Welger AP 42 User manual

Working Instructions
The serial number of Jour pick-up baler
is stamped into the machlne piste shown
by arrow on the adjolnlng photo. Please
enter the number in the space below
as soon as you take delivery of the
machine. Guarantee claims and querles
cannot be dealt wlth unless the number
Is quoted in full.
Contents
TechnicalData 2
Preparing for Werk 4
AttachingtheBaler... . .. ... 4
Positioning Drawbar 4
Fitting the Universal Drive Shaft. 5
Cleaning Knotters 5
Inserting Twine Spools 5
Securing the Knotter Trip. .. . . . . 6
Threading the Twine 6
Setting the Twine Tensioner... .. 7
Tripping the Knotter Mechanism. 7
Bringing Twine info Knotter 7
BaleCounter 7
Bale Density "7
Adjusting Pick-up Height 7
Windguard Adjustment 8
Setting the Bale length 8
pro Speed 8
Windrowing 8
EvenBaling 8
Before Turning .." 8
Safety Devices 8
Useful Accessories 8
Service end lubrication 10
Oil Change of Gear Box. .. . . .. 11
lubricating the Knotter Unit 11
Adjustment of Ram 12
Setting of Frame Knife 12
Grinding Knives 12
BalerTiming 12
Timing Need!e to Ram 13
Timing Top Feed to Ram 13
Packer Position Adjustment 14
Timing of Cross-feed
to Top Feed 14
NeedleSetting 15
----
'128-10
Knotter Beak Tension 15
Twine Retainer Tension 16
Adjusting the Twine Flicker 16
Twme Stop Spring 16
Twine Guide Plots "16
Twine Tensioner "16
Overloading Safety Devices 17
Double Slip Clutch end Shear
Bolt in Main Drive AP 42, AP 53 .17
Single Slip Clutch Unit end Shear
Bolt in Main Drive AP 48 17
Slip and Overrunning Safety
Clutch of Pick-up Drive 17
Safety Device for Packer end
Cross-feed AP 42 end AP 53 18
Packer with Mechanical Over-
loading Safety (AP 48) 18
Safety of Tripping Mechanism ... 18
Pick-up Balance Spring.. 18
Need le protection " 19
lubrication Chart 20
Troubles end Remed:es 22
Faultytwine Knots 24
Wire Tying - AP48 D / AP 53 D ... 26
Inserting the Wi.re 26
Pulling Wire info the Tiers. . . . .. 27
Service end lubrication 27
Needle Adjustment ,28
Shear lever Adjustment 28
Timing of Twister Hook 29
Needle to Ram Timing 29
Mistying Wire 30
General Accident Prevent-ive
Safety Rules 32
After season Maintenance of
Baler 32
IMPORTANT NOTE
This operation manual covers the models AP 38, AP 42, AP 48 and AP 53. If not
stated differently, text and figures refer to all tour models. Pages 28 -33 refer only to
AP 48D respeetively AP 53 D. The indication right, left, front and rear refer to
the baler operating direction.
RePn>duetion prohibited -all rights reserved, including design alterations without
prior nollee, technieal details are not binding.
Copyright 1984 by GEBRODER WELGER, Wolfenbüttel -'- Printedin the Federal
Republie of Germany.
,I
,1 PICK-U P BALERS
AP3B
AP42
AP4B-AP4BD
AP~53-AP53D
Twine Tying Wire Tying
i'
'I Domestic and Foreign Patents
"
GEBRUDER 1IIIELGER
GMBH & CO. KOMMANDITGESELLSCHAFT
Address:
Telephone:
Telex:
Teletex:
Telegrams:
D-3340 Wolfenbüttel, P. O. Box 1560
5331-404-0
95639
(17) 5331831
welger wolfenbüttel
~

--1
Technical Data
AP 38/42 AP 48/53
Dimension of baler
(in mm)
, Overaillength:
a) transport
b) at werk with chute
Overall width:
a) with standard tyres
b) with special tyres
Height:
Weight of baler inStandard version (kg):
a) twine tying
b) wire tyjng
Bale si:z:e:
Height x width (mm):
Length (m):
Steplessly variable from
Bale weight (kg):
according to length
end density
Pick-up width (mm):
Tines per row:
Tine space (mm):
Track width (mm):
a) standard tyres
b) special tyres
Tyres:
a) standard Irres left
right
b) special tyres left
right
Required tractor pro speed I):
2
4400
4670 4600 14650
5000 15050
2410
2490
1445
2490 12560
2515 12585
1500
1170/1180 1300/1380
1320/1400
310x410
0.5- 1.0 360x 480 0.5- 1.2
1
I
1
AP 38/42 AP 48/53
Required tractor power:
dependingon duty end terrain from 15kW (20hp)
Number of ram strokes 100/min
Capacity (hay):
a) haiesdepositedon theground
b) withloading chute up to 12 t/h
depending on
loading personneil
Tying: double twine
Tying material:
a) sisalbaling twine 200 or 150 m/kg
300 or 225 ft./rlb.
1,8 kg/t
400 or 320 m/kg
600 or 385 ft.llb.
0,9 kg/t
consumption approx. 2)
b) plastic baling twine
consumption approx. 2)
c) wire
18 kW (25 hp)
100/min
upto14
respectively 16t/h
depending on
loading personnel
double twine or
double wire
200 or 150 m/kg
300 or 225 ft./lb.
1,4 kg/t
400 or 320m/kg
600 or 385ft./lb.
0,7 kg/t
Ungalvanized,
annealed end oiled
tying wire of 1.8
or 2 mm gauge,
tensile strength
35-49 kg/mm2
610ngation mini-
mum of 12% at
25,4 cm length
Dimension of wire
coil (mm):
a) euter coil
dia. 336mm
b) inner wil
dia. 208 mm
c) coil width
152mm
d) coil weight
approx. 45 kg
consumption
approx. 3.6 kg/t 2)
') Required:
clutch-controlled standard PTO (DIN 9611 -pottern A); highly recommended: angina PTO; in-
dependent clutch; impermissible: usa of ground PTO, governed by engoged geer; under no
circumstances usa 1080r.p.m. PTOspeed.
'J ot medium bole weight
3
8-20 10-35
1660/1730 1660/1730
20 20
71 71
2105 2200/2240
2185 2245
7.00-12Impl. 10.0175-15Impl.
5.60-15 5.60-15/7.00-12Impl.
10.0175-15Impl. 11.5/80-15Impl.
7.00-12Impl. 8.00-12Impl.
540/min 540/min

