Bauer RAINSTAR A3 User manual

OPERATIING MANUAL
for
RAINSTAR A3
Version VII-2009
Art. No. 827 9978

Manual for BAUER RAINSTAR A3
II
Introduction
Thank you for buying BAUER RAINSTAR A3 !
The present manual is a very important document that describes how to operate and BAUER
RAINSTAR A3.
This manual describes the system as detailed as possible. If you need still more information, please
contact your dealer or turn directly to BAUER in Voitsberg/Austria.
Please note that the content of this manual neither constitutes part of nor alters in any way any
previous or existing agreement, promise or legal relationship. BAUER’s commitment is based solely
on the respective purchase contract which also contains the complete and only valid warranty
agreement. Said contractual warranty is neither extended nor limited by the content of this manual.
All information contained in the present manual is based on the latest product details available at the
time of printing.
BAUER reserves the right to change without notice without assuming any liability!
BAUER RAINSTAR A3 is designed for highest performance safety and reliability provided it is
operated in accordance with the present operating instructions.
Therefore you should study this manual thoroughly before starting your BAUER RAINSTAR A3 !
Strictly observe all instructions pertaining to system handling, operation and service!
On this condition, BAUER RAINSTAR A3 will operate to your satisfaction for many years!
Non-observance of this manual may cause personal injury or damage the equipment!
Please make this manual available to your staff. State the pump type and serial number of your
BAUER RAINSTAR A3 in all inquiries, correspondence, warranty problems, or parts orders.
We wish you a lot of success with BAUER RAINSTAR A3 !
This manual is to be considered an integral part of BAUER RAINSTAR A3. Suppliers of both new
and used systems are advised to put down in writing that they delivered the manual together with the
system.

Manual for BAUER RAINSTAR A3 III
Product details
Type designation: RAINSTAR A3
Type number:
Serial number1:
Dealer: Name:
Adresse:
ph./fax:
Date of shipment:
Manufacturer: Röhren- und Pumpenwerk BAUER Ges.m.b.H.
Kowaldstr. 2
A - 8570 Voitsberg/Austria
Tel.: [phone] – 0
Fax: [phone] /-340
www.bauer-at.com
e-mail: [email protected]
Owner or operator: Name:
Address:
ph. / fax:
Note: Please make a note of the type and serial number of your RAINSTAR A3 and accessories. Be sure to
specify these details every time you contact your dealer.
1In all warranty claims and correspondence relating to this machine it is essential to specify the full serial number group including all letters.
This applies to both the machine and the components concerned. We cannot emphasise this point often enough.

Manual for BAUER RAINSTAR A3
IV
General Safety Instructions
Symbols and terms
The CE symbol that has to be affixed on the machine by the manufacturer
outwardly demonstrates compliance of the machine with the directives for
machines and other relevant EU directives.
This “Warning” symbol refers to important safety instructions in this
manual. Whenever you see this symbol be aware of possible injury
hazards. Read the note following the symbol very carefully and
inform the other operators accordingly.
Non-observance of this instruction may cause damage to or destroy
the machine or individual components.
It is very important to observe this note or condition!
Qualified operators are persons who on account of their training, experience and instruction as well as
their knowledge of relevant standards, rules, precautions to be taken for accident prevention, and
prevailing operating conditions, have been authorised by the person in charge of plant safety to perform
the respective tasks required, and in doing so are able to recognise and avoid potential hazards. Among
other things, knowledge of first-aid procedures is also required.
Product liability
As defined by the product liability law every farmer is also an entrepreneur!
According to §9 PHG (Product Liability Law), liability for damage to corporeal things caused by defective
products is expressly excluded. This exclusion of liability also applies to parts not manufactured by
BAUER itself but purchased from external suppliers.
Duty to furnish information
Even if the customer passes on the machine later-on he is obliged to hand the operating manual on to
the new receiver, too. The receiver of the machine must be instructed with reference to the mentioned
regulations.
Intended use
•BAUER RAINSTAR A3 is built exclusively for normal agricultural applications (intended use).
•Any use beyond this normal use is considered non-conforming. Manufacturer is not liable for damage
resulting from such non-conforming use, the sole liability for damage from non-conforming use is with the
user.
•Intended use also includes compliance with the manufacturer’s operating, maintenance and service
instructions.
•The BAUER RAINSTAR A3 may be used and operated only by persons who are familiar with the
device and aware of the hazards involved.
•All rules for accident prevention as well as any other generally valid specifications and regulations
relating to safety, work medicine and traffic law must be strictly observed.
•Unauthorised modifications on the machine release the manufacturer from liability for damage
resulting therefrom.
WARNING!
CAUTION
NOTE

