lely baler

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LELY WELGER

RP 405 / 435 / 505 / 535

RP 435 MASTER

1755.99.03.03 10.08

Operating Manual


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Send back to:

Lely International N.V.TSS (Technical Service Support)Postfach 1965D-38289 Wolfenbttel

Handover declaration 1 (Copy for the Manufacturer)

Complete and return this document within 4 weeks 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 / RP 505 / RP 535........................................................................

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 togetherwith 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 thesecomponents have been correctly installed again!

The following components must be reinstalled prior to first commissioning:

RP 405 / RP 435:

Wheels: see spare parts list pages A10, A20, A21Maintenance platform: see spare parts list page K25 (items 0106, 0810, 1214)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, C35Pick-up guard rail: see spare parts list page K25 (item 7)Support foot: see spare parts list page B30Ladder on support foot: see spare parts list page K25 (items 15-20)Drawbar head: see spare parts list page B20Branch 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 B70Handles of side cover: see spare parts list pages K10, K11 (items 35)Hydraulic system control block: see operating manual page 31

RP 505 / RP 535:Wheels: see spare parts list pages A10, A20, A21

Maintenance platform: see spare parts list page K25 (items 0106, 0810, 1214)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, C35Pick-up guard rail: see spare parts list page K25 (item 7)Support foot: see spare parts list page B30Ladder on support foot: see spare parts list page K25 (items 15-20), page B35 (items 56)Drawbar head: see spare parts list page B20Chain tensioning blocks: see spare parts list page C10 (item 11)Bale ejector shock absorber: see spare parts list page B70Handles of side cover: see spare parts list pages K10, K11 (items 3233)Hydraulic system control block: see operating manual page 31

Before first use: Unlock hydraulic of bottom door(see chapter "7.4.2 Release bottom door")

.............................. .............................................................Date Customer's signature


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Send back to:

Lely International N.V.TSS (Technical Service Support)Postfach 1965D-38289 Wolfenbttel

M

Complete and return this document within 4 weeks 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:

...................................................................................



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Handover declaration 2 (Copy for the Customer)

Complete this document when the machine is delivered and keep it.

Date of delivery: ........................................................................






RP 405 / RP 435:







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Customer

Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................


Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................



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Handover declaration 3 (Copy for the Trader)


Date of delivery: ........................................................................






RP 405 / RP 435:







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Customer

Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................


Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................



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Handover declaration 4 (Copy for the Importer)


Date of delivery: ........................................................................






RP 405 / RP 435:







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Customer

Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................


Name:

..................................................................................

Postcode/Place:

..................................................................................

Phone:

..................................................................................

Street:

...................................................................................

Land/State:

...................................................................................

eMail:

...................................................................................



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WELGER RP 405 RP 435 RP 505 RP 535 3

The serial number is shown on data plate on the rightmachine side, as shown aside. Warranty claims and queriescannot 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. Inthis operating instruction all positions required for safety reasons are marked with a warning sign. Instructall other operators in safety instructions! The warning- and information signs located at the machine giveinformation for safe operation. Watch them for safety reasons!Read and heed the separate operating instruction "E-LINK for RP 435 MASTER / RP 535 MASTER".

* Please watch, that the equipment marked with a [*] in this operating instruction, belong only to definedtypes 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.

2006 by Welger Maschinenfabrik GmbH, Wolfenbttel. Made in Germany.

Maschinenfabrik GmbHGebrder-Welger-Strae 3 D-38304 WolfenbttelPhone: (+49) 53 31 / 404-142 Fax: (+49) 53 31 / 404-143

eMail: [email protected]


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4 WELGER RP 405 RP 435 RP 505 RP 535

Table of Contents

1 VARIANTS ................................................................................................................................................... 6

2 SAFETY........................................................................................................................................................ 8

2.1 General safety instructions................................................................................................................. 82.2 Noise level........................................................................................................................................ 102.3 Instructions for fire protection........................................................................................................... 102.4 Tail gate safeguard........................................................................................................................... 112.5 Maintenance Platform and Ladder ................................................................................................... 112.6 Hydraulic System ............................................................................................................................. 122.7 Guard casings .................................................................................................................................. 132.8 WARNING SYMBOLS ..................................................................................................................... 142.9 Symbolised operating instructions ................................................................................................... 172.10 Proper use........................................................................................................................................ 212.11 Electromagnetic compatibility........................................................................................................... 212.12 To heed in the road traffic ................................................................................................................ 222.13 Environment/Disposal ...................................................................................................................... 26

3 ASSEMBLY GROUPS............................................................................................................................... 27

4 START UP.................................................................................................................................................. 28

4.1 Coupling the baler ............................................................................................................................ 284.2 Drive shaft ........................................................................................................................................ 314.3 Hydraulic System ............................................................................................................................. 334.4 Electrical system .............................................................................................................................. 364.5 Compressed-air braking system ...................................................................................................... 37

4.6 Hydraulic braking system................................................................................................................. 38

5 TWINE TYING*........................................................................................................................................... 39

5.1 Threading the twine.......................................................................................................................... 395.2 Adjusting the twine brake................................................................................................................. 425.3 Setting the edge clearances............................................................................................................. 435.4 Adjusting the wrapping distance ...................................................................................................... 435.5 Edge wrapping adjustment............................................................................................................... 44

6 NET TYING* ............................................................................................................................................... 45

6.1 Inserting the net................................................................................................................................ 456.2 Tightening the net knife.................................................................................................................... 516.3 Adjusting the net length.................................................................................................................... 52

7 CUTTING DEVICE*.................................................................................................................................... 53

7.1 Equipment ........................................................................................................................................ 537.2 Knife groups ..................................................................................................................................... 537.3 Moving in and out the cutting device................................................................................................ 567.4 Lock bottom door.............................................................................................................................. 717.5 Brittle crop material .......................................................................................................................... 727.6 Assembly and disassembly of the cutting device knives ................................................................. 72

7.7 Regrinding the cutting device knives................................................................................................ 73


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WELGER RP 405 RP 435 RP 505 RP 535 5

8 FIELD USE ................................................................................................................................................ 74

8.1 Locking the tail gate ......................................................................................................................... 758.2 Adjusting the bale diameter.............................................................................................................. 768.3 Setting the bale density.................................................................................................................... 77

8.4 Raising / lowering the pick-up .......................................................................................................... 788.5 Pick-up guide wheels ....................................................................................................................... 788.6 Windguard / Pick-up shield* ............................................................................................................. 798.7 Feed guide plate............................................................................................................................... 808.8 PTO speed ....................................................................................................................................... 808.9 Driving style...................................................................................................................................... 818.10 Safety clutch..................................................................................................................................... 83

9 OPERATION / TYING................................................................................................................................ 84

9.1 BALERCONTROL E control box...................................................................................................... 849.2 E-LINK control box........................................................................................................................... 87

9.3 Eject bales........................................................................................................................................ 919.4 Emergency operation ....................................................................................................................... 93

10 REMOVING A MATERIAL JAM................................................................................................................ 98

10.1 Main drive reversing......................................................................................................................... 9810.2 Hydraulic bottom door*..................................................................................................................... 99

11 MAINTENANCE / SETTING .................................................................................................................... 102

11.1 General notes................................................................................................................................. 10211.2 Grease knife lever .......................................................................................................................... 102

11.3 Tensioners...................................................................................................................................... 10311.4 Maintenance of the net tying unit ................................................................................................... 10311.5 Tensioning the roller chains ........................................................................................................... 10411.6 Hydraulic layouts............................................................................................................................ 10511.7 Tire air pressure RP 405 / RP 435................................................................................................. 10811.8 Tire air pressure RP 505 / RP 535................................................................................................. 10811.9 Chain lubrication (oil lubrication).................................................................................................... 10911.10 Winter pause .................................................................................................................................. 11111.11 Lubrication chart............................................................................................................................. 11211.12 Lubrication points ........................................................................................................................... 114

12 TECHNICAL DATA.................................................................................................................................. 115


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6 WELGER RP 405 RP 435 RP 505 RP 535

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

without cutting device

MASTERCUT13-knife

XtraCut 1717-knife

Cutting device

XtraCut 2525-knife

firmly bolted

FLEXCONTROL Bottom

HYDROFLEXCONTROL

Net tying

Tying

Twine tying

BALERCONTROL Ewith BCE control box

ControlBALERCONTROL IIIwith E-LