP 202 RP 220 RP 302 RP 320

29 Setting the twine brake Basic set up Spring length at the twine brake (fig. 29) BALERCONTROL E (fig. 26) BALERCONTROL III (fig. 27) Twine A (shown as continuous line ) Twine B (shown as dashed line ) 39 mm 33 mm 37 mm 28 mm The twines brakes [1] (fig. 26 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. 28). fig. 29 WELGER RP 202 RP 220 RP 302 RP

30 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. 28). 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. 30 and fig. 32), 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. 31 In order to achieve this, the right-hand shuttle [4] (fig. 30) 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. 30) 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 WELGER RP 202 RP 220 RP 302 RP 320

31 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. First place the net roll at an angle over both net roll recesses from the left side (Fig. 33). Unscrew the hand-wheel [1] on the disc brake anti-clockwise. Pull out the axle tube [2] from its mounting. Push the net tensioner [3] backwards and lock with a plug-in split pin. Push the net roll onto the spindle to the right (in the driving direction) (fig. 35). fig. 33 Lift the net roll onto the left side of baler, push in and lock the axle tube [2] (fig. 35). Align the net roll sideways so that it is in the middle of the roll chamber. Screw the hand-wheel [1] on the disc brake clockwise. fig. 34 fig. 35 WELGER RP 202 RP 220 RP 302 RP

32 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 WELGER RP 202 RP 220 RP 302 RP 320

33 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. WELGER RP 202 RP 220 RP 302 RP

34 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). It can be used for silage, hay and straw. The cutting device is hydraulically moved in and out. fig Cutting device operation RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI fig.42 SW Twine Cut 2(4) 1. Press the button on the BALERCONTROL panel; "CD" (=Cutting Device) appears in the panel display. 2. Activate the attached tractor control valve. (The actuating direction can be changed by swapping the connected hydraulic hoses.) 3. When the blades are in the cutting position, CUT ( cutting ) is shown in the control panel display. 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. 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. 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 is disabled when keeping the button depressed! Finally, the blades must definitely be once again moved in and out without having to depress the cutting device button. Otherwise, the machine overload will result in a cancellation of the warranty! 30 WELGER RP 202 RP 220 RP 302 RP 320

35 fig RP 220 FARMER - RP 320 FARMER with cutting unit and swivel floor Activating the cutting device: 1. Open the shut-off valve on the left side of the baler (fig. 43), 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. 4. Close the shut-off valve (fig. 43), i.e. move the lever into the horizontal position. I fig Deactivating the cutting device: 1. Open the shut-off valve on the left side of the baler (fig. 43), 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. 43), i.e. move the lever into the horizontal position. 4. Activate the "raise" function on the connected tractor control valve until the conveyor channel floor is completely closed. 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. 43) 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. 44). WELGER RP 202 RP 220 RP 302 RP

36 Hydraulic protection of the cutter blades Note: The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This activates at a factory set pressure limit. This is also the 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. 45 without the protective guards) fig Move the shut-off valve, on the left side of the baler, into a vertical position (fig. 46). 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. 45 and fig. 47) fig. 46 o. k. 7. 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. 46), i.e. move the lever into the horizontal position. Warning: If the ball valve lever (fig. 45) 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. 47) 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

37 RP 220 FARMER RP 320 FARMER with cutting unit and 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. fig. 48 o. k 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. Remedy: 1. Move the ball valve under the left protective guard towards the back (fig. 48). 2. Activate the control valve until the blades are in the cutting position. 3. Move the ball valve once again towards the middle of the baler. 4. Move the blades once more in and out. Only after this process can the baler be brought into normal operation. Warning: If the ball valve lever (fig. 48) is pointing towards the back, the common protection of the cutter blades is deactivated! After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler! (fig. 49) After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty! fig. 49 WELGER RP 202 RP 220 RP 302 RP

38 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. 50 Move the cutting device into the cutting position. Lower the HYDROFLEXCONTROL bottom flap* approximately halfway (fig. 50). Open the tailgate and secure it by using the cut-off valve (fig. 3). 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. fig. 51 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. 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. 51). Note: Removed blades should be replaced by dummy blades* in order to prevent the slots from becoming blocked. (Part no ) 34 WELGER RP 202 RP 220 RP 302 RP 320

39 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. As described above, remove the blades and grind the cutting edge from the smooth side. Pay attention that the hardened cutting edges are not drawn when grinding. A grinder is available as a spare part. (Part no ) Warning: Never strike the installed blades with a hammer from underneath the baler The magnets can be damaged! WELGER RP 202 RP 220 RP 302 RP

40 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. 52). In order to avoid any danger to other road users, both rectangular tubes of the bale ejector must be pushed in and secured (fig. 53) 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. 53 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 m 2.00 m 2.25 m Optimal 1.30 m windrow width (approx.) 1.40 m 1.50 m WELGER RP 202 RP 220 RP 302 RP 320

41 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. RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI 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. "PU" (=Pick Up) appears in the panel display. The connected tractor control valve can now be used to actuate the pick-up lifting mechanism fig. 54 PU Twine Cut 2(4) 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. 55); secure the support wheels once again with the spring retainer. Provide the same setting on both sides fig. 55 WELGER RP 202 RP 220 RP 302 RP

42 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. 56) 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. 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. fig RP 202 SPECIAL / RP 302 SPECIAL Pick-up unit width 2.00 m (fig. 57) 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. 57 RP 220 and RP 320 Pick-up unit width 2.00 m and 2.25 m (fig. 58) 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

43 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. 59) 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 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. 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. 60). 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. 60 falsch wrong faux WELGER RP 202 RP 220 RP 302 RP

44 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. 61 RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI The desired bale density can be viewed and set with the aid of the BALERCONTROL control panel. The baling density is represented by the numbers from 1 to 10. After connecting the power supply, the most recently set baling density (e.g. (4) ) is shown on the Balercontrol control panel display. PU Twine Cut 2(4) The figure that is not shown in brackets (in this case 2 ) shows the density that has been reached by the bale that has already been started. The display shows a * if the density has not yet reached the value 1. The desired baling pressure can be set with the buttons (shown opposite). In order to minimize crumbling losses from delicate straw-type materials or to achieve a light bale center (e.g. hay bales), the baling density should be reduced accordingly. The same applies if the overload protection devices are frequently activated. 40 WELGER RP 202 RP 220 RP 302 RP 320

45 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 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI A short signal tone informs the tractor driver that the tailgate is fully locked. WELGER RP 202 RP 220 RP 302 RP

46 9. Wrapping The following wrapping modes* can be selected manual wrapping (twine and net) automatic twine wrapping automatic net wrapping manual combined 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. 62): No. Component Function 1 Green LED Correct power supply 8 2 Red LED Set bale density reached V 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) Button Changes between manual and automatic wrapping (manual: lights [3] and [4] go out). 6 7 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 (on back side) Pre-selected bale density reached 1 DLC = Daily Counter 2 LTC = Life Time Counter 42 WELGER RP 202 RP 220 RP 302 RP 320

47 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 fig. 63 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]; corresponding yellow LED flashes simultaneously. 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. 63). As soon as the detection pulleys stop, the wrapping process is finished Open the tailgate and eject the bale. the Manual net wrapping fig. 64 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. With normal P.T.O. speed allow the net to wrap the bale Check the net is running by the detection pulley (fig. 64). 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

48 Automatic twine wrapping Selection: Depress button [5] (fig. 62) 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. 63). 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. 62) 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. 64). 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. 44 WELGER RP 202 RP 220 RP 302 RP 320

49 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 / SPEEDMASTER / SPEEDPROFI 1 For wrapping operations, the BALERCONTROL III control panel contains the following functions and displays (fig. 65): No. Component Function 1 Display Display: Wrapping type, bale density 2 Button <AUTO/MAN> Alternate between various wrapping types 5 3 fig Button <NET> Trigger the net wrapping by hand 4 Button <TWINE> 5 Buzzer (on back side) Trigger the twine wrapping by hand Pre-selected bale density reached WELGER RP 202 RP 220 RP 302 RP

50 Wrapping the bale Repeatedly depress the button <AUTO/MAN> on the control panel until the desired wrapping type is selected. The following sequence appears: PU Man Cut Set to: manual wrapping (twine and net possible) 4(4) PU Twine Cut Set to: automatic twine wrapping 4(4) PU Net Cut Set to: automatic net wrapping 4(4) PU Combi Cut Set to: automatic combined wrapping 4(4) PU Man Cut Set to: manual wrapping (start setting) 4(4) 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: 46 WELGER RP 202 RP 220 RP 302 RP 320

51 Twine wrapping, manually triggered: Audible (3 sec.) and visual signal when reaching the selected baling density (visual: bale density display flashes). PU Man Cut 4(4) While driving depress button <TWINE>: Twine wrapping 4(4) 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): Open tailgate Open tailgate with tractor control valve. As soon as lock opens: Tailgate is open Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. PU Man Cut *(4) ("* " indicates that the bale density is still less than "1" and that it is too early to trigger the wrapping) More crop can be once again added Net wrapping, manually triggered: Audible (3 sec.) and visual signal when reaching the selected baling density (visual: bale density display flashes). PU Man Cut 4(4) Stop driving the tractor and allow the pick up unit to operate freely.depress button <NET> until the net is grasped by the bale. Net wrapping 4(4) After completion of the net wrapping (net cutting knife was operated): Open tailgate Open tailgate. As soon as lock opens: Tailgate is open 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. PU Man Cut *(4) ("* " indicates that the bale density is still less than "1" and that it is too early to trigger the wrapping) More crop can be once again added 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): Open tailgate Open tailgate with tractor control valve. As soon as lock opens: Tailgate is open Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. PU Man Cut *(4) ("* " indicates that the bale density is still less than "1" and that it is too early to trigger the wrapping) More crop can be once again added. WELGER RP 202 RP 220 RP 302 RP

52 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): Open tailgate Open tailgate. As soon as lock opens: Tailgate is open 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.. 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. PU Man Cut *(4) ("* " indicates that the bale density is still less than "1" and that it is too early to trigger the wrapping) More crop can be once again added. 48 WELGER RP 202 RP 220 RP 302 RP 320

53 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. 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

54 1 fig 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: 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. 68): Switch off the pto shaft Switch off engine and remove the ignition key fig. 68 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! 50 WELGER RP 202 RP 220 RP 302 RP 320

55 10.4. Reversing the pick-up unit RP 202 / RP 302 SPECIAL For blockages in the inlet section, the pick-up unit drive can be manually rotated backwards (see fig. 69): Switch off the pto shaft Switch off engine and remove the ignition key Apply a hexagonal spanner (22 mm jaw width) and rotate the drive backwards far enough so that the blockage in the inlet section can be removed. fig Before restarting the baler, remove the crank lever and close up all protective guards! WELGER RP 202 RP 220 RP 302 RP

56 10.5. 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.70 What to do if material jams: RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI 1. Stop driving and switch off pto shaft. 2. If the cutting device was used, first press the button <CUTTING DEVICE> and use the tractor control valve to swing the cutter blades away from the conveyor channel. The text CUT disappears from the upper right corner of the control panel display. 3. If the cutting device was not used, press the button <BOTTOM FLAP> and use the tractor control valve to open the conveyor channel floor. The text BOTT (=bottom) appears in the lower left corner of the control panel display. 4. Engage the universal drive shaft; 5. Return the bottom flap to the working position once the blockage has been removed ( BOTT disappears from the display). 6. If the cutting function is required, the blades must be swung in once again. RP 220 FARMER / RP 320 FARMER 1. Open the conveyor channel floor by using the tractor control valve. 2. If the cutting device was used, the cutting blades can also still be swung down (see Section "Cutting device"). 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! 52 WELGER RP 202 RP 220 RP 302 RP 320

57 11. "BALERCONTROL"* Not only the control unit (only with BALERCNTROL 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 Control panel program (Software)... BC2BG... By switching on the power supply while keeping any control panel buttondepressed. Control unit S/N... After switching on, keep the button Control program (Software) SW. Rev.... depressed until "Systeminfo" appears in the display. Depress briefly once more the button to read the Software Version. WELGER RP 202 RP 220 RP 302 RP