Manual for BAUER RAINSTAR A3 1
Index
GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION.........................2
GENERAL..................................................................................................................................7
1SAFETY PRECAUTIONS FOR THE RAINSTAR A3..........................................................8
2DESCRIPTION ....................................................................................................................9
3PUTTING INTO OPERATION...........................................................................................10
3.1 STEPS TO BE CARRIED OUT ONCE OR FROM TIME TO TIME....................10
OPERATING MODE I: PE-PIPE PULL-OFF...............................................................11
3.1.1 Transport of Machine to Set-up Position............................................................................11
3.1.2 LOWERING THE CART.....................................................................................................12
3.1.3 PULLING OFF THE PE-PIPE.............................................................................................13
3.1.4 SPEED ADJUSTMENT with mechanical regulation...........................................................14
3.2 OPERATING MODE II: Laying down the PE-pipe..........................................17
3.2.1 FUNCTIONAL DESCRIPTIONOF THE MAIN COMPONENTS.........................................17
4MECHANICAL REGULATION..........................................................................................20
5QUICK STOP ....................................................................................................................21
6WINDING MECHANISM....................................................................................................21
7SHUT-OFF AND SAFETY EQUIPMENT ..........................................................................21
8CART.................................................................................................................................22
9OVERPRESSURE SHUT-OFF VALVE.............................................................................22
10 WINTERIZATION – DRAINING .....................................................................................23
11 WINDING MECHANISM – STARTING POSITION........................................................24
12 SETTING THE GEARBOX SHUT-OFF DEVICE ...........................................................26
12.1 TESTING THE SHUT-OFF DEVICE...................................................................27
13 SPEEDOMETER............................................................................................................28
14 SERVICE AND MAINTENANCE....................................................................................29
15 TROUBLE-SHOOTING..................................................................................................30
14. CONFORMITY CERTIFICATE.......................................................................................33

Manual for BAUER RAINSTAR A3
2
General instructions for safety and
accident prevention
Check the operational safety of the machine before every start-up.
1. In addition to the instructions contained in this manual, all specifications generally valid for safety
and accident prevention must be observed!
2. The warning and instruction signs affixed to the machine give very important instructions for safe
operation. Observing them serves your own personal safety!
3. Never put the machine into operation unless all guards and safety devices are completely
mounted and in their proper working position!
4. Acquaint yourself with all equipment components and controls as well as their respective functions
before starting to work. It is too late when the device is already running!
5. The operator’s clothes should fit tightly. Avoid wearing loose clothes!
6. When handling slurry always keep in mind that the gasses produced are highly toxic and extremely
explosive in combination with oxygen. Therefore, open fires, light tests, sparking and smoking are
strictly forbidden!
7. Utmost care is required with regard to gasses in slurry and dung channels at open valves to the
preliminary pit, before the main pit, or at cross channels. The same applies to mixing and
withdrawal points when mixers or pumps are running!
8. When handling slurry always ensure sufficient ventilation!
9. Keep the machine clean to avoid fire hazards!
Power take-off (applies only to PTO driven machines)
1. It is not allowed to use any other types of PTO drive shafts except the ones prescribed by the manufacturer!
2. Drive-shaft guard tube and guard cone as well as the PTO guard – also on the machine side -
must be mounted and in good working order!
3. When using a PTO drive shaft always observe the specified overlap in transport and working
position!
4. Never connect or disconnect the PTO drive shaft unless the PTO is stopped, the engine turned
off, and the ignition key pulled out!
5. Make sure the drive shaft is always connected and secured properly!
6. Attach the safety chain to keep the drive shaft guard from rotating with the shaft!
7. Before you turn on the PTO make sure that the selected tractor PTO speed corresponds with
the permissible implement speed!
8. Before starting the PTO make sure that nobody is standing in the danger zone of the machine!
9. Never turn on the PTO when the engine is turned off or during a transport drive!
10. When working with the PTO nobody is allowed near the turning PTO or drive shaft!
11. Warning! The PTO shaft may continue turning due to its centrifugal mass after the PTO has
been turned off! Keep clear of the machine during this time and do not touch until the PTO
shaft stands absolutely still!
12. For cleaning, greasing, or adjusting the PTO driven implement or drive shaft, PTO and engine
must be switched off and the ignition key pulled out!
13. Place the disconnected drive shaft on the provided support!
14. When drive shaft has been removed put the guard on the PTO shaft!
15. If a defect occurs repair it immediately before starting to work with the machine!
Hydraulic system
1. Hydraulic system is under high pressure!
2. When connecting hydraulic cylinders and motors, make sure the hydraulic hoses are connected
as specified!
3. Before coupling the hydraulic hoses with the tractor’s hydraulic system make sure that the
entire hydraulic system is pressureless both on the tractor and implement side !
4. Inspect the hydraulic lines at regular intervals and replace them immediately in case of defects
or ageing. Replaced hoses must comply with the technical specifications of the implement
manufacturer!
5. When looking for leaks use only suitable equipment because of the injury hazard involved!