Preparing tor Work
Balersare thoroughlytested and carefull
rlubricated before leaving our werks and
are ready tor immediate service at fu,l capacity when observing the following
instruetions.
4
Attaching the Baler
Connect to traetor possibly without play, usa
the same dia. hole in traetor drawbar and
baler drawbar are. Standard fitting on baler
22mm dia. drawbar eye (also available with
32 mm dia. hole).
Stabilize traetor hitch or drawbar. Set baler
info horizontal position by turning handle 2
(fig. 1) and conneet to tantra of traetor hitch
or drawbar. If necessary re-set hitch on baler
drawbar according to height, side displacement
can be made up to 160 mm. Secure safety chain
of conneeting pin around front of drawbar.
Retraet jack till stop by turning handle 2 (fig. 1).
Positioning Drawbar
Release bell 3 (fig. 2) and lock (operation of
bell 3 is also possible with a puUing rope from
traetor seal). Swing baler info position A or B
and re-positi,on bell 3 again.
ATTENTION!
Usa drawbar jack when storing baler, mind pin-
thing po,ints on swivel drawbar.
Hydraul,ic operated drawbar shifting device is
ava,i:lable as specia,! equipment tor AP 53.
ShiUing device is opera ted through traetor
hydraul,ic. The traetor must be equipped with
double aeting hydraulic valve.
1
FiHingthe Universal Drive Shaft
Clean splines on traetor and baler pto from
proteeting grease. Press in slide pins and fit
joints on both stubs (fig. 3), slide pins must snap
info position. Secure safety chai,n on to draw-
bar. Fold joint prop 4 away to the rear as
shown in fig. 1, see arrow.
Clearance between pro end and traetor draw-
bar hole (distance C in fig. 3) should be 330-
600mm. Usa Ionger pro shaft (size h) if distance
is more thon 600 mm. If i.t is smaller thon
330 mm, fit a drawbar extension. Telescoping
length of PTO-shaft tubes (distance D in fig. 3)
should be at least 300mm when driving straight
ahead. If necessary, shorten shaft by cutting off
equallengths from euter and inner tubes.
Cleaning KnoHers
Carefully clean knotter beaks and twine re-
tainers (see arrows in fig. 4), so thaI the twine is
securely held and cannot wind round the twine
retainer shaft.
~
"
Inserting Twine Spools
Only usa baling twine of best quality, see
technical data page 3. Place tour spools of
twine (fig. 5) side-by-side in upright position
info the twine box (wrongly inserted spools may
lead to tangled twi.ne and breakage). Four
balls of twine can be stored in the additional
twine box (AP53).
Pull twine end from spool E out of paper cover
and join to twine start of spool F (conneet
spool G and H in the same manner).
Plastoietwine allows any normal knot, but a
special knot is recommended tor si,sal twine as
fellows :
Rough up and untwist both ends. Make a single
knot, spließ and roll open ends together as
per fig. 6. Now hold ends closed (fig. 7) and
fighten the knot slowly.
Give knot a final hard lug and roll proieeting
ends between hands. Properly made, this spe-
cial knot (fig. 8) is hardly thicker thon the twine
itself.
I-
fig.4
fig. 5
fig. 6
fig, 7
5

fig. 9 fig.8
Attention! Securing the Knotter Trip
If needles are in bole chamber turn flywheel in fight direction unHI needle end
knotter geer is in resting position. Turn lolch 1 (fig. 9) upwards, slide it outwards
through the sial info position "Aus" end turn it down again.
Threading the Twine
Attention!Weit for standstill of baler before threading, secureknaller trip first as
describedabove.
fig.10
Observe fig. 10 closely when threading the
twine. Correctly threaded twine should not
touch end run freely.
Setting the Twine Tensioner
For fight adju'Stmentof twine tensioner check
distanceU on page 16.
,
~
Tripping the Knotter Mechanism
Disengage trip (fig. 9). Turn metering wheel 2
by hand in direction of arrow until control
rod 3 trips.
Bringing Twine info Knotter
Turn flywheel in direction of arrow (fig. 11)
until needles have risen end returned end have
threaded the twine info both twine retainers.
PulI loops off .both knotters, remove twine ends
from needle frame.
Bale Counter
To have a control of the number of boles
made, the bole counter has to be turned to
"zero" with the key supplied before storting
to bole (fig. 12).
.Bale Density
Loosen tension spring 6 (fig. 13) on both sides
of the bole chamber before storting to boJe:
Tighten them only gradually to desired bole
denstity when the boler is at werk.
Adjusting Pick-up Height
Set pick-up with rope 23 (fig. 14) so thai fines
have a ground clearance of approx. 2 cm. Tie
the control rope to the tractor leaving a little
slack. A light short pull reises the pick-up. To
lower it, first give one strang pull, then a
second light end brief one.
The hydraulic pick-up lifting device (extra equip-
meßt) is operated through the tractor hydraul,ic
system (single acti,ng control valve is necessary).
Connect hydraulic coupling (ba'ler side) to the
hydraul,ic connecting of tractor, open block
valve. Adjustment of pick-up is now made
through tractor hydraulic control valve.
7
fig. 12
fig. 13
fig.14

'4:
Windguard Adjusfmenf
The windguard can be set info two different positions, freely movable between
two stops. Accordingly to different baling material, the windguard can be set
info a lower or higher position. T0 pick-up short material the windguard is fixed
intb ,tower hole po
.sition of pick-up side guard. Normal baling material in higher
hole position of pick-up side guard.
, Seffing fhe Bale Lengfh
By turning adjusting nut 4 (page 6, fig. 9) in direction of arrow the bole is getting
Ionger, turning in opposi.te direction the bole is getting shorter.
pro Speed
To maintain the specified number of rem strokes of 100/min. your pro speed
must be 540 r.p.m. Check this against your watch from time to time. Fast running
may causa trouble end wear -slow running overloads drive components end
universal joint.
Windrowing
The machine's capacity can only be lJ.tilized to the full when the crop is carefully
raked info' windrows. The windrow should be about 1.60m wide.
EvenBaling
end close matching of tractor speed to windrow height are very important. Where
windrows are tigntly bunched, briefly stop the tractor end allow the baler to
clear itself.
Before Turning
Before turning sharp curves disengage pro to prevent damage to drive parts.
Safety Devices
Indicating end teil lights must be kept clean end. shou,ld not be covered by over-
hanging material. Check function of lighting system regular. Two chocks should
always be carried on the baler.
Useful Accessories
Deflecfor Chufe
throws the boles to the left or right for more clearance of tractor with baler
attached (part number 1115.81.91.01). Fit deflector chute underneath bole chute
end secure with hooks.
Special Tyres
Special Irres are availbale if needed for special purpose.
Order number 1121.02.10.00for AP 38/42 with ~yres 10.0/75-15Impl. 2.3 bar for the
left end 7.00-12 Impl. 2 bar for the ride side. Necessary for operation with P23.
Order number 1122.02.10.00for AP 48/53 comprising of one Irre 11.5/80-15 Impl.
2 bar for the-Ieft side end 8.00-12Impl. 1.5 bar for the right side.
8
/
Bale Wedges
narrow baling chamber cross section end so increase bole density. They should
only be fitted when handling dry crops, optional 2 or 4 pe. Order number
1115.03.90.00.
Drawbar Eye for 20 mm (/) Pin
Thi5 type of drawbar eye (order number 1105.05.90.00) with pin (part number
2101.05.07.00)has been designed to f.it the baler more easily to the drawbar of
small tractors.
~
Pick-upCover Sheef
Pick-up cover sheet i5 recommended for pic~ing up short-stalk crops. (Order
number 1705.42.92.00for AP 38/48, for AP 42/53 order number 1121.42.92.00).
Wide-Angle Universal Shaft -
Tractor with attached baler becomes more manoeuvrable, as the wide-angle
joint can deflect up to 70 degrees end needs no disengaging when negotiating
curves (order number 0930.14.03.00).
Universal Drive Shaft wifh Overrunning Clufch
It is advisable to use drive shaft with overrunning clutch on tractor's with hydraulic
opemted pro. If fitted, overrunning dutch shou'ld be fitted on baler side. Drive
sllaft with overrunning clutch, order number 0930.10.13.00i wide angle drive
sIlan with overrunning clutch order number 0930.14.04.00.
TrailerHifch
Trailer hitch for AP 38/42 (order number 1121.81.01.00)end for AP 48/53 (order
number 1122.89.01.00) adjustable for length is -necessary when working with
loading chute or the baler mounted bole thrower P 23.
Fit support pipe underneath of ba,le chamber. Insert trailer h,itch ,info support
pipe in required position end secure with pin end spr,ing clip.
Mounti.ng: AP 38/42 the trai,ler hitch ,is pushed ,info the pipe which is welded under
fhe boJe chamber end i5 locked info required position with pin end spning clip.
Attention! It is not allowed to have more thon 1000mm overhang behind teil
lights villen trave,lIing on open roads.
Deflecfor Chufe
throws the boles to the left or right for more clearance of tractor with baler
attached (part number 1105.81.90.00).
Assembly: by shaft, safety spring end chain at the chamber outtet.
Loading Chute
Loading chute (order number for AP 38/42: 1104.81.06.00 end for AP 48/53:
1105.81.06.00)fitted with trailer hitch,pushes the boles on to an attached trailer.
Attenfion: Bale chute mu~t be laken off the baler for road transport.
Foldable Loading Chufe
A foldable loading chute is also available for AP 48/53 (order number
1122.80.00.00).The chute remains on the baler during transport, it is only folded
to the front. For AP 38/42 order number 1121.80.00.00.
9
~

:t~
Pick-up Guide Wheel
The baler can be equipped with a adjustable piä-up guide wheel to have optimum
matching of pick-up to ground condi,tion even on uneven fields end to guarantee
clea,n picking up of baling materi.ail.Order number 1121.42.93.00.The gU'idewheel
can be adjusted :in heighrt as requested. Set pick-up so thai fines have a ground
alearance of approx. 2 cm (fig. 14). Observe correot Irre pressure of 11.5bar.
Baler-Mounted Bale Thrower P 23
is mounted to the end of the bale chamber. It loads the boles on to an allached
trailer with special body extension. Economical one man operation where baling
end loading is doneat the same time. The acreage covered is increased by up
to 40%.
ASSEMBLY: at the factory when the baler is ordered with thrower allached, or
by your loGoidealer, if ordered at a leier stage.
Normal Irres of AP 38/42 should be changed against speoiallIrres, see page 8.
Service and Lubrication
To keep the value end long life of the machine, generous lubrication end careful
regular serv,icing wil.l keep your baler at peak performance and avoid prema-
lure repairs.
General Hints: 'after the first 20 working hours, firmly fighten up all bolts and
nuts, inside and outside the machine. Timing boHs on knoller and rom sildes
shou,ld not be changed.
Usa lithium multi-purpose grease only for your grease gun. NeVer lubricate the
runni,n
,
g machine! Clean grease nipples before applying the gun. Drive greas,
e
in until the old packing emerges from the sides of the bearings. Do not wipe
off old grease rims (dust protection I).
Service of Gears
Teeth of all spur end beye! gears should be cleaned as necessary.
Road Wheels
Check wheel nuts and Gaps and fixing bolts of wheel stub axles for light fit.
Maintain correct Irre pressure, on AP 38/42 standard Irres on both sides 2.0bar.
On AP 48/53 standard Irres for right side 7.00-12 also 2.0 bar, on left Irre 10.0/75-
152.3 bar. Pressure for special Irres see page 8.
10
~
eil Change of Gear Box
Carry out first oil change after first 10 duty
hours! Remove crank guard, take off oil filling
bolt 1 with breather, oil drain bolt 2 end oil
level bolt 3 (fig. 15). Clean drain bolt, replace
and fighten. Fi.11about 1 liter of Hypoid Gear
Oi,1SAE 90 (EP 90) info geer box until oil leve,1
is reached. Refit bolts 1 and 2 fighten. Change
oll again at the end of every season. Oll level
hag to be checked regu,larly.
Lubricating the Knotter Unit
After every season apply a light coating of
"Lithium" grease to shafts of twine retainer 4
and knoller back 5 (fig. 16). Loosen lock nut 6
and bolts 7 and 8, remoye leaf spring 9. Un-
screw bolt 10 (fig. 17) end balls 11, then re-
moye knoller unit. Expanding pins 12 are
knocked out of pinion 13, then pull twine
retainer and knotter back out of knoller frame
and apply "Lithi'um"grease onto shafts. Care-
fuJ.lywipe off all surplus paste.
,J IMPORTANT: The lubricant shou'ld never gel
on to retainer taper 4 end clamp
14.
Re-fit twine retainer and beak at correct
position of clamp 14 and knaller cam 15. Fit
pins 12 in correct posiJion of pinlion 13. Mount
knaller unit in reverse order. Adjust screws 7
end 8 at leaf spring 9 as detailed on page 17.
Fit balls 7 and 8 on tension spring as described
on page 15 and 16.
Ii.
fig. 15
fig. 16
fig.17
11

Adjuslmenl of Ram
Ram 1 (fig. 18) is guided in the bole chamber
by rollers. Its position on forward end back-
ward stroke is assured by two stee,1 angle
guides, one situated on bollom of knife side,
the second one on top of opposite side in bole
chamber. It has 10 be checked regulari,ly if rom
is running free of pier, if not guide angle 2
has to be adjusted accordingly:
Remove gu'ide plate from feed fable.
Loosen fixing bolls 3 (5 pe.) fig. 18, adjust angle
guide 2 with bolts 4 up against rom roller,
repeat until parallelism of guide angles is as-
sured. Fix bolts 3 end lock adjusting bolt 4.
IMPORTANT: After rom adjustment
Setting of Frame Knife
After rom guide adjustment end after the rom
knife is set against the bollom guide angle, the
distance between rom knife end side of bole
chamber must be even on top end bollom.
Frame kni,fe 5 (fig. 19) is set as fol,lows: Loosen
knife bolts, adjust knife 5 with shims to a dis-
tance between 0.1- 0.8 mm, then firmly fighten
knife bolts.
Grinding Knives
Blunt end serrated knives should be regrinded.
Culling angle end leading edges should be
grinded, 100 (fig. 19 and 20). Grind rom knife 6
to a cutting angle of 30 degrees end the low
lead on frame knife, too (fig. 20).
Baler Timing
The following baler timings
Needle 10 Ram
Top Feed 10 Ram end
Cross Feed 10Top Feed
should, if possible, be done in
servi,ce station. a dealer's
12
fig. 20
Timing Needle 10 Ram
If new needles have been fitted they shou,ld
be adjusted first (see setting of needles on
page 15).
Disengage knotter (see fig. 9), open side cover 5
(fig. 25), remove locking bracket 7 from pinion
8 (fig. 21). Loosen olamping washer on pinion 8
end move pinion 8 sideways in direction of
arrow until it is disengaged out off knotter
drive geer 9. Turn knotter drive geer in direction
of arrow until point of needles 10 (fig. 22) is
flush with top edge of bollom bar in bole
chamber.
~
Block knoller drive geer 9. Turn flywheel in
direction of arrow until point of rom 12 has
post the point of needle by 15- 20 mm on its
working stroke. Engage pinion 8 back info
knotter drive geer 9. If it is not possible to
engage pinion 8 info the above mentioned
position, then remove guard out of Iwine box,
move circlip .13 (fig. 23) on hex. shaft about
300 mm to the left. Block top feed end fly-
wheel. Shift hex. shaft 14 out of bevel geer 15
(fig. 24) eHer loosening oIamping disk 18 unti,1
pinion 8 (fig. 21) can be pul.led away from hex.
shaft end be turned '/6 of a turn end be pushed
back on to hex. shaft. If pinion ,is sti,111not
ma,tching repeat ,this operation un~il pinion 8
is matching knoller dnive geer perfectly.
Push hex. shaft 14 back info bevel geer 15,
fighten clamping disk 18 replace locking
bracket 7 end clamping washer aga,inst pinion 8
andtighten. Remove oll blockings.
Now check Dislance L (fig. 22) with rom located
in this position:
Clearance between needle tip 10 end rom
tip 12 must now be 20-30 mm.
Timing Top Feed 10 Ram
When the intake hole is dear of the retracting
rom, the packer feeds the crop info the bole
chamber. This very speedy procedure requires
a perfecttiming.
Lift crank guard end remove guard out of
twi.ne box, take circlip 17 (fig. 23) away from
hex. shaff 14 end loosen clamping washer
on pinion 8 (fig. 21).
13
fig.22
fig. 23
fig.24

f
~
14
Pushhex. shaft 14 out of cross lead drive
pinion 16 (fig.23). Removecirclip 13 and also
push hex. shaft out of top feed drive pinion.
Align crank 1 (fig. 25) para-liel to top edge of
packer box 2 and block it there. Move con-rod
3 by turning the flywhee-Iin indicated di,rection
to distance J =605 mm (fig. 26) from con-rod
head to front edge of bole chamber. Push hex.
shaft 14 (fig. 23) in this position info top feed
drive pinion. If the hex. shaft does not fit, con-
rod head must be turned so offen by lIywheel
to the distance of 605 mm until hex. shaft 14
fils perfectly info top lead drive pinion. Remove
blockings of top feed. Check distance J again
which must now be between 600 end 620 mm.
Packer Position Adjustment
A good shaped bole depends upon even filling
of the bole chamber by the top feed. To reach
optimum bole shops when baling different
crops, pin 6 (fig. 25) can be changed info diffe-
rent holes of adjusting bracket to obtain the
best fi,lIing of the bole chamber. By moving
pin 10 info the bollom holes of adjusting bracket
more material is moved info the opposite side
of the frame knife in bole chamber, by moving
pin 10 info the ,top holes of adjusting bracket
more material is packed on the knife side
of the bole chamber. Secure pin 10 with spring
clip in adjusting bracket.
Packer position adjustment can a.lso be made
on AP 38/48. Through adjusting pack fingers
on top end cross lead the feeding effect can
also be changed.
Timing Cross Feed to Top Feed
Align cross lead crank 4 (fig. 27) parallel to top
edge of packer box 2 end block it there. Turn
flywheel in indicated direction until packer
crank 1 (hg. 27) is in vertiwl position (crank
hanging downwards). Now push hex. shaft 14
info cross feed drive pinion 16 (fig. 23). If the
hex. shaft doesn't fit turn packer crank 1 (fig.27)
by flywheel so offen info the vertical downward
position until you canpush the hex. shaft 14
info the cross feed drive pinion.
:t
Re-fit circlips 13 end 17 (fig. 23), tighten clamp-
ing washer on pinion 8 (fig. 21) end re-fit oll
guards.
IMPORTANT: Any repairs on cross end top
feed shou-Id be clone in a dealer's service
station. Plots springs of the deflecling packers
on AP 42/53 are spring loaded, dismant,le care-
fu'lly!
Needle Setting
Trip knollers according to 'illustration 9. Turn
flywheel in direction of arrow until needles
have reached their highest posi,tion.
Distance M betweenleaf spJing end needle tip
(fig.28) mustbe 108-115mm tor AP 48/53end
90-110mmtor AP38/42.Ifnot,slackenlocknut7
(fig.29) end remove expanding pin out of pin 9.
Turn lork 10 in or out until measure M is
reached. Rep,lace fork 10 end pin 9 info
position, secure with expanding pin 8 end
fighten 'locknut 7.
Distance N between needle head end knoller
base plots (fig.30)mustbe 170mmon AP38/42
end 175mm on AP 48/53. Otherwise reshape
needle.
Distance 0 between needle end plots spring
(fig. 30) must be between 1-2 mm.
~,
When operating slationary oll dirt end short
baling materia,1has to be removed from under-
neath the needle.
Knotter Beak Tension
Spring tension (fig. 31) should be adjusted to
di,stance P of 23-28 mm tor proper functioning,
if not adjust screw 11accordingly.
fig.32
fig. 28
fig. 29
fig. 30
fig.31

~fig.36
Twine Retainer Tension
Adjust twine tension spring to distance Q (fig.
32).Themeasuring gauge along side the spring
gi,ves the correct measure. Adjust discrepan-
eies with holt 12.
Distance R is set as fellows end shown in fig.33:
glocken lock nut 1 by tour full turns. Slacken
holt 2 until leGt spring 3 is unloaded. Run down
holt 2, first till it contacts leGt spring 3, then by
exactly 3'/2 turns. This gives spring 3 a pre-
loading of 5 mm. Finally fighten lock nut 1
again.
Adjusting the Twine Flicker
Trip knotters (see fig. 9), turn flywheel in
direction of arrow until flicker 4 (fig. 34) stops
in forward position. Distance S must now be
1-2 mm. If not, glocken lock nuts 5 end turn set
screw 6 as required end secure again.
Twine Stop Spring
Spring 7 (fig. 35) must rest under tension against
nase 8 of twine guide plate. If necessary, bend
spring 7 as required.
Twine Guide fiale
After replacing twine guide plate 9 (fig. 36)
checkDistanceT,clearance between nase 8 end
knotter heck 10 should be 1.5-2.5mm. If not,
fit shims to adjust twine guide plate 9.
Twine Tensioner
Tighten both wing nuts of twine tensioner 11
end 12 until spring length is 26 mm Distance U.
fig. 37
j
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Overloading Safety Devices
Double Slip Clutch and ShearBolt in Main
Drive AP42,AP53
The mein drive is protected against overload
by d double automatically reacting slip clutch.
. One overrun slip clutch in front of flywheel
(fig. 38) end one behind ihe flywheel situated
cone slip clutch with additional shear holt 1
(fig. 39) M7x50 DIN 931-8.8. The shear holt musr
.be fitted light with hex. nut M 7 DIN 934-8 end
spring washer A 7 DIN 127.
For the safety of the baler it is important thaI
the double acting slip eluIeh is operating
trouble-free. The torque of 500-650 Nm is se,tat
the factory. Normally no adjustment is needed
hut if clutch plates end linings are warn they
should be replaced.
IMPORTANT:
fig. 38
fig..39
Before the sepsen starts, remove clutch plates 2 of the front. over-
run clutch (fig. 38) end clean any fUgt from clutch surface with
emery paper. Clean the linings of the cone eluIeh if the safety holt 1
(fig. 39) shears tao offen. T0 remove clutch plates 2 (fig. 38) glocken
the 8 halts of triangular pfote spring 3 (fig. 38) until the spring is
without load. Do not remove the spring completely. To chonge
the above mentioned torque of 500,...650Nm, shim washers are
placed behind or in front of plate spring 3.
Single Slip Clutch Unit and Shear Bolt in Main Drive AP 38/48
A single slip alutch unit with shear holt M7x50 DIN 931-8.8is fitted on AP 38/48
instead of double slip clutch unit.
Slip and Overrunning Safety Clutch of Pick-up Drive
The Pick-up drive is operated through abevel geer with subsequently added over-
load slip oIutch. Bevel geer end eluIeh are combined in one drive unit which is
fitted underneath the ba,le chamber. The effect of the clutch is to prevent any
damage to be düne to pick-up end geer box. The torque of the eluIeh is set at
300-450 Nm. The built in overrunning cluleh pIlaws easy, backwardturning of
pick-up drum when baler runs out or für clearing of deflecting packers.
17