58 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 times be in a position where it is protected from water spray (tractor cab or the baler twine compartment, with the cable outlet pointing downwards). When welding on the baler: Do not allow the welding current to pass through the control unit; Disconnect the power supply between the tractor and baler; Be careful of heat generated at welding points; detach any potentially sensitive components (cables, sensors etc) before welding; 54 WELGER RP 202 RP 220 RP 302 RP 320

59 The "BALERCONTROL III" Control Panel RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI Important baler functions can be controlled and monitored with the control panel remotely from the tractor. The control panel (fig. 71) consists of: LCD-Display with 2 x 12 digits 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. 72). fig. 71 After power supply connection: e.g. WELGER RP 320 (Accoustic Signal) after 2 sec. S / N SW. Rev Serialnumber of Control Unit Software-Version Valveblock in pos. "Pickup" Bottom door is open after 2 sec. Standard - Display PU Twine CUT Bottom 2 (4) Twine tying selected (Automatic) Knifes in working position Bale density indicates:excisting step 2, preselected step 4, autom. twine trip at step 4. fig. 72 WELGER RP 202 RP 220 RP 302 RP

60 for further function Menu structure Functions that are often used during normal baling can be directly operated by pressing the appropriate button on the keypad. (fig. 73). Menu structure BALERCONTROL III keep button depressed RP 220 RP 320 MASTER / PROFI / SPEEDMASTER / SPEEDPROFI PU Twine Cut Bottom 2 (4) Balercontrol '95 1x short + - or Bale press. Set Val lower higher Bale density Activate valveblock Pick up Activate valveblock Bottom door Activate valveblock Cuttingdevice The Value of the density can be altered in steps of 1 unit between 1 and 10. 1x short without pressing button after 3 sec. PU Twine CUT Bottom 2 (4) 1x short Mode Trip Net Trip Twine Net tying Automatic PU Net CUT Bottom 2 (4) 1x short PU Twine CUT Bottom 2 (4) 3 sec. Mode press simultaneously for 3 sec. TAZ= B Daily counter (TAZ) = 235 Bales 1x short - + Reset Daily counter after another 3 sec. Combi tying Automatic PU Combi CUT Bottom 2 (4) 1x short PU Twine CUT Bottom 2 (4) 3 sec. Mode Mode LTC= B Lifetime counter (LTC) = Bales TAZ= B reset Daily counter 1x short Mode Manual tripping (Twine or Net possible) PU Man CUT Bottom 2 (4) 1x short PU Twine CUT Bottom 2 (4) Twine tying Automatic PU Twine CUT Bottom 2 (4) Other functions like: fig. 73 Basic settings ("Set-up"), Control information ("Systeminfo") or Checking individual components("diagnostics") are operated by pressing the button (see following page). 56 WELGER RP 202 RP 220 RP 302 RP 320

61 hold down Mode Indication circulates Mode: Monitor PU Twine CUT Bottom 2 (4) Mode 3 sec. Mode 3 sec. Mode 3 sec. Mode: Setup release Language: English 1x short Mode Maschinery type RP 320 w.. MC 1x short Mode Delay 2,5 sec. - or or If required other languages are available. if required other. machinetypes can be selected. or + A deley can be selected either 2,5 sec. or 5 sec.. PU Twine CUT Bottom 2 (4) Mode 3 sec. Mode 3 sec. Mode: Systeminfo release Serialnumber x short Mode SW Rev dd (Software Revision 1.05 from ) PU Twine CUT Botom 2 (4) PU Twine CUT Bottom 2 (4) Mode 3 sec. Mode 3 sec. Mode 3 sec. Mode 3 sec. Mode: Diagnosis release Diag Sensor Twine. li xx I 1x short Mode Diag Analog 115 (0) 127 1x short Mode Diag Actor Mag.Net + / + 1x short Mode Diag Voltage 11.7V w. load - or + All other Sensors can be selected and checked. load on load of Actors - or + all other actors can be choosed. Diag Voltage 13.2V w. load PU Twine CUT Bottom 2 (4) Mode 3 sec. Mode 3 sec. Mode 3 sec. Auto Diagnosis 1x short AutoDiag Sensor Netgl. bld xx I 2 x short Mode AutoDiag Actor Mag.Net + / + 1x short Mode AutoDiag Voltage 13.2V w / o. load In Diagnosis Sensor the Display always indicates the sensor checked last. In Diagnosis Actors every magnet is switched on and off for appr. 1sec.. In Diagnosis Voltage a testload is switched on and off for appr. 1sec. WELGER RP 202 RP 220 RP 302 RP