Manual for BAUER RAINSTAR A3
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6. Liquids emerging under high pressure (hydraulic oil) may penetrate the skin and cause serious
injuries! An injured person must see a doctor immediately! Danger of infection!
7. Before working on the hydraulic system the machine must be lowered, the system
depressurised and the engine turned off!
Electric-driven implements
1. All work beyond normal maintenance of the implement should be performed only by a professional
electrician!
2. Defective or broken plugs and sockets must be replaced by a professional electrician!
3. Never pull a plug out of the socket at the flexible electric cord!
4. Extension cables for power supply should be used only temporarily! Never use such lines
permanently as a substitute for the required fixed installations!
5. Flexible lines laid across traffic areas on the farm must have at least 5 m ground clearance!
6. Always turn off the power supply before you do any work on the machine!
7. Check all electric lines for visible defects before you put the machine into operation! Replace
defective cables and do not start the machine before that!
8. Never use electric-driven implements in damp situations or locations exposed to fire hazard
unless they are adequately protected against moisture and dust!
9. Covering electric motors may cause heat concentration with high temperatures which could
destroy the operating equipment and cause fires!
Hand-operated devices (valves)
1. Because of the slurry gasses produced in the lines, no slurry is allowed to remain in closed
pipelines – bursting hazard!
2. Lay the pipelines with sufficient inclination and make sure that the selected closing order of valves
allows all lines to be drained completely!
3. Protect the valves against unauthorised handling!
4. If a valve gets jammed do not apply force! Use only the operating levers supplied with the
implement!
5. Observe the permissible maximum operating pressure of valves and pipelines when pumps are
operated!
6. Service only when the tanks are empty!
Maintenance
1. Never perform any maintenance, service or cleaning work or fault elimination steps unless the
drive is turned off and the engine is standing still!
2. Check proper fit of all nuts and bolts regularly and tighten them, if necessary.
3. If maintenance work is required on the lifted machine always secure it by means of appropriate
supports!
4. When exchanging tools with cutting edges always use proper tools and wear safe protective
gloves.
5. Dispose of oil, grease and filters according to local laws and regulations!
6. Always turn off power before working on the electric system!
7. Before electric welding on the tractor and mounted machines the generator and battery cables
must be disconnected!
8. Spare parts must meet manufacturer’s minimum technical specifications! This is the case for
instance with original spare parts for instance!