r
Safety Device tor Packer end Cross Feed
AP42 end AP53
fig. 40
Cross feed end packer are fitted with an
automatie safety release whi,ch causes the
packer fines to swing away. If the baler be-
comes clogged or a foreign body has been
drawn on to the feed fable the fines deflect,
as in fig. 40a end then automatically swing
back info working position (fig. 40). In that
war, the clogged baler will freeitself.
Briefly reducing PTO speed increases the'
deflection resistance in the packer linkage.
The ti,ght bunch of material is pushed info
the chamber end the machine resumes un-
obstructed working. The torque of the
deflecting cross-feed is set between 600 end
850 Nm end on top-feed between 750 end
850 Nm. The connecting rod must be fitted in 2nd. hole tram bottom of the ad-
justing bracket. If the fines swing away repeatedly, this indicates thaI the machine
is work,ing at the limit of its capa city. Engage the next lower tractor geer, as
frequent tine deflection increases wear of aH drive parts.
fig. 40a
IMPORTANT: If fines of c;:rossfeed end packers deflect five or six limes running
end the
,trouble stil,1 pe,rsists, the obstruction 'is ,too great to be cleared by the
automatie system. In that case, shut off the pto end clear the feed fable by hand.'
On no account, attempt to remove the obstruction by reversing the PTO dri,ve,
as this is Jiikely to band the leaf spring of the automatie clearing system out of
share.
Packer with Mechanical Overloading Safety (AP 38/48)
The AP 38/48 has a mechaniwl overloading safety device instead of a deHecting
safety device in the packer system. One hex. bo.It each M6x35 DIN 933-10.9 with
two hex. nuts M 6 DIN 934-10 are acting as shear olutch safety.
Safety of Tripping Mechanism
Unintentional tripping of knotter mechanism can be prevented if safety latch
is in position "Aus". Even if baler is running the needles will s'tay in resting
position. Operation of safety latch see page 6 end 7.
Pick-up Balance Spring
T0 avoid damage to the pick-up by travelling on uneven ground the pick-up is
equipped with a torsion spring. In working posi.tion the pick-up is ba,ianced by
the torsion sproingend will be released of its own weight to fellow the contours
of the ground.
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Needle protection
The needles are protected against overload.
If the upward stro
,
ke of needles is obstructed,
holt 1 (fig. 41) will break. Trace the causa end
remove it. Pul,! needle lift rod tram crank after
removing expanding pin 2 end pin 3. Take off
the te,lescop,ing tube end remove broken shear
holt. Refit needle lift rod 4 with new holt 1
(Order No. 0901.98.10.00)end fighten carefully.
~
fig. 41
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Lubrication Chart
SymbolsI
;
None
Lubricants and Notes
Lithium multipurpose greose
Number of greasing .points
x
0Only for twine tying
Only for wire tying
,0.
«
Hypoid gear oil SAE90
[see poge 11)
Thin flowing machine oil
10 ,0.Twisterframe
11 ,0.Bearing frame
12 ,0.Crank guide
Check regular, grease as
necessary
14 * Gear box
15,0.«Shear lever shaft
160 Twine grip end knotter
bearing see fig. 16
17 «Bearing plates on
deflecting packer end
cross feed AP42/53 only1x
'"
3~
1x
1x
2x
8x
Lubricate daily
1Cross feed bearing 1 x
2Packer bearing 1 x
3Knotter drive geer 1 x
Lubricate weekly
4 0 Knotter shaft 1x
4 ,0.Knotter shaft 2x
5Guard tube bearing 2x
6 Tractor universal shaft 2x
7 Profile tube 1 x
8Needle liftrod 1 x
9Blockinglever 2x
20 21

Troubles and Rernedies
.Working conditions vary so wide.ly that it is impossible to cover oll causes which
may lead to operating troubles. Seil properties, thickness of windrows, condition
of crap, inexperienced handling or negligent servicing of the machine may a,1I
be responsible. If the following chart does not help you to trace end eliminate
a fault, call on the expert advice of our appointed representatives, dealers end
service engineers who are always af your disposal.
... -.- - -. =-~= ~,~
~Trouble! Possiblec~1 Remedy Remarks
'
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111
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8IMistying(twine)
9fMistyihg (wire)
.
1Continuous res- IReduce speed by ponse of deflecting
I
same pto speed
Ipacker (540rpm)
I I
Ir
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I seepage 24
r see page 30
"
23
No. I
Trouble Possible causa IRemedy
I
Remarks
Curves taken tao IShutoff pto before usawide
angle uni,-
Universal shaft tight,ly
Imakingaturn versal shaft
1knacks end runs
out of balance IAttach baler Iseefig. 2
-Incorrect C:UPli:9 .[ correctly land 3
IBQleVO"ooded
IDrive more slowly I
Ipick up lass I
Main dri,ve material
2Idutch is slipping
IAdjustclutch
Torque is to smaH Iseepage 17
(300-450 Nm)
Clogged through I Clear clogging,
overload, safety reduce speed,
clutch operates pick up less
3IPick-up stops I
material I
Pick-up drags on
ISet pick-op high.,
Iseepage7
ground, set to lew Ifig.14
Reduce speed, I
Crop bunched
IBaler overloaded Ipick up lass
4up between materi.al I
Ipick-up end
Ife.edfable IWindguard isbellt IStraightenwind- Iguard
22 '-
ICrop is damp Slacken density Iseepage7
control
Ifig.13
laboured working
1.,-g"Od '0;1,
see page 12
5gradually getting BI'unt knivas fig.19
worse end 20
Baling chamber Empty chamber, I
stuck with squashed
material clean inside waJls
I
IShearbolt broken Removeforeign I
foreign matter
body, fhtnewshear Iseepage17
6Ram stops in crop bolt .
Baler overloaded
IReducespeed,pick-
by very thick
windrows Iup less material
.IRe-setpackerad- see page 14
Uneven compachon .b k
lustment rac et
7Curved Bales
-.-.

fig.42
fig. 43
Faulty twine knots are shown in the adjoining
illustrations (No. 1-9). No. 10 is a correctly
lied knot, with oll specified distances main-
tained end all springs properly tensioned. Figu-
res 42 and 43 show the knotter assembly. The
fable on page 27 lists possible causes end
remedies tor badly lied knots. Strictly observe
the following instruction:
When re-setting with bolts e - 9 - i, always
maintain specified Distances P-Q-R to fig.
31,32 end 33.
24
('
Remedy ~
No.! KnoHer fault (twine) I Possible cause
ITwine tensioner too loose.
Twine does not run over
nose of guide pfote a
1Knot weil forrned,
but too fight,
twine tom off
Tension spring on twine
tensioner fig. 37
1
!
2Loop too short
ICorrectly set twine
Iflicker fig. 34
Spring b jammed by point
I
Clean spring b to restore
or dirt free action
Twi.ne not held by twine
flicker end not led over
nose of guide plate a
So thaI twine Spring c
insufficiently tensioned,
too loosely held by
knotter beak d
Spring c much too slack,
knotter beak d holds
twine far too slack
",
3Knot not lied
Knotter beak does not
dose properly
Spring h too slack,
twine retainer k does
not hold twine during
bole compaction
Needle too far frorn
knotter frame, retainer
k end knolfer beak d do
not seize twine
Knotter beak d does not
seize twine raised by
needle
Material between rom
I
'end top casing forces
twine awayfrom knotter
beakd
I
IAll distances correctly
10 Correctly lied knot
I
set ',8'"springs properly
tensloned
6Knot looks firm,
but under strain
one end'slips
out again
7Only one twine
end knotted, loop
end too short
8Simple kn?t lied,
so thai twlne runs
back to next bole
9Only one twine end knotted,
loop end too long
Tighten bolt e, maintain
distance p fig. 31
Slacken bolt g, maintain
distance Q fig. 32
Tighten bolt e, check
correct distance p fig. 31,
if necessary clean knotters
Tighten bolt i, check
correct distance Rfig. 33
Note fig. 30:
0 = 1- 2 mm
Note fig. 22, 28 end 30:
check distance L, M end N
Re-settwine flicker
Remove ba,ling material
from between top of rom
end knotter base pfote
'J'\
Long twine end
4Ifrayed, twine fluff IS.f t t t
left on twine pnng 00 au
reta'iner
Ends tom, approx.
5I5 cm weste drops ISpring f much too taut
away

1
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AP 48 D / AP 53 D-Wire Tying
Inserting the Wire
Use only top qua:lity (trade-mark) wire{ note techniwl detai,ls on palge 2, when
ordering. WirB coils shou,ld be neatly end evenly wound. Before fitti,ng coils{
immerse them in eil to compilete saturation. Switch off prof weit until oll moving
parts have come to a complete stop. The wirB box takes two cous as shown
in fig. 44{ !wo spare coih can be placed in the com-
partment behind the packer box. Fit coils wh,ile stil<!
closed by straps{ turns running clock-wise. Do not
tangle the winding turns when cutting the straps.
PuMinner wirB ends out through holes in box. Avoid
kings end loops{ or mistying may result. Fix rree
euter wirB end to box edge.
Thread wirB as indicated in fig. 45{ which shows the
run as seen from below:
/-"
Carefully tie end of wirB "A" end "B" to cross bracket.
Pulling Wire info the Tiers
Trip tie unit as shown in fig. 9. Turn flywheE)1in direction of arrow fig. 11until
needles have moved up end down end the tiers have laken up the wirB. Pull wirB
ends "A" end "B" tram cross bracket 5.
Service and Lubrication
Treat wirB coils with care end immerse them
in eil before storing them tor any length of
time. Regu.larly check thai oll wirB guide rollers
move easi.ly{ grease as required.
Thoroughly lubri,cate twister drive chain 11
(fig. 46) at frequent intervals. Chain tension is
operated automatically through tension spring
12 end tension roller 13. If chain 11 is removed
the following points have to be observed.
IMPORTANT: Before re-fi.tting the chain 11{
re-set twister hock to fig. 51.
Inspect edges of shear plate 14 end shear
bar 15 (fig. 47) tor bluntness or wear. Both
are double-edged end can be turned around
once before needing are-grind: '
Remove protE!cta,r cop out of deflector bar 16.
Slacken nut 17and bolt 18. Take off bar 15{
slacken ball 19{ fit shear bar 15 with deflector
bar the ether war round{ run down ball again.
Slacken balls 20{turn around shear pIlote 14 end
re-assemble. Fina.I,ly{ fit shear level 15 with
deflector bar 16 again end secure i1'.
IMPORTANT: Note positionand sequence of
shims 21 end re-fit them in origi-
nal arrangement.
Safety Device for Needles see page 19
Wire B:
Through wirB guide tube 1{ around guide roller 2{ between track
rollers 3{ over needle head 4 to cross bracket 5.
Through wirB guide tube 6 around guide roller end around guide
roller 7{ between t~ack rollers 8{ over needle head 9 to cross
bracket 5. Check Distance A-D (page 28 end 29) regu-
larily end adjust{if necessary.
26
fig.47
27

'"- -!~"2'
Needle Adjustment
Pulloff wi,re,trip tying mechanism (see fig. 7).
Turn flywheel to raise needles to topmost po-
sition.
Timing of TwisterHook
Ali.gn marking holes (see arrows in fig. 52) on
both chain wheels end the marking bores under-
neath, then lock chain wheels with 4 mm cf) pin
slid through the bores. Now fit chain ovar
correctly located wheels.
IMPORTANT: Never turn flywheel in reverse
with tying mechanism tripped.
Distance A between needle end twister hock
shaft shourldbe 0-2 mm (fig. 48). Needle to Ram Timing
If new needles have been fitted they should be
adjusted first (see setting of needles).
Note: Re-shape needles only i,f no more thon
slightly bent end take cera to restore original
shape.
Distance B between needle roller end shear
lever should be between 3-8 mm (fig. 48). If
Distance B is less: Slacken bolts 1 (fig. 49) turn
out holt 2 end run down holt 3 to set needle
height. Secure holt 2 end fighten bolts 1 again.
Disengage knotter (see fig. 9), open side cover
5 (fig. 25). Remove locking bracket 9 from pinion
10 (fig. 53). Loosen clamping washer on pinion
10 end move pinion 10 sideways in direction
of arrow until it is disengaged out of knotter
drive geer 11. Turn knotter drive geer in di-
rection of arrow until point of needles 12
(fig. 54) are flush with top edge of bottom bar
in bole chamber 13. Block knotter drive geer 11.
Turn flywheeL in direction of arrow until point
of rom 14 has post the point of needle 12 by
about 25 mm on its working stroke. Engage
pinion 10 back info knotter drive geer 11. If it
is not possible to engage pinion in the
above mentioned position, remove guard out
of twine box, moye circlip 13 (fig. 23) on hex.
shaft about 300 mm to the left. Block lead end
flywheel. Shift hex. shaft 14 out of bevel geer 15
(fig. 24) after loosening olamping disk 18 until
pinion 10 (fig. 53) can be pulried out of hex.
shaft end can be moved '/6 of a turn end be
pushed barck on to hex. shaft. If pinionis still
not matching repeat this operation until pinien
10 is matching knotter drive geer 11 perfectly.
If clearance Bis exceeded: Slacl<en bolts 1, set
needle height by turning out holt 3 end running
down holt 2. Then secure holt 3 end fighten
borlts1 again.
Distance C tram needle head to twister hock
shaft should be between 80-110 mm (fig. 50). If
any difference, adjust needle lift rod as shown
in (~ig.29).
When operating stationary all dirt end short
baling material has to be cleaned away from
underneath the needle.
Shear Lever Adjustment
Note that shear lever 4 clamps down the wirB
alternaterly on left end right (fig. 51). Push hex. shaft 14 back info bevel geer 15, (fig.
(24), tirghten clamping disk 18 replace .Iocking
bracket 9 end clamping washer against pinion
10 end tighten (fig. 53). Remove a,1Iblockings.
If wirB is to weakly clamped down, watch baler
at werk to see on which lever side the wirB is
pulled away. Let machine run on unHI needle
has once again placed wirB on that side of
lever 4 where it is not held firmly. Now stop
machine end glocken lock nut 5 (or 6), run down
set screw 7 (or 8) by '/2 to 1 JulI-turn until wirB
is firmly held, then secure again with nut 5 or 6
(fig.51).
Now check Distance D(iiig. 54) with rom located
in this position:
Clearance between needle tip 12 and rom
tip 14 must now be 25-40 mm.
28
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lig. 52
lig.53
fig.54
29

'$;
30
-- ~- -
No. LFaulty Wire Twist~ock I Function Fault Cause Remarks
1No twist; one wire end
cut straight, the other
pinched, then tom
off
IBale comes out
2
I
wi,thout wire strap
on one or both sides
I
Wires wind round
3twister shaft :- bole
I
c,?mes ::,ut 'Nlithout
wlre tymg
4Wires not twisted -
one end cut off
straight, the other
bent end cut
Wires not twisted-one
end cut off strai,ght,
5 the other pinched but
puHed straight end
scraped bright
6Twisting lock too short
end tom open
7
I
One wire tom close
to twisting length
I
8Both wi res tom close
to twisting length
Windings jammed when
coil was fitted
Wire rusty or not oiled
Wire tom before
twisting
Wire run obstrueted
Crop very damp
Wire jumped out of
guide rollers
Weste wire ,endsnot
removed after threading
Needle bent sideways
Needle does not
piece wire on tiers Track rollers shifted
1
1
Wire not seized end
not cut by shearl.ever
!
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I
Needile too low
Needle bent sideways
Crop pushes wire
away from twister
hook
Volume per rom stroke
too big because of slow
rom speed
IRemedy I
ICut off faulty ends re-thread wire I
I
lmmerse
,coils in oi,l, allways store
I
them weil oiled
I
Clean end lubricate wire guide tubes
I
end rollers -replace if necessary
I
Slacken dens:ity controll or set
I
shorter bole length
IRe-fit wire or re-thread completely I
I
Pull wa'ste ends off hooks under
I
ba,ling chamber
ICheckspecifiedclearanceA I
IUne up roJ.lersto needles I
ISet clearance B I
ISet clearance A I
I,"""",am ,p"cl 10taO/rn;". I
See page 26
fig.45
See page 26
fig.45
See pages 6-7
figs. 9 end 13
See page 26
fig.45
See page 28
fig.48
See page 26
fig.45
See page 28
fig.48
See page 28
fig.48
Clamping at shear bar
too weck
Wire not held by
shear lever
Wire rusty or unoiled
Twister hook wrongly set
Wire broken during
,twisting or when
I
pu.I.led off twister
hook Wire run obstructed
Guide roller spindie
jammed or worn
Re-setbar tor positive clamping
action
I
rFree twister hook; immerse coils
Iin olil, store them weil oi,led
IFree twister hook end re-set
Free twister hook, clean end
grease guide tubes end rollers;
replace if necessary
Free twister hook, take out roller
spindies, clean end grease -
replace if necessary
See page 28
fig.51
See page 29
fig.52
31

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AGeneral Accident Preventive Safety Rules
After Season Maintenance of Baler
Clean baler thoroughly.
, Always stop baler before doing repairs or maintenance werk to the machine.
'4: Cover oll knotler parts with grease.
, Disconnecf and remove pro shaft working on moving parts. Tighten oll halts and nuts on baler.
Never remove hay or straw tram running pick-up, disengage pro first. Check oll movable parts for easy moving.
Only one operator is allowed on tractor. Replace oll damaged and lost parts.
Do not step on to barer frame when machine is running, keep away from running
pick-up and cross-feed.
Touch up point if necessary.
Store baler in dry place.
Stop barer before threading needles, move safety lolch on tripping mechanism
to position ."Aus".
All guards most be fitted in place and be in good condition.
Block road wheels with two chocks when barer is parked on the slope. Always
have two chocks on baler.
w
The pick-up barer may be employed only for its approved usage, otherwise no
liability for resulting damage can be accepted. Approved usage includes strict
adherence to the manufacturers' operating and maintenance instructions, as weil
as the exclusive fitting of Original Spare Parts.
The pick-up barer may be operated, serviced and repaired only by persons trained
in these duties and instructed on the possible hazards. The ruling accident pre-
vention code,as weil os generally recognized rules on occupational safety and
health and the local roadtraffic code should be observed at oll times.
32
-- - - -, -