Challenger RB452 User manual
Service Manual
RB452
Round Baler
79033773 A Rev. 01-i
CHALLENGER®
RB452
Round Baler
79033773 A Rev.
CONTENTS
GENERAL INFORMATION ................................................................................................................................................01
DRIVES................................................................................................................................................................................02
PICKUP................................................................................................................................................................................03
ELECTRICAL ......................................................................................................................................................................04
BALE FORMING.................................................................................................................................................................05
BALE WRAPPING...............................................................................................................................................................06
CHASSIS.............................................................................................................................................................................07
HYDRAULICS .....................................................................................................................................................................08
INDEX..................................................................................................................................................................................09
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79033773 A Rev. 01-1
Contents
Challenger®
RB452
Round Baler
SERVICE MANUAL
79033773 A Rev.
01 - General Information
Contents
Safety ............................................................................................................................................................. 01-3
Safety Alert Symbol ................................................................................................................................. 01-3
Safety Signs ............................................................................................................................................ 01-3
Safety Messages ..................................................................................................................................... 01-3
Informational Messages .......................................................................................................................... 01-3
Manual ..................................................................................................................................................... 01-4
A Word to the Operator ........................................................................................................................... 01-4
Prepare for Operation .............................................................................................................................. 01-5
Operation ................................................................................................................................................. 01-5
Travel On Public Roads .......................................................................................................................... 01-7
Fire Prevention ........................................................................................................................................ 01-8
Maintenance ............................................................................................................................................ 01-8
Tire Safety ............................................................................................................................................. 01-10
Introduction .................................................................................................................................................. 01-11
Units of Measurement ........................................................................................................................... 01-11
Replacement Parts ................................................................................................................................ 01-11
Serial Number Plate Location ................................................................................................................ 01-11
Machine Identification ............................................................................................................................ 01-11
Baler Operation ..................................................................................................................................... 01-12
Tailgate Lockout Valve .......................................................................................................................... 01-13
Baler Components ................................................................................................................................. 01-14
Specifications ............................................................................................................................................... 01-19
Dimensions and Weights ....................................................................................................................... 01-19
Bale Size ............................................................................................................................................... 01-19
Bale Chamber ....................................................................................................................................... 01-19
Tires ...................................................................................................................................................... 01-20
Drives .................................................................................................................................................... 01-20
Pickup .................................................................................................................................................... 01-20
Twine Wrapping Mechanism ................................................................................................................. 01-20
Lighting .................................................................................................................................................. 01-20
Tractor Requirements ............................................................................................................................ 01-21
Lubrication ............................................................................................................................................. 01-21
General Service Procedures ........................................................................................................................ 01-22
Bolt Torque Values ................................................................................................................................ 01-22
Wheel Hardware .................................................................................................................................... 01-22
Bearing Replacement (Eccentric Self-Locking Collar) .......................................................................... 01-23
Gib Key Removal And Installation ......................................................................................................... 01-24
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79033773 A Rev. 01-3
General Information
GENERAL INFORMATION
SAFETY
Safety Alert Symbol
FIG. 1: The safety alert symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
This safety alert symbol indicates important safety
messages in this Operator Manual. When you see this
symbol, carefully read the message that follows and be
alert to the possibility of personal injury or death.
Safety Signs
If a used machine has been purchased, be sure all safety
signs are in the correct location and can be read.
Replace any safety signs that can not be read or are
missing. Replacement safety signs are available from
your dealer. The location of safety signs is illustrated at
the end of this division.
Safety Messages
FIG. 2: Whenever you see the words and symbols
shown below, used in this manual, you MUST take note of
their instructions as they relate to personal safety.
mDANGER: Indicates an imminently
hazardous situation that, if not avoided, will
cause death or very serious injury.
mWARNING: Indicates a potentially
hazardous situation that, if not avoided,
could result in death or serious injury.
mCAUTION: Indicates a potentially
hazardous situation that, if not avoided,
may result in minor injury.
Informational Messages
The words IMPORTANT and NOTE are not related to
personal safety, but are used to give additional
information and tips for operating or servicing this
equipment.
IMPORTANT: Identifies special instructions or
procedures which, if not strictly observed, could
result in damage to or destruction of the
machine, process, or its surroundings.
NOTE: Identifies points of particular interest for more
efficient and convenient repair or operation.
FIG. 1
Saf
FIG. 2
WC1957
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General Information
01-4 79033773ARev.
Manual
The photos, illustrations, and data used in this manual
were current at the time of printing, but due to possible
in-line production changes, your machine can vary slightly
in detail. The manufacturer reserves the right to redesign
and change the machine as necessary without
notification.
mWARNING: In some of the illustrations or
photos used in this manual, panels or
guards may have been removed for clarity.
Never operate the machine with any panels
or guards removed. If the removal of panels
or guards is necessary to make a repair,
they MUST be replaced before operation.
A Word to the Operator
FIG. 3: It is YOUR responsibility to read and understand
the Safety section in this book before operating this
machine. Remember that YOU are the key to safety.
Good safety practices not only protect you, but also the
people around you. Study the features in this book and
make them a working part of your safety program. Keep in
mind that this Safety section is written only for this type of
machine. Practice all other usual and customary safe
working precautions, and above all REMEMBER -
SAFETY IS YOUR RESPONSIBILITY. YOU CAN
PREVENT SERIOUS INJURY OR DEATH.
This Safety section is intended to point out some of the
basic safety situations that may be encountered during
the normal operation and maintenance of your machine,
and to suggest possible ways of dealing with these
situations. This section is NOT a replacement for other
safety practices featured in other sections of this book.
IMPORTANT: This manual covers general safety
practices for this machine. It must always be kept
with the machine.
mWARNING: An operator should not use
alcohol or drugs which can affect their
alertness or coordination. An operator on
prescription or 'over the counter' drugs
needs medical advice on whether or not
they can properly operate machines.
FIG. 3
S-1123
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79033773 A Rev. 01-5
General Information
Prepare for Operation
Read this manual completely and make sure you
understand the controls. Know the positions and
operations of all controls before you operate this machine.
Check all controls in an area clear of people and
obstacles before starting your work.
All equipment has a limit. Make sure you understand the
speed, brakes, steering, stability, and load characteristics
of this machine before you start.
Make sure your machine has the correct equipment
needed by the local regulations.
Operation
Make sure the machine is in the proper operating
condition as stated in the Operator Manual.
Make sure the tractor is in proper operating condition with
the brakes adjusted, especially when operating on terrain
that is not even.
To achieve proper braking capacity, the weight of the baler
with a bale must not exceed 1.5 times the weight of the
tractor.
FIG. 4: Wear all protective clothing and personal
protective equipment issued to you or called for by job
conditions. Wear approved hearing protection whenever
operating the machine as required by country/local
regulations. Do not wear loose clothing, jewelry, or other
items that could entangle in moving parts. Tie up long hair
that also could entangle in moving parts. Always keep
hands, feet, hair, and clothing away from moving parts.
FIG. 5: Securely fasten your seat belt before operating
the machine. Always remain seated when operating the
machine.
Never start the tractor with PTO engaged.
Always slide the hitch pin lock plate over the hitch pin and
install the Klik pin when connecting the baler to the tractor.
Always install the safety transport chain between the baler
and tractor drawbar.
• Use a chain with a strength rating equal to or more
than the gross weight of the towed machine.
• Supply only enough slack in the chain to permit
turning.
• Do not use the safety transport chain as a tow chain
for towing.
FIG. 4
S-1127A
FIG. 5
Wc1953a
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General Information
01-6 79033773ARev.
FIG. 6: Always put the tractor transmission in park and
apply the parking brake and remove the tractor key when
parking the machine and take the key with you.
Do not allow children or unqualified persons to operate
your machine.
Do not permit others to ride on the machine. Keep others
away from your area of work.
FIG. 7: Because of the flammable nature of many hay
crops, a water fire extinguisher must be placed within
easy reach.
Keep a first aid kit handy for treatment for minor cuts and
scratches.
FIG. 8: Stay at least 3.7 m (12 ft) away from the tailgate
at all times. The tailgate operates faster than you can
move away.
Always make sure the area around the tailgate is clear for
at least 3.7 m (12 ft) before opening the tailgate and
unloading the bale. Keep bystanders away from the baler
and the tailgate when unloading a bale.
Before raising the tailgate, make sure the baler is securely
fastened to the tractor drawbar. The baler tongue may lift
up when the tailgate is raised. This can cause the baler to
tip to the rear, causing personal injury or damage to the
machine.
Avoid contact with electrical power lines. Never open the
tailgate near electrical wires. Contact with electrical power
lines can cause electrical shock, resulting in very serious
injury or death.
FIG. 6
d-7084
FIG. 7
S-1131
FIG. 8
L98A-145a
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79033773 A Rev. 01-7
General Information
FIG. 9: When moving bales, never use a tractor front end
loader that is not equipped with a grapple or the proper
bale handling equipment. Use the grapple to prevent the
bale from rolling down the loader frame onto the operator.
Always keep the load close to the ground to keep from
off-balancing the tractor.
Never unload or store bales on a slope where bales can
roll.
Always disengage the tractor PTO, put the tractor
transmission in PARK and apply the parking brake before
getting off of the tractor. Stop the tractor engine and
remove the key before servicing or doing any
maintenance on the machine.
Travel On Public Roads
FIG. 10: Use the lighting and marking system supplied
with the machine when roading.
Make sure reflectors are correctly installed, in good
condition, and wiped clean. Be sure the SMV emblem is
clean, visible, and correctly mounted on the rear of the
machine.
Familiarize yourself with and obey all road regulations that
apply to your machine. Consult your local law
enforcement agency for local regulations regarding
movement of farm equipment on public roads.
Adjust travel speed to maintain control at all times. Limit
speeds to 32 km/hr (20 mi/hr).
Be aware of other traffic on the road. Keep well over to
your own side of the road and pull over, whenever
possible, to let faster traffic pass.
Be aware of the overall width and length of the machine.
Be careful when transporting the machine on narrow
roads and across narrow bridges.
Do not road the baler with a bale in the chamber.
FIG. 9
S-1143
FIG. 10
s-1025
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General Information
01-8 79033773ARev.
Fire Prevention
FIG. 11: Due to the nature of the crops this machine will
operate in, the risk of fire is of concern. Regular
inspection of the machine can reduce the risk of fire. Keep
the machine free of crop debris.
Check the machine daily for any noises that are not
normal. Such noises could indicate a failed bearing that
can cause heat buildup.
When finished baling and before leaving baler, remove
the bale from the bale chamber. Raise the tailgate and put
the tailgate lockout valve in the lock position. Check for
accumulation of hay or hot spots in the bale chamber and
pickup area. Remove hay accumulation. Put the tailgate
lockout valve in the unlock position and lower the tailgate.
If a fire occurs while baling, eject the bale, move tractor
and baler upwind away from bale 12 m (40 ft). Raise the
tailgate. Engage the tailgate lockout valve in the LOCKED
position. Use a fire extinguisher or other water source to
put out the fire.
Maintenance
FIG. 12: Before doing any unplugging, lubricating,
servicing, cleaning, or adjusting:
• Park the machine on a solid level surface.
• Close the tailgate.
• Disengage the tractor PTO.
• Put the tractor transmission in PARK and apply the
tractor parking brake.
• Stop the tractor engine and take the key with you.
• Put the tailgate lockout valve into the LOCKED
position if the tailgate is raised.
• Look and Listen! Make sure all moving parts have
stopped.
• Put blocks in front of and behind the wheels of the
tractor and the baler before working on or under the
baler.
FIG. 13: Never service, check or adjust drive chains or
belts while the tractor engine is running.
Never remove crop, twine, or mesh from the machine
while the tractor engine is running. Moving parts can pull
you in faster than you can move away.