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Safety distances Z from electric lines at:
IRrigation = ZRe. g.: with drinking water, ground water (e. g. well) or running
water (e. g. river)
SlurryG= ZGe.g.: with liquid manure or slurry
H= minimum distance between sprinkler upper edge and conductor cable when
crossing beneath an electric line
The safety distance when crossing beneath an electric line, is reached when the distances as per the
below chart are kept. The water beam may touch the conductor cable but it may not be higher than the
conductor cable.
Sprinkler with rubber wheels Sprinkler with skids
Running direction
Pump tanker on rubber wheels Sprinkler jet pipe directed by hand
ATTENTION: DO NOT SPRAY SLURRY ON INSULATORS AND MASTS!
Safety distance Z in m, measured on the ground
Type and operation mode of
the sprinkler
With rubber wheels or directed by hand
With metal or synthetic pipes With skids or stationary/fixed With metal cart and metal pipes
Nozzle diameter in mm or flow in m³/h
26 mm ≙50 m3/h 36 mm ≙100 m3/h 26 mm ≙50 m3/h 36 mm ≙100 m3/h
Jet type Spray Full Spray Full Spray Full Spray Full
Up to 1.000 V
H = 1 m ZR 1 5 1 5 1 5 1 5
ZG 1 8 1 8 1 8 1 8
Up to 30.000 V
H = 2,5 m ZR 3 9 5 21 3 7 4 9
ZG 5 11 7 23 5 9 6 11
Up to 110.000 V
H = 3 m ZR 3 12 5 24 3 9 4 15
ZG 5 14 7 26 5 11 6 17
Up to 220.000 V
H = 4 m ZR 4 14 6 26 4 12 6 22
ZG 6 16 8 28 6 14 8 24
Up to 380.000 V
H = 5 m ZR 5 16 7 26 5 14 6 22
ZG 7 18 9 28 7 16 8 24

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The safety distances indicated in the above chart are valid for a nozzle diameter of 26 mm and/or 36 mm at an
operating pressure of 5 bar. For higher operating pressures the safety distances have to be increased by 2 m.
The safety distances are not valid when standardized jet pipes like those of fire brigades are being used.
When applying polluted water or slurry, note that a conductive layer can build up on the insulators. Therefore do
not spray on the insulators! Flashovers and insulator damage can otherwise cause power failure.
If metal sprinkler pipes are laid in parallel to a high voltage power line, this can lead even without irrigation to a
perceptible contact voltage because of the electric influence. Touching the pipes is not dangerous but can be
unpleasant and painful. This is why it should be avoided to lay metal pipes in parallel to high voltage lines or only
over the shortest distances possible. When using synthetic pipes, you will not encounter any of these problems.
Note! Do not put pipeline pieces into a vertical position in the range of high voltage lines! Only transport
them horizontally!
WARNING SIGNS
The hazard points of the RAINSTAR A3 are marked by special safety labels on the machine. These
labels must be affixed well visibly to the points indicated and they serve to protect persons staying
around the machine.
1.
WARNING !
Study and observe carefully the operating manual and the safety hints
before starting the machine.
2.
WARNING!
Stop the machine and read the operating manual before carrying out
maintenance jobs and repairs.
3.
WARNING!
1. The working range of the RAINSTAR A3 always must be at a safe
distance from electric high-voltage lines.
2. This applies to both the use of wide-range sprinklers and boom carts
AS 26 / 32.
The water jet of the nozzles and the sprinkler must not reach any
electric lines.

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4.
WARNING!
Safety covers must not be removed during operation.
For repairs, make sure that the reel of the RAINSTAR A3 cannot move.
Slacken the PE pipe.
5.
WARNING!
1 Do not stay at rear of the RAINSTAR A3 !
Operator is in danger of being crushed by the retracted sprinkler cart. Keep
the distance !

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GENERAL
BAUER products are designed and manufactured carefully, subject to a system of continuous quality
control. The BAUER RAINSTAR A3 is a turbine-driven machines designed for fully mechanised and
labour-saving irrigation. Individual pipe sets are no longer laid down by hand; system set-up,
repositioning, and operation are all done with the tractor only.
The BAUER RAINSTAR A3 is a universal machine suitable of covering fields of varying lengths and
widths. There is no need for supervision while the system is operating.
Strict observance of all operating and service instructions in this manual is the basic prerequisite for
many years of trouble-free operation. Therefore please make sure that all operators on your staff are
familiar with the instructions given in this manual.
The model number as well as the serial number (Vehicle identification number) are stamped into the
nameplate. In addition, the serial number is stamped into the frame of the undercarriage. Please state
these data in all your inquiries, correspondence, warranty matters and parts orders.
We warrant according to our General Terms of Sale.

Manual for BAUER RAINSTAR A3
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1 SAFETY PRECAUTIONS FOR THE RAINSTAR A3
1. Read this manual before putting the system into operation for the first time.
2. Never handle the PE-pipe near the machine or the machine itself during pull-off or pull-in.
3. During PE-pipe rewind with the tractor's PTO or during pipe pull-off, always make sure that the
shifting lever is in the proper position. Moreover, the maximum permissible speed must not be
exceeded. Max. speed: 200 rpm
Danger by improper handling!
4. Never carry out service- or setting jobs (except speed settings) while the machine is operating.
5. Keep clear of all moving parts.
6. Never expose any moving parts by removing protective elements.
7. Keep a safe distance from the sprinkler during operation.
8. Be careful in case of high connecting pressure!
9. Make sure that the water jet from spray nozzles does not hit public roads.
10. The RAINSTAR A3 is licensed for transport in agricultural operation only. For transportation on
public roads, all applicable traffic requirements must be strictly observed.
For safety reasons, it is not allowed to transport the RAINSTAR A3 by pulling it with
a fork-type drawbar (OPTIONAL) nor with the toolbar!
11. When loading the machine on a trailer, note that the water remaining in the pipe shifts the
system's centre of gravity upward.
12. When driving in curves with the RAINSTAR A3 loaded on a trailer, the permissible maximum
driving speed is reduced considerably in dependence on the position of the RAINSTAR A3's
centre of gravity!
13. Always make sure that the locks and stops are secured according to the machine's general
conditions for transport.
14. Before starting irrigation near electric power lines, you should contact your local power supply
company regarding the safety distances to be observed.
15. Maximum permissible speed: 10 km/h.
WARNING!
WARNING!

Manual for BAUER RAINSTAR A3
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2 DESCRIPTION
The RAINSTAR A3 is a universal irrigation machine for varying lengths and widths of fields and it is best
suited for sprinkling seed crops and horticultures, parks, vegetable plantations as well as any kind of
grassland.
The main components are a two-wheel undercarriage, the swiveling turntable and the reel with the
special PE-pipe, the compact gearbox and the Ti 7-A turbine as well as the high-rise cart that is ideal
particularly for high crops with the BAUER wide-range gun.
The material of the PE-pipe corresponds to the latest state-of-the-art. One end of the pipe connects to
the reel drum and to the water supply through its axle. The other end of the pipe is coupled with the
high-rise cart. The cart's track width is infinitely adjustable (see technical data).
The heart of the RAINSTAR A3 is the Ti 7-A turbine. This is a full-flow turbine, nearly insensitive to
soiled water and offers maximum efficiency. The drive shaft is made of stainless steel. The regulating
flap inside the turbine is coated with a wear-proof rubber lining.
The lifetime lubricated drive shaft bearing is sealed by a maintenance-free rotating mechanical seal.
The Ti 7-A turbine is designed for water flow rates from 4,8 to over 20 m³/h and features a wide control
range. Impeller speeds range from 200 to 1000 rpm.
The system's connecting pressure should not exceed 8 bar.
Power is directly transmitted from the turbine to the change-speed gearbox as well as from the chain
drive onto the reel. A reel brake prevents fast reverse rotation of the reel in the final shut-off position
when the PE-pipe is stretched.
The reel brake and the gearwheels in the change-speed gearbox filled with oil, act as brake and prevent
the PE-pipe windings on the reel from loosening during pipe pull-out.
For safety reasons, the drive is fitted with an emergency stop and a reversing stop. With this emergency
stop device, the drive can be stopped immediately by hand.
Never remove the drive cover before you have turned off the water supply
to the machine and slackened the stretched PE-pipe.
A winding carriage moved by a helically grooved spindle ensures that the PE-pipe is wound up properly
on all layers.
WARNING!

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Mechanical regulation: To keep the retraction speed constant on all layers independent of the pipe
length still lying on the field, the RAINSTAR A3 is equipped with a layer compensating device. It is
actuated by the shut-off frame that is always resting against the PE-pipe and acts on the regulating flap
of the turbine via control rods.
At the end of the irrigation strip, the cart is lifted automatically to transport position. Thereby the drive is
shut-off automatically by rods.
After shut-off, the cart lifted automatically, is locked through the transport lock. If the machine is
equipped with a shut-off valve (mechanical regulation), the water supply will be shut off simultaneously.
After shut-off, apply the reel brake (see item 5 "Quick Stop"). Now the RAINSTAR A3 can be
transported to its next setting-up position immediately. Pull-off or lay down the PE-pipe, connect the
water supply and the machine is ready for the next run.
When driving on public roads, the reel must be turned into driving direction and secured with the lock
bolt. The PE-pipe must be fully wound up on the reel, the cart must be lifted and the reel brake must be
applied. The jack and both rear machine supports must be withdrawn to their top position.
On public roads, the drawbar must be hitched to the tractor's yoke. Without administrative authorization,
the driving speed must not exceed 10 km/h.
Basically it is possible to transport the machine between hydrants in the field with the cart lifted on the
side. In this configuration, the driving speed always must be adapted to the existing conditions and it
should never exceed 5 km/h.
3 PUTTING INTO OPERATION
Before and during the first start-up, grease all bearings, chains and guide parts of the winding
mechanism. Use normal ball bearing grease for all bearing assemblies with grease nipples and a
viscous and durable type of grease for chains, guide rods and joints.
Tighten the wheel nuts before the first starting and check the tires on the specified pressure (see
technical data).
Tighten also the connecting bolts, the ball race on the undercarriage and turntable according to the
"Service and Maintenance" table.
3.1 STEPS TO BE CARRIED OUT ONCE OR FROM TIME TO TIME
Set the required track width on the cart depending on the
existing type of crop.

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OPERATING MODE I: PE-PIPE PULL-OFF
3.1.1 Transport of Machine to Set-up Position
During transport, the reel should be turned into the driving
direction and secured with the lock bolt. The reel brake must
be applied. Cart, jack and both rear support legs must be lifted
or retracted. For lateral PE-pipe pull-off, set up the RAINSTAR
A3 on the headland at right angles to the selected irrigation
strip and detach it from the tractor.
Adjust the undercarriage in a level position with the jack.
When positioning the RAINSTAR A3, make sure that the machine's vertical axis of rotation is in the
middle of the driving lane or centered between two crop rows.
For lateral pull-off of the PE-pipe, remove the lock bolt, turn
the reel into the direction of the driving lane and secure it
again with the lock bolt.
Extend the supports into the ground by means of a winch.
On very hard soil, the supports must be extended into holes dug into the ground for this purpose.

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3.1.2 LOWERING THE CART
Unlock the cart mechanically in working position. Pull up the
locking lever.
Now loosen the reel brake.
SWITCHING POSITIONS OF THE SHUT-OFF LEVER
834 9274
PE-pipe pull-off
Tractor rewind
Working position
PE-pipe retraction

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3.1.3 PULLING OFF THE PE-PIPE
Hitch the toolbar on the pulling hook and pull the cart into the
field.
The standard wheel cart need not be lifted (therefore 1 pulling
hook is sufficient).
Pull-off speed: Do not exceed 5 km/h!
Do not stop abruptly but slow down gradually at an intermediate stop or at the end of the pull-off.
If the PE-pipe was exposed to the sun for a longer period or if its surface
temperature rose above 35°C, you will have to cool the pipe by water flow before
rewinding it.
Couple the pressure hose. Open the water supply.
WARNING!

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14
When the full operating pressure has been reached and clear
water is discharged at the sprinkler's nozzle in a full jet without
air bubbles, push the gear shift lever to the "PE-pipe
retraction" position.
The reel starts to rewind the PE-pipe.
3.1.4 SPEED ADJUSTMENT with mechanical regulation
Adjust the speed only when the PE-pipe already has been rewound by half a
winding and/or when it is stretched.
Slower Faster
Loosen the knurled nuts (for fixation of the adjusting lever).
Set the retraction speed which can be read on the
speedometer (optional) by means of the adjusting lever. Then
lock the adjusting lever again with the knurled nuts.
Retractionspeedm/h102030
Waterflow10m³/h21‐
14m³/h211
18m³/h221
In the table you find the hole position.
Hole 1 is the bottom hole.
Note:
Smalls corrections deviating from the chart could be necessary, because the friction resistance of the
Pipe on the ground is equal.
IMPORTANT!

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At the end of irrigation, the cart is lifted automatically and the
drive is shut off by means of rods.
The water supply is stopped by the optional "overpressure
shut-off valve".
Once the PE-pipe retraction has been finished, withdraw the
supports by means of the winch.