LELY WELGER RPC 445 TORNADO User manual

LELY WELGER
RPC 445 TORNADO
RPC 445 TORNADO
4895.99.03.01 10.10 (Translation of the original manual)
Operating Manual

Send back to:
Lely International N.V.
TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbüttel
Handover protocol 1 (Copy for the Manufacturer)
Complete this form on delivery of the machine and return it within 4 weeks.
Possible guarantee requests cannot be handled before this document has not been sent back.
Date of delivery: ........................................................................
Machine type:
RPC 445 Tornado
........................................................................
Machine no. on the data plate (e. g. 4895.00.001): ........................................................................
I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating
manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the
machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
The following components must be reinstalled prior to first commissioning:
See separate document "Container Removal and Assembly Instructions".
Remove installed steel shipping wheels. Install the enclosed pneumatic tired wheels.
Remove the installed shipping rod (see picture).
..................................... ...........................................................................
Date Customers Signature

Send back to:
Lely International N.V.
TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbüttel
M
Complete this form on delivery of the machine and return it within 4 weeks.
Possible guarantee requests cannot be handled before this document has not been sent back.
Customer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Signature Customer Service

Handover protocol 2 (Copy for the costumer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RPC 445 Tornado
........................................................................
Machine no. on the data plate (e. g. 4895.00.001): ........................................................................
I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating
manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the
machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
The following components must be reinstalled prior to first commissioning:
See separate document "Container Removal and Assembly Instructions".
Remove installed steel shipping wheels. Install the enclosed pneumatic tired wheels.
Remove the installed shipping rod (see picture).
..................................... ...........................................................................
Date Customers Signature

M
Complete this document when the machine is delivered and keep it.
Customer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Signature Customer Service

Handover protocol 3 (Copy for the trader)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RPC 445 Tornado
........................................................................
Machine no. on the data plate (e. g. 4895.00.001): ........................................................................
I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating
manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the
machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
The following components must be reinstalled prior to first commissioning:
See separate document "Container Removal and Assembly Instructions".
Remove installed steel shipping wheels. Install the enclosed pneumatic tired wheels.
Remove the installed shipping rod (see picture).
..................................... ...........................................................................
Date Customers Signature

M
Complete this document when the machine is delivered and keep it.
Customer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Signature Customer Service

Handover protocol 4 (Copy for the Importer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RPC 445 Tornado
........................................................................
Machine no. on the data plate (e. g. 4895.00.001): ........................................................................
I purchased / use this machine. The operating manual including the EC conformity declaration (page next to the last in the operating
manual) was delivered to me together with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the
machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
The following components must be reinstalled prior to first commissioning:
See separate document "Container Removal and Assembly Instructions".
Remove installed steel shipping wheels. Install the enclosed pneumatic tired wheels.
Remove the installed shipping rod (see picture).
..................................... ...........................................................................
Date Customers Signature

M
Complete this document when the machine is delivered and keep it.
Customer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Signature Customer Service

Type Overview
LELY WELGER yRPC 445 Tornado 3
PREFACE
Please read this operating manual!
 This operating manual provides you with important
information for the safe operation of your machine.
 Pass on this operating manual to every user of this
machine.
 This manual must always be available wherever the
machine is in use.
Please read the separate operating manual
"PRO-LINK for LELY WELGER RPC 445 Tornado"
 Observe all safety instructions!
Attention, danger of injury!
Prior to first commissioning the machine must be calibrated!
See separate operating manual:
"PRO-LINK for RPC 445", chapter "CALIBRATION".
The serial number is shown on the name plate (Figure 1).
Warranty claims and queries cannot be dealt with unless the
ident number is stated. Please enter the ident number here
immediately after delivery:
Ident no.:
Figure 1

Type Overview
4LELY WELGER yRPC 445 Tornado
IMPRINT
Reprint without express written approval not permitted. All rights and technical
alterations reserved. Illustrations are not binding on form and design of the
machine.
© 2010 by Welger Maschinenfabrik GmbH Wolfenbüttel Made in Germany.
4895.99.03.01 Rev 10.10 Print 10.10
Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143
eMail: [email protected]

