Welger RP 405 User manual
1755.99.03.01 07.05
from year of manufacture 2005
RP 405 / RP 435
1755-003
RP 435
Master
Operating Manual
Send back to:
Welger Maschinenfabrik GmbH
Abteilung CSC
Postfach 1965
D-38289 Wolfenbüttel
Handover declaration 1 (Copy for the Manufacturer)
Complete and return this document when the machine is delivered.
Possible guarantee requests cannot be handled before this document has not been sentback.
Date of delivery: ........................................................................
Machine type:
RP 405 / RP 435
..................................
Machine no. on the data plate (e. g. 1755.00.001): ........................................................................
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:
Wheels: see spare parts list pages A10, A20, A21
Maintenance platform: see spare parts list page K25 (items 01–06, 08–10, 12–14)
Railing: see spare parts list page K25 (item 11)
Guard hoods on pick-up: see spare parts list page C25 (items 7, 8)
Pick-up guide wheel: see spare parts list pages C30, C35
Pick-up guard rail: see spare parts list page K25 (item 7)
Support foot: see spare parts list page B30
Ladder on support foot: see spare parts list page K25 (items 15-20)
Drawbar head: see spare parts list page B20
Branch deflector on machine roof: see spare parts list page J80 (item 45)
Sensor support with sensor: see spare parts list page J80 (items 25, 32)
Chain tensioning blocks: see spare parts list page C10 (item 11)
Bale ejector shock absorber: see spare parts list page B70
Handles of side cover: see spare parts list pages K10, K11 (items 3–5)
Hydraulic system control block: see operating manual page 31
.............................. .............................................................
Date Customer's signature
Send back to:
Welger Maschinenfabrik GmbH
Abteilung CSC
Postfach 1965
D-38289 Wolfenbüttel
M
Complete and return this document when the machine is delivered.
Possible guarantee requests cannot be handled before this document has not been sentback.
Customer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Customer's signature
Handover declaration 2 (Copy for the Customer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RP 405 / RP 435
..................................
Machine no. on the data plate (e. g. 1755.00.001): ........................................................................
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:
Wheels: see spare parts list pages A10, A20, A21
Maintenance platform: see spare parts list page K25 (items 01–06, 08–10, 12–14)
Railing: see spare parts list page K25 (item 11)
Guard hoods on pick-up: see spare parts list page C25 (items 7, 8)
Pick-up guide wheel: see spare parts list pages C30, C35
Pick-up guard rail: see spare parts list page K25 (item 7)
Support foot: see spare parts list page B30
Ladder on support foot: see spare parts list page K25 (items 15-20)
Drawbar head: see spare parts list page B20
Branch deflector on machine roof: see spare parts list page J80 (item 45)
Sensor support with sensor: see spare parts list page J80 (items 25, 32)
Chain tensioning blocks: see spare parts list page C10 (item 11)
Bale ejector shock absorber: see spare parts list page B70
Handles of side cover: see spare parts list pages K10, K11 (items 3–5)
Hydraulic system control block: see operating manual page 31
.............................. .............................................................
Date Customer's 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 Customer's signature
Handover declaration 3 (Copy for the Trader)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RP 405 / RP 435
..................................
Machine no. on the data plate (e. g. 1755.00.001): ........................................................................
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:
Wheels: see spare parts list pages A10, A20, A21
Maintenance platform: see spare parts list page K25 (items 01–06, 08–10, 12–14)
Railing: see spare parts list page K25 (item 11)
Guard hoods on pick-up: see spare parts list page C25 (items 7, 8)
Pick-up guide wheel: see spare parts list pages C30, C35
Pick-up guard rail: see spare parts list page K25 (item 7)
Support foot: see spare parts list page B30
Ladder on support foot: see spare parts list page K25 (items 15-20)
Drawbar head: see spare parts list page B20
Branch deflector on machine roof: see spare parts list page J80 (item 45)
Sensor support with sensor: see spare parts list page J80 (items 25, 32)
Chain tensioning blocks: see spare parts list page C10 (item 11)
Bale ejector shock absorber: see spare parts list page B70
Handles of side cover: see spare parts list pages K10, K11 (items 3–5)
Hydraulic system control block: see operating manual page 31
.............................. .............................................................
Date Customer's 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 Customer's signature
Handover declaration 4 (Copy for the Importer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
RP 405 / RP 435
..................................
Machine no. on the data plate (e. g. 1755.00.001): ........................................................................
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:
Wheels: see spare parts list pages A10, A20, A21
Maintenance platform: see spare parts list page K25 (items 01–06, 08–10, 12–14)
Railing: see spare parts list page K25 (item 11)
Guard hoods on pick-up: see spare parts list page C25 (items 7, 8)
Pick-up guide wheel: see spare parts list pages C30, C35
Pick-up guard rail: see spare parts list page K25 (item 7)
Support foot: see spare parts list page B30
Ladder on support foot: see spare parts list page K25 (items 15-20)
Drawbar head: see spare parts list page B20
Branch deflector on machine roof: see spare parts list page J80 (item 45)
Sensor support with sensor: see spare parts list page J80 (items 25, 32)
Chain tensioning blocks: see spare parts list page C10 (item 11)
Bale ejector shock absorber: see spare parts list page B70
Handles of side cover: see spare parts list pages K10, K11 (items 3–5)
Hydraulic system control block: see operating manual page 31
.............................. .............................................................
Date Customer's 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 Customer's signature
WELGER RP 405 • RP 435 3
The serial number is shown on data plate on the right
machine side, as shown aside. Warranty claims and queries
cannot be dealt with unless the serial number is stated.
Please enter this number here immediately after delivery:
..............................................................................
Read and heed the operating instruction and safety instructions prior to commission the machine. In
this operating instruction all positions required for safety reasons are marked with a warning sign. Instruct
all other operators in safety instructions! The warning- and information signs located at the machine give
information for safe operation. Watch them for safety reasons!
Read and heed the separate operating instruction "E-LINK for RP 435 MASTER".
* Please watch, that the equipment marked with a [*] in this operating instruction, belong only to defined
types of the machine or that they are only deliverable for defined types as additional equipment.
Copy is not permitted - copyright and technical changes are reserved.
Illustrations are not binding on form and design.
©2005 by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany.
Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143
eMail: wmf@welger.com
4 WELGER RP 405 • RP 435
Table of Contents
1
VARIANTS ................................................................................................................................................... 6
2
SAFETY........................................................................................................................................................ 7
2.1
General safety instructions................................................................................................................. 7
2.2
Noise level.......................................................................................................................................... 9
2.3
Instructions for fire protection............................................................................................................. 9
2.4
Tail gate safeguard........................................................................................................................... 10
2.5
Maintenance Platform and Ladder ................................................................................................... 10
2.6
Hydraulic System ............................................................................................................................. 11
2.7
Guard casings .................................................................................................................................. 11
2.8
WARNING SYMBOLS ..................................................................................................................... 12
2.9
Symbolised operating instructions ................................................................................................... 15
2.10
Proper use........................................................................................................................................ 17
2.11
Electromagnetic compatibility........................................................................................................... 17
2.12
To heed in the road traffic ................................................................................................................ 18
2.13
Environment/Disposal ...................................................................................................................... 22
3
ASSEMBLY GROUPS ............................................................................................................................... 23
4
START UP.................................................................................................................................................. 24
4.1
Coupling the baler ............................................................................................................................ 24
4.2
Drive shaft ........................................................................................................................................ 27
4.3
Hydraulic System ............................................................................................................................. 29
4.4
Electrical system .............................................................................................................................. 32
4.5
Compressed-air braking system ...................................................................................................... 33
4.6
Hydraulic braking system ................................................................................................................. 34
5
TWINE TYING*........................................................................................................................................... 35
5.1
Threading the twine.......................................................................................................................... 35
5.2
Adjusting the twine brake ................................................................................................................. 38
5.3
Setting the edge clearances............................................................................................................. 39
5.4
Adjusting the wrapping distance ...................................................................................................... 39
5.5
Edge wrapping adjustment............................................................................................................... 40
6
NET TYING* ............................................................................................................................................... 41
6.1
Inserting the net................................................................................................................................ 41
6.2
Tightening the net knife.................................................................................................................... 47
6.3
Adjusting the net length.................................................................................................................... 48
7
CUTTING DEVICE*.................................................................................................................................... 49
7.1
Equipment ........................................................................................................................................ 49
7.2
Knife groups ..................................................................................................................................... 49
7.3
Moving in and out the cutting device................................................................................................ 52
7.4
Lock bottom door.............................................................................................................................. 67
7.5
Brittle crop material .......................................................................................................................... 68
7.6
Assembly and disassembly of the cutting device knives ................................................................. 68
7.7
Regrinding the cutting device knives................................................................................................ 69
WELGER RP 405 • RP 435 5
8
FIELD DEPLOYMENT ............................................................................................................................... 70
8.1
Locking the tail gate ......................................................................................................................... 71
8.2
Adjusting the bale diameter.............................................................................................................. 72
8.3
Setting the bale density.................................................................................................................... 73
8.4
Raising / lowering the pick-up .......................................................................................................... 74
8.5
Pick-up guide wheels ....................................................................................................................... 74
8.6
Windguard / Pick-up shield* ............................................................................................................. 75
8.7
Feed guide plate............................................................................................................................... 76
8.8
PTO speed ....................................................................................................................................... 76
8.9
Driving style...................................................................................................................................... 77
8.10
Safety clutch..................................................................................................................................... 79
9
OPERATION / TYING ................................................................................................................................ 80
9.1
BALERCONTROL E control box......................................................................................................80
9.2
E-LINK control box ........................................................................................................................... 83
9.3
Eject bales........................................................................................................................................ 87
9.4
Emergency operation ....................................................................................................................... 89
10
REMOVING A MATERIAL JAM ................................................................................................................ 94
10.1
Main drive reversing ......................................................................................................................... 94
10.2
Hydraulic bottom door*..................................................................................................................... 95
11
MAINTENANCE / SETTING ...................................................................................................................... 98
11.1
General notes................................................................................................................................... 98
11.2
Grease knife lever ............................................................................................................................ 98
11.3
Tensioners........................................................................................................................................ 99
11.4
Maintenance of the net tying unit ..................................................................................................... 99
11.5
Tensioning the roller chains ........................................................................................................... 100
11.6
Hydraulic layouts ............................................................................................................................ 101
11.7
Tire air pressure ............................................................................................................................. 104
11.8
Chain lubrication (oil lubrication) .................................................................................................... 105
11.9
Winter pause .................................................................................................................................. 106
11.10
Lubrication chart............................................................................................................................. 107
11.11
Lubrication points ........................................................................................................................... 109
12
TECHNICAL DATA.................................................................................................................................. 110
6 WELGER RP 405 • RP 435
1 Variants
RP 405 SPECIAL RP 435 RP 435 MASTER
2.00 m
Pick-up width
2.25 m
—
NONCUT
— —
Ring type rotor
—
Rotor
PROFICUT
— —
MASTERCUT
13-knife
—
XtraCut 17
17-knife
—
Cutting device
XtraCut 25
25-knife
— —
firmly bolted
—
FLEXCONTROL
— —
Bottom
HYDROFLEXCONTROL
—
Net tying
Tying
Twine tying
BALERCONTROL „E“
with BCE control box
—
Control
BALERCONTROL III
with E-LINK control box
— —
= series equipment
= variant
— = not available
WELGER RP 405 • RP 435 7
2 Safety
2.1 General safety instructions
Attention!
Even if all instructions are observed the machine involves
residual dangers. Always handle the machine with care to avoid
danger to yourself and others!
• Before starting work perform a visual inspection of the
machine. Check whether any device has been changed or is
missing and pay attention to any unusual noise or leaks
which occur during operation.
• All protective devices, as for example casing sheets, rubber
skirts or distance brackets are for your safety! Never operate
the machine with defective or removed protective devices e.
• Keep all safety relevant parts always in correct function.
Before commissioning all guard casings must be mounted
and closed!
• Never perform maintenance- and repair works during
machine is in operation.
• In case of all work on movable parts or in the range of action
of movable parts: Switch off power take-off shaft, switch off
tractor engine, remove ignition key and disconnect drive
shaft from power take-off shaft end. Interrupt electrical
connection between tractor and machine.
• Bring no metal parts close to the machine, as long the
electric control is in operation (e.g. tools, safety boots with
metal caps). Reason: unintentional triggering of proximity
switches and thus unexpected machine moves.
• When carrying out work on the opened tail gate: insert tail
gate safeguard (chapter „2.4 Tail gate safeguard“).
• Never remove any crop material from the machine while the
drive is running, or while the disconnected machine is still
moving. Always switch-off power take-off shaft and tractor
engine first.
• During work only the driver must be on the tractor. Riding on
the machine is prohibited!
• Never step onto the maintenance platform during machine is
in motion. Before stepping onto the maintenance platform:
stop machine, switch-off power take-off shaft and tractor
motor, take out ignition key and wait for standstill of the
machine.
8 WELGER RP 405 • RP 435
• Do not step onto the drawbar or other parts of the machine,
when the machine is in operation. Keep sufficient distance to
baler (pick-up, running gear, bale unloading area).
• Before threading the tying material: stop machine, switch-off
power take-off shaft and tractor motor, take out ignition key
and wait for standstill of the machine. Make the control
powerless (disconnect electrical connection to the tractor).
• All protection devices must be mounted to the baler and
must be in correct state. Prior to opening the protection
devices switch-off power take-off shaft and tractor motor and
wait for standstill of the machine.
• Block the wheels of the baler with wheel chocks when
machine is parked. Carry the chocks on the machine when
transporting it or during field use.
• When opening the tail gate keep a minimum distance of 2 m
from electrical high-voltage lines.
• There is danger of cutting during works at the net knife or at
the knives of the cutting device of the baler. Wear protective
gloves.
• Works at the magnets of the knife holders: the function of
cardiac pacemakers can be interrupted by magnetic fields.
• Works at the magnets of the knife holders: Danger of injury
by splinters – never hit the inserted knives from below with a
striking tool. Magnets could be damaged!
• Maintenance work may be carried out by trained persons
only. All maintenance- and repair works that are not part of
this operating instruction must be carried out by authorised
personnel only.
• Replace wearing parts of the braking system only at both
sides.
• Prior to disassembling the complete pick-up the machine
must be secured against backward tilt.
• In case of locations on a slope: place the round bales always
so that they cannot move automatically.
WELGER RP 405 • RP 435 9
2.2 Noise level
The EC directive 86/188/EEC (or EC directive 2003/10/EC)
concerning noise at the workplace instructs employers and
employees to assess noise at the place of work and to control it.
The noise level during normal field work is subject to variations
which depend on the one hand on the noise level of the tractor
and on the other hand on the deployment conditions of the
baler.
The noise level generated by the WELGER balers, measured at
the head height of the driver with the tractor cabin window
open, is, under normal operating conditions, less than 70 dB
(A). The combined noise level of baler and tractor primarily
depends on the level of the noise from the tractor (radios are an
additional source of noise). We recommend that the tractor is
operated with closed windows.
2.3 Instructions for fire protection
The harvested crop can easily ignite! To prevent fire:
• remove crop remains and oil leaks.
• If any machine parts run hot: find and remove cause.
• Do not begin a journey with the machine attached unless the
manually operated brake has been completely released.
Otherwise there is danger of fire by brakes running hot (e. g.
in the field).
• Keep the electrical systems of tractor and baler and the
exhaust system of the tractor in proper condition.
• The existing wiring must not be used for any other
consumers than those installed in the factory or approved by
the manufacturer. Overloading the electrical lines leads to
excessive heating.
• Do not smoke in the vicinity of the machine.
• Keep fire extinguisher within reach.
Figure 1
10 WELGER RP 405 • RP 435
2.4 Tail gate safeguard
If any short-time maintenance or assembly work is carried out
with the tail gate open, the tail gate must be hydraulically
secured against lowering: use shut-off valve (on the
maintenance platform). When the valve is shut off, the actuating
lever is at right angles to the flow direction (Figure 2).
In case of longer maintenance or assembly work with the tail
gate open, the tail gate must (in addition to the hydraulic
safeguard) be mechanically secured against lowering - using
suitable means.
After completion of any maintenance and/or assembly work
reset the valve to its initial position (along flow direction, Figure
3) and/or remove the mechanical safeguard.
2.5 Maintenance Platform and Ladder
Attention, danger of falling!
Never step on the maintenance platform [14] (Figure 4), while
the machine is in motion. Before stepping on the maintenance
platform: stop machine, switch-off power take-off shaft and
tractor motor and wait for standstill of the machine.
Climb and leave the maintenance platform exclusively via the
ladder [10]. Never step on the ladder when folded up – always
fold down the ladder before using it.
(Figure 4) To climb the maintenance platform: fold down the
ladder [10].
(Figure 4) Before the machine can move on: fold up and lock
the ladder [10] again.
(Figure 4, Figure 5) For transportation the railing [15] is
removed from the maintenance platform in the factory and
enclosed with the machine. The railing must be mounted again
before commissioning of the machine:
Take the dismounted railing [15] out of the machine.
Mount the railing [15] to the maintenance platform using the
6 enclosed screws [16] (Figure 5).
Figure 2
Figure 3
Figure 4
Figure 5
WELGER RP 405 • RP 435 11
2.6 Hydraulic System
Max. operating pressure of the hydraulic system:
• 210 bar
During assembly work on the hydraulic system, in particular if
accumulators are used (Figure 6):
• Depressurise the hydraulic system (control unit to "Lower")
• Secure hydraulically operated components (pick-up, tail
gate, cutting device, HYDROFLEXCONTROL bottom door)
mechanically against uncontrolled movement.
According to DIN 20066 hoses must not be older than six years,
including storage time.
2.7 Guard casings
To comply with the European safety regulations, since Jan. 1,
1995 manufacturers of machines have been obliged according
to EN 704 to design fixed, isolating guard casings in such a way
that they can only be opened by means of a tool, and will
automatically lock again without the need for a tool.
Open guard casings:
(Figure 7) Using a 13 mm spanner turn the hexagon head of
the locking mechanism slightly in counterclockwise direction
– the casing engages in a safety catch.
(Figure 8) Push safety catch up. The casing opens fully.
To close the casing, press the panel against the machine so
that the locking mechanism can be heard to engage.
Attention, danger of injury!
Never operate the machine with open guard casing!
Open guard casings only, when a free swivelling area is
available.
Never operate the machine with defective or removed protective
devices (e. g. guard casings and distance bracket). Before
opening the protections: Switch off p.t.o. shaft drive and tractor
engine, wait until machine has stopped, remove the ignition
key.
Figure 6
Figure 7
Figure 8
12 WELGER RP 405 • RP 435
2.8 WARNING SYMBOLS
2.8.1 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.
2.8.2 Symbols on the machine
Danger zones that cannot be secured by construction are
labelled with prohibition signs and yellow warning symbols.
Because they are without text in most cases the exact meaning
is described in the following.
The symbols must always be kept in recognisable state.
If any symbols on this machine are missing or have been
damaged, they must be replaced.
Prohibition signs Meaning / Spare part No.
No smoking!
Spare part no.: 0388.37.00.00
Do not step on the area!
Spare part no.: 0386.11.00.00
This manual suits for next models
1
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