62 11.5. Instruction sequence Change bale density: Operate 1) Bottom flap*: Operate 2) pick up up/down * : Operate 3) Cutting device*: PU Twine 2 (4) PU Twine 2 (4) BD Twine 2 (4) PU Twine Bottom 2 or Press briefly once Press briefly once Press briefly once Bale density Pre-set 4 BD Twine 2 (4) PU Twine 2 (4) CD Twine 2 (4) lower higher Bale density The density can be altered in steps of 1 unit between The number in brackets "(4)" indicates the preset density. The number "2" before it indicates the current density. If the current density is below 1, a "*" appears in the display. without pressing a button PU Twine 2 (4) Bottom flap is activated and can now be operated from the tractor control unit. Remains activated, until the buttons or are pressed. BD Twine Bottom 2 (4) "Bottom" indicates that the bottom flap is open. 1) For balers without a cutting device, the bottom flap is activated directly from the tractor hydraulic system. Therefore the button Pick-up unit is activated and can now be operated from the tractor control unit. Remains activated, until the buttons or are pressed. 2) For balers without a cutting device, the pickup unit is activated directly from the tractor hydraulic system. Therefore the button Cutting device is activated and can now be operated from the tractor control unit. Remains activated, until the buttons or are pressed. CD Twine CUT 2 (4) "CUT" indicates that the cutting device is moved into position. Note: To ensure the accumulators are filled, the control valve must be operated for another 2 seconds after "CUT" appears in the display. 3) For balers without a cutting device, the for these balers does not function. for these balers does not function. button does not function. 58 WELGER RP 202 RP 220 RP 302 RP 320

63 Read daily counter Reset daily counter: Read life time counter: Change language: Press briefly once Press briefly once Press briefly once keep pressed: DLC= B TAZ= B TAZ= B Mode: Setup Daily counter (DLC) = 235 Bales 3 sec. Depress simultaneously for 3 sec Press briefly once release button: Language: English or if button not pressed after 30 sec. PU Twine CUT 2 (4) Reset daily counter? (Audible warning signal) release after 3 sec. LTC= B Life time counter (LTC) = bales, 3 sec. or The following languages can be chosen: English French German TAZ= B or if button not pressed after 30 sec. 3 sec. 3 sec. PU Twine 2 (4) PU Twine 2 (4) or if button not pressed after 30 sec. PU Twine 2 (4) Note: After resetting the daily counter, check the wrapping type setting WELGER RP 202 RP 220 RP 302 RP

64 Read machinery type: Set machinery type: Read wrapping delay: Change wrapping delay: keep pressed: keep pressed: keep pressed: keep pressed: Mode: Setup Mode: Setup Mode: Setup Mode: Monitor release button: release button: release button: release button: Language: English Language: English Language: English Language: English Press briefly once Press briefly once Press briefly twice Press briefly twice Type RP 320 m. MC 3 sec. PU Twine 2 (4) Type RP 320 m. MC MC= Cuting device or The following available baler models can also be selected as required: - RP 320 w/o MC - RP 220 w. MC - RP 220 w/o MC Delay 2.5 sec. The time delay (2.5 or 5 sec.) is the time between triggering the wrapping and the tone signal at the control panel. For twine wrapping, the tone signal is heard after triggering the wrapping. Delay 2.5 sec. or A delay time of 2.5 or 5 sec can be chosen. 3 sec. 3 sec. For net wrapping, the tone signal is heard before triggering the wrapping. PU Twine 2 (4) 3 sec. PU Twine 2 (4) PU Twine 2 (4) 60 WELGER RP 202 RP 220 RP 302 RP 320

65 Diagnosis Sensor: Diagnosis Analog Sensor: Diagnosis Acutator: Diagnosis Voltage: keep pressed: keep pressed: keep pressed: keep pressed: Mode: Diagnosis Mode: Diagnosis Mode: Diagnosis Mode: Diagnosis release button: release button: release button: release button: Diag Sensor Netg.bld. xx I Diag Sensor Netg.bld. xx I Diag Sensor Netg.bld. xx Diag Sensor Netg.bld. xx I xx I is the symbol for a vapour-coated sensor, i.e. the sensor has detected metal. Press briefly once Press briefly twice Press briefly 3 times xx is the symbol for a sensor that is not vapour-coated, i.e. the sensor has not detected metal within its coverage area. or The other sensors can be interrogated. 3 sec. Diag Analog 133 (2) 177 Analog senor = Clearance sensor The values of the clearance sensors (right and left) are 133 and 177 respectively. From this a bale density of 2 can be calculated. 3 sec. Diag Actuator Mag. net +/+ or The other actuators can be interrogated. ( - / - ) ( + / + ) Switch the load off on. Diag V 11,7 V w load Diag V 13,2V w/o.load The buttons are used to switch the load on or off. This can be used to test the stability of the on-board power supply. PU Twine 2 (4) PU Twine 2 (4) 3 sec. 3 sec. PU Twine 2 (4) PU Twine 2 (4) WELGER RP 202 RP 220 RP 302 RP

66 Diagnosis sensors (automatic): Diagnosis actuators (automatic): Diagnosis voltage (automatic): keep pressed: keep pressed: keep pressed: Mode: Diagnosis release button: Mode: Diagnosis release button: Mode: Diagnosis release button: Diag Sensor Netg.bld. xx I Diag Sensor Netg.bld. xx I Diag Sensor Netg.bld. xx I Press briefly once Press briefly once Press briefly once Auto Diag S. Netg.bld. xx I With this function, the display jumps to the sensor last activated so that this does not need to be done manually. Auto Diag S. Netzg.bld. xx I Press briefly once Auto Diag S. Netg.bld. xx I Press briefly twice 3 sec. Auto Diag A. Mag. Net - / - Auto Diag V. 13,2V w/o. load PU Twine 2 (4) With this function, each actuator is switched on and off for 1 second. It then switches over to the next actuator. With this function, the test load is switched on and off in 1 second cycles. 3 sec. 3 sec. PU Twine 2 (4) PU Twine 2 (4) 62 WELGER RP 202 RP 220 RP 302 RP 320

67 Read serial number: Read software version: Select wrapping unit: keep pressed: Mode: Systeminfo release button: keep pressed: Mode: Systeminfo release button: PU Twine 2 (4) Automatic twine wrapping Press briefly once Serial number sec. Serial number: Press briefly once PU Net 2 (4) Automatic net wrapping Press briefly once PU Twine 2 (4) SW 1.05 (Software Version 1.05 from ) 3 sec. Version PU Comb 2 (4) Automatic combination wrapping Press briefly once PU Twine 2 (4) PU Man Manual wrapping (For twine and net) 2 (4) WELGER RP 202 RP 220 RP 302 RP

68 64 WELGER RP 202 RP 220 RP 302 RP 320

69 12. Maintenance / Settings General instructions After about the first 20 operating hours, tighten all screws and nuts, including those inside the machine. When doing so, do not change adjustment screws, e.g. on the twine guide or the net brake 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. 74 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

70 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. 76) 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. 76 Never reach into the cutting knife area danger of injury! 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 Standby net wrapping* The electrical connector plug [2] is simply inserted into the free plug socket [1]. Net wrapping is triggered by switching on the parking light for such a time until the bale catches onto the net (detected by the faster rotation of the net role). fig Standby twine wrapping* The twine wrapping motor can be connected to the plug socket [1] (plug-socket has to be altered accordingly). Twine wrapping is triggered by switching on the parking light for such a time until the bale catches onto the twine. Note: Carry out a brief trial run after provisionally attaching the twine wrapping unit. Change over the poles of the connecting cable if the twine insertion rollers do not rotate. 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. 66 WELGER RP 202 RP 220 RP 302 RP 320