Type Overview
LELY WELGER yRPC 445 Tornado 5
CONTENTS
1 TYPE OVERVIEW...................................................................................................................................................... 7
2 WARNING SYMBOLS ............................................................................................................................................... 8
2.1 Symbols in this manual ....................................................................................................................................................................... 8
2.2 Symbols on the machine..................................................................................................................................................................... 9
3 SAFETY ................................................................................................................................................................... 18
3.1 Proper use......................................................................................................................................................................................... 18
3.2 Foreseeable misuse.......................................................................................................................................................................... 19
3.3 General safety instructions ............................................................................................................................................................... 20
3.4 Operator positions on the machine ................................................................................................................................................... 22
3.5 Fire protection ................................................................................................................................................................................... 23
3.6 Noise protection ................................................................................................................................................................................ 23
3.7 Guard casings................................................................................................................................................................................... 24
3.8 Emergency stop ................................................................................................................................................................................ 25
3.9 Maintenance Platform and Ladder.................................................................................................................................................... 26
3.10 Tailgate Safeguard............................................................................................................................................................................ 26
3.11 Net Knife Safeguard.......................................................................................................................................................................... 27
3.12 Film Knife Cut Protection .................................................................................................................................................................. 27
3.13 Wrapping Ring Safeguard................................................................................................................................................................. 28
3.14 Driving on the road............................................................................................................................................................................ 29
3.15 Data Plate Specifications .................................................................................................................................................................. 31
3.16 Hydraulic System .............................................................................................................................................................................. 32
3.17 Electromagnetic Compatibility (EMC) ............................................................................................................................................... 33
4 TECHNICAL DATA.................................................................................................................................................. 34
5 THE MACHINE......................................................................................................................................................... 35
5.1 Function ............................................................................................................................................................................................ 36
6 THE CONTROL ELECTRONICS ............................................................................................................................. 38
6.1 Safety................................................................................................................................................................................................ 38
6.2 Serial Numbers of the Control Electronics ........................................................................................................................................ 39
7 COMMISSIONING.................................................................................................................................................... 40
7.1 Safety................................................................................................................................................................................................ 40
7.2 Transport........................................................................................................................................................................................... 42
7.3 Connection of Hydraulic System....................................................................................................................................................... 44
7.4 Adjustment of Hydraulic System / Load Sensing .............................................................................................................................. 46
7.5 Connecting the Pneumatic System (Compressed Air Braking System) ........................................................................................... 47
7.6 Connecting the Hydraulic System (Hydraulic Braking System) ........................................................................................................ 49
7.7 Manually operated brake .................................................................................................................................................................. 49
7.8 Connection of Electrical Equipment .................................................................................................................................................. 50
7.9 Prior to first commissioning............................................................................................................................................................... 52
7.10 Checks before operation................................................................................................................................................................... 52
7.11 Coupling the Machine ....................................................................................................................................................................... 53
7.12 Drive Shaft ........................................................................................................................................................................................ 56
7.13 Inserting the Net................................................................................................................................................................................ 58
7.14 Tensioning the Net Knife................................................................................................................................................................... 64
7.15 Setting the Net Layers ...................................................................................................................................................................... 64
7.16 Selection of film prestretching rate.................................................................................................................................................... 65
7.17 Inserting/Replacing Film Rolls .......................................................................................................................................................... 66
7.18 Narrow Films – Wide Films ............................................................................................................................................................... 67
7.19 Spare Film Rolls................................................................................................................................................................................ 67
7.20 Film Layers and Film Overlap... ........................................................................................................................................................ 67
8 CUTTING DEVICE ................................................................................................................................................... 68
8.1 General Information .......................................................................................................................................................................... 68
8.2 Definition: Knife Groups .................................................................................................................................................................... 68
8.3 Definition: Cutting Position and Home Position ................................................................................................................................ 69
8.4 Working with the Desired Knife Group.............................................................................................................................................. 70
8.5 Cutting Device Protection ................................................................................................................................................................. 71
8.6 Bale optimisation............................................................................................................................................................................... 74
8.7 Brittle Crop Material .......................................................................................................................................................................... 74
8.8 Removing the cutting device knives.................................................................................................................................................. 75
8.9 Regrinding the Cutting Device Knives .............................................................................................................................................. 78