FIG. 11
wc1946
FIG. 12
D-8518
FIG. 13
wc1943
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79033773 A Rev. 01-9
General Information
FIG. 14: DO NOT operate the machine with drive shafts
shields open or removed. Entanglement in rotating drive
shafts can cause serious injury or death.
Stay clear of rotating components.
Make sure rotating guards turn freely.
A loose yoke can slip off the tractor PTO shaft and result
in injury to persons or damage to the machine.
When installing a quick disconnect yoke, the spring
activated locking pins must slide freely and be seated in
the groove on the PTO shaft.
Pull on the implement driveline to make sure the quick
disconnect yoke cannot be pulled off the PTO shaft.
FIG. 15: When the tailgate is raised for any maintenance
or service work, put the tailgate lockout valve (1) into the
LOCKED position.
Always unload the bale from the bale chamber before
raising or working under the machine.
FIG. 16: Escaping hydraulic fluid under high pressure
can be almost invisible but can penetrate the skin causing
serious injury.
Fluid injected into the skin must be surgically removed
within a few hours. If not treated immediately, serious
infection or reaction can develop. See a doctor familiar
with this type of injury immediately.
FIG. 17: Use a piece of cardboard or wood to search for
possible leaks, never use your hands. Wear leather
gloves for hand protection and safety goggles for eye
protection. DO NOT use your bare hand.
Relieve all pressure before disconnecting any hydraulic
lines. Make sure all connections are tight and hydraulic
lines are not damaged before applying pressure.
Make sure electrical connectors are free of dirt and
grease before connecting.
Check for loose, broken, missing, or damaged parts.
Have everything in good repair. Make sure all guards and
shields are in place.
Check all nuts and bolts periodically for tightness.
FIG. 14
wc1941
FIG. 15
1
hb06304
FIG. 16
wc1938
FIG. 17
D-5842a
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General Information
01-10 79033773ARev.
After unplugging, lubricating, servicing, cleaning, or
adjusting the machine make sure all tools and equipment
have been removed.
Tire Safety
FIG. 18: Tire explosion and/or serious injury can result
from over inflation. Do not exceed tire inflation pressures.
See Tires in Specifications for correct tire pressure.
Check tires for cuts and bulges. Replace worn or
damaged tires. When tire service is necessary, have a
qualified tire mechanic service the tire. See Tires in
Specifications for correct tire size.
Do not weld on the rim when a tire is installed. Welding
will cause an explosive air/gas mixture that will ignite with
high temperatures. This can happen to tires that are
inflated or deflated. Removing air or breaking the bead is
NOT enough.
FIG. 18
D-8386
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79033773 A Rev. 01-11
General Information
INTRODUCTION
The operation and maintenance instructions included in
this manual are assembled from field testing and other
data. The information is written for general conditions.
Make adjustments as necessary for specific conditions.
Right-hand and left-hand, as used in this manual, is
determined by facing the direction the machine will travel
when in use.
Units of Measurement
Measurements are given in metric units of measurement
followed by the equivalent in U.S. units. Hardware sizes
are given in millimeters for metric hardware and inches for
U.S. hardware.
Replacement Parts
To receive prompt efficient service, always remember to
give the dealer the following information:
• Correct part description or part number.
• Model number of your machine.
• Serial number of your machine.
Serial Number Plate Location
FIG. 19: The serial number plate (1) is located on the
inside of the left-hand side panel.
Machine Identification
Machine Model No.: ____________________________
Machine Serial No.: ____________________________
Date of Delivery: _______________________________
Dealer Name and Address: ______________________
____________________________________________
____________________________________________
____________________________________________
Dealer's Telephone No.: _________________________
Dealer's Fax No.: ______________________________
FIG. 19
1
KC03034
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01-12 79033773ARev.
General Information
Baler Operation
FIG. 20: The illustration shows the windrowed crop
being picked up. The crop moves across the pickup
assembly (1) into the bottom of the open throat bale
chamber. The windguard (2) holds the crop against the
pickup assembly. In the bale chamber the crop contacts
the rough top surface of the forming belts (3), which are
moving upward. The forming belts carry the crop to the
top of the starting chamber which is formed by the bale
density rolls (4). The downward motion of the forming
belts turns the crop downward against the starting roll (5).
The starting roll folds the crop rearward into the crop
coming in. The core is started and begins to roll.
Springs and hydraulic cylinders pull down on the tension
arm (6). The bale density rolls are held down to reduce
the size of the bale chamber to a starting size. The belt
tension roll (7) is held down to remove the slack from the
forming belts. As the bale increases in size, the bale
density rolls are forced upward moving the bale size
indicator (8) downward. The bale density roll puts an
increasing downward force against the bale. This force
keeps tension on the bale and compresses the crop
coming into the baler.
The stagger roll (9) holds the outside forming belts in front
of the other forming belts. This releases crop deposits
from behind the forming belts.
The forming belts are driven by the drive roll (10).
FIG. 20
4
2
1
3
5
6
7
8
10
d-8134a
9
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79033773 A Rev. 01-13
General Information
FIG. 21: The illustration shows the full size bale. The
bale density rolls (1) have moved upward, to increase the
size of the bale chamber. The bale is on the tailgate
carrier roll (2).
The bale must now be wrapped with twine and unloaded.
Tailgate Lockout Valve
FIG. 22: When the tailgate is raised for any maintenance
or service work, push the lockout valve (1) into the
LOCKED position to prevent the tailgate from being
lowered. The tailgate can only be lowered when the
tailgate lockout valve is released (pulled out).
FIG. 21
2
1
d-8135a
FIG. 22
1
hb06304
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01-14 79033773ARev.
General Information
Baler Components
FIG. 23: Right-hand side of the baler.
(1) Twine arm actuator
(2) Windguard
(3) Tailgate latch strap
(4) Tailgate hydraulic cylinder
(5) Tailgate hinge pivot point
(6) Right-hand twine box
(7) Drive roll shaft
(8) Forming belts tensioning arm
(9) Forming belts tensioning cylinder
(10) Forming belts tensioning spring
(11) Implement driveline
(12) Slip clutch
FIG. 23
5
67
8
4
3
2
10
1
9
11
12
Q401215
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79033773 A Rev. 01-15
General Information
Tailgate
The tailgate is the rear half section of the bale chamber
and is supported by a hinge at the top. The tailgate is
operated by two hydraulic cylinders to unload the bale.
The tailgate has two forming belt idler rolls and a bale
carrier roll.
When the tailgate closes, the hydraulic cylinder must be
completely retracted in to latch the tailgate. If the tailgate
is not latched, the tailgate will swing open as the core is
started and the core will stop rolling. The bale must be
unloaded. The tailgate hydraulic cylinders are connected
to linkage that releases the latches when the tailgate is
opened.
Pickup Assembly
FIG. 24: The pickup assembly (1) picks up and feeds the
hay into the bale chamber. The major components of the
pickup assembly are the rotor shaft, tine bars, cam track,
windguard, and the pickup height control crank.
Forming Belts
FIG. 25: The forming belts are made of a high tensile
strength, controlled stretch, synthetic fabric bonded to the
covering material. The surface pattern on the forming
belts helps to roll the bale. See Specifications for more
information on the forming belts.
FIG. 24
1
j325033
FIG. 25
1
HB21469
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General Information
01-16 79033773ARev.
Bale Density System
FIG. 26: The bale density is controlled by two springs (1)
and a hydraulic tension system. As the bale increases in
size, oil is forced from the rod end of the forming belts
tensioning cylinder (2) through a non-adjustable relief
valve (3) to the base end. The pressure in the hydraulic
tension system is held at 13 790 kPa (2000 psi).
Bale Size Indication
FIG. 27: The bale size indicator (1) is located on the front
right-hand side of the baler. As the bale increases in size,
the bale size indicator pointer will move down. Begin
wrapping the bale immediately when the bale has
reached the desired size.
The bale size indicator must be checked for accuracy for
each tractor used.
FIG. 26
2
3
1
j325005a
FIG. 27
1
HB06243
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