Type Overview
6LELY WELGER yRPC 445 Tornado
9 FIELD DEPLOYMENT..............................................................................................................................................79
9.1 Safety................................................................................................................................................................................................ 79
9.2 Driving on the Road .......................................................................................................................................................................... 81
9.3 Bale Wrapper: Bale Tipper ............................................................................................................................................................... 83
9.4 Laying swaths ................................................................................................................................................................................... 86
9.5 Pick-up Guide Wheels ...................................................................................................................................................................... 86
9.6 Windguard ........................................................................................................................................................................................ 87
9.7 Material Jam / Feed Guide Plate ...................................................................................................................................................... 87
9.8 PTO speed........................................................................................................................................................................................ 88
9.9 Driving style ...................................................................................................................................................................................... 89
9.10 Adjusting the bale diameter .............................................................................................................................................................. 91
9.11 Setting the Bale Density (Baling Pressure) ...................................................................................................................................... 92
9.12 Tailgate Locked ................................................................................................................................................................................ 93
9.13 Net Tying and Bale Unloading.......................................................................................................................................................... 94
9.14 Overload Protection.......................................................................................................................................................................... 98
9.15 Monitoring cameras .......................................................................................................................................................................... 98
9.16 Removing a material jam.................................................................................................................................................................. 99
10 MAINTENANCE BALER ........................................................................................................................................101
10.1 Safety.............................................................................................................................................................................................. 101
10.2 Remarks ......................................................................................................................................................................................... 102
10.3 Manual Control Box ........................................................................................................................................................................ 102
10.4 Maintenance platform ..................................................................................................................................................................... 103
10.5 Screw check ................................................................................................................................................................................... 103
10.6 Tensioners ...................................................................................................................................................................................... 103
10.7 Wheels............................................................................................................................................................................................ 104
10.8 Compressed Air Brake Cylinder ..................................................................................................................................................... 105
10.9 Hydraulic Braking System .............................................................................................................................................................. 105
10.10 Winter pause................................................................................................................................................................................... 106
10.11 Lubricant disposal........................................................................................................................................................................... 107
10.12 Disposal of consumables................................................................................................................................................................ 107
10.13 Cleaning.......................................................................................................................................................................................... 107
10.14 Chain Lubrication System (Oil Lubrication) .................................................................................................................................... 108
10.15 Maintenance of the net tying unit.................................................................................................................................................... 110
10.16 Grease knife lever........................................................................................................................................................................... 111
10.17 Lubrication chart ............................................................................................................................................................................. 112
10.18 Maintenance of Hydraulic System .................................................................................................................................................. 115
10.19 Hydraulic System (Complete Machine) .......................................................................................................................................... 116
10.20 Maintenance of Pneumatic System ................................................................................................................................................ 118
10.21 Tensioning the roller chains............................................................................................................................................................ 119
10.22 Locking the Belt Rocker.................................................................................................................................................................. 121
10.23 Pin Assignment of the Control Electronics ..................................................................................................................................... 122
11 MAINTENANCE OF ROUND BALE WRAPPER ...................................................................................................125
11.1 Safety.............................................................................................................................................................................................. 125
11.2 Remarks ......................................................................................................................................................................................... 125
11.3 Manual Control Box ........................................................................................................................................................................ 126
11.4 Screw check ................................................................................................................................................................................... 127
11.5 Winter pause................................................................................................................................................................................... 127
11.6 Lubricant disposal........................................................................................................................................................................... 128
11.7 Disposal of consumables................................................................................................................................................................ 128
11.8 Cleaning.......................................................................................................................................................................................... 128
11.9 Lubrication Chart ............................................................................................................................................................................ 129
11.10 Film Stretching Unit ........................................................................................................................................................................ 131
11.11 Wrapping Ring Brake...................................................................................................................................................................... 131
11.12 Chains of Wrapping Table Rollers.................................................................................................................................................. 132
11.13 Belt Guide Pulleys .......................................................................................................................................................................... 132
11.14 Film Knife Change .......................................................................................................................................................................... 133
11.15 Hydraulic System (Complete Machine) .......................................................................................................................................... 134
11.16 Visual Inspection of Hydraulic System ........................................................................................................................................... 134
11.17 Pin Assignment of the Control Electronics ..................................................................................................................................... 134

Type Overview
LELY WELGER yRPC 445 Tornado 7
1 TYPE OVERVIEW
Hitch, rigid
Hitch, rotating
Drawbar
Ball hitch 80 mm
Pick-up width 2.25 m (DIN 11220)
Roller lubrication manual roller lubrication
Chain lubrication automatic lubrication
MasterCut (13 knives)Cutting device
XtraCut 25 (25 knives)
Ring type rotor (for 13 knives)Feed rotor
ProfiCut rotor (star type rotor) (for 25 knives)
Tying Net tying
Control box / control electronics Control box PRO-LINK
Control electronics Balercontrol III
Feed channel floor Feed channel floor (HYDROFLEXCONTROL, swivelling)
(hydraulic opening and closing)
Hydraulic brake
Compressed air brake
Brakes
Mechanical manually operated brake
Table 1

WARNING SYMBOLS
8LELY WELGER yRPC 445 Tornado
2 WARNING SYMBOLS
2.1 Symbols in this manual
Instructions of particular importance in this manual are marked
by the following symbols and signal words:
Attention!
This symbol stands next to warnings: danger to life, danger
of injury, possible serious material damage.
Caution!
This symbol stands next to safety instructions: malfunctions
and impairments of correct operation, possible material
damage.
Note!
This symbol stands next to useful information: special
information on how to use the machine most efficiently.

WARNING SYMBOLS
LELY WELGER yRPC 445 Tornado 9
2.2 Symbols on the machine
Not all danger zones of the machine can be secured by
constructional measures. Such danger zones are therefore
marked by symbols:
 Prohibition signs (red)
 Warning sign (yellow)
 Symbolised operating instructions
Keep all symbols in a recognisable state. If any symbols on this
machine are missing or have been damaged, they must be
replaced.
2.2.1 Prohibition signs
No smoking!
Spare part no.: 0388.37.00.00
Do not step on the area!
Spare part no.: 0386.11.00.00

WARNING SYMBOLS
10 LELY WELGER yRPC 445 Tornado
2.2.2 Warning signs
Attention, danger due to wrong operation!
Prior to first commissioning: read and observe operating
manual and safety instructions.
Spare part no.: 0388.11.00.00
Attention, danger of bruising and drawing-in!
Prior to first commissioning: close the guard casings of the
machine!
Spare part no.: 0389.92.00.00
Attention, danger of bruising and drawing-in!
Never reach into the pick-up area as long as the tractor engine
is running with the drive shaft connected.
Spare part no.: 0389.94.00.00
Attention, danger of injury!
Prior to any repair, maintenance and cleaning work: Switch off
power take-off shaft, switch off tractor engine, remove ignition
key and disconnect drive shaft from power take-off shaft end.
Spare part no.: 0388.25.00.00
Attention, danger of injury!
Prior to any repair, maintenance and cleaning work: stop the
engine and pull off the plug of the power supply.
Spare part no.: 0388.13.00.00

WARNING SYMBOLS
LELY WELGER yRPC 445 Tornado 11
Attention, danger of injury!
Riding on the machine is prohibited for the entire machine
Spare part no.: 0391.06.00.00
Attention, danger of bruising and drawing-in!
Stay clear of tailgate swinging area while in operation.
Spare part no.: 0389.93.00.00
Attention, danger of injury by cutting!
Handle the cutting unit blade only when wearing protective
gloves and using suitable tools.
Spare part no.: 0387.33.00.00
Attention, danger of bruising!
Keep out of the range of action of the support feet plates when
lowering the support feet.
Spare part no.: 0386.32.00.00

WARNING SYMBOLS
12 LELY WELGER yRPC 445 Tornado
Attention, danger of injury!
Keep out of the turning circle of the wrapping arms or the
swivelling range of film knives and wrapping table during
operation. Safety distance: 3 meters.
Spare part no.: 0387.87.00.00
Attention, danger of bruising and cutting!
Never reach into the swivelling range of film or net knives.
Spare part no.: 0387.90.00.00
Attention, danger of bruising and drawing-in!
Be careful with rotating machine parts: Film rolls and stretch
rollers rotate during operation.
Spare part no.: 0387.86.00.00
Attention, danger of running-over! Use wheel chocks!
Keep out of the travelling range of the wheels.
Secure wheels by means of wheel chocks.
Spare part no.: 0386.25.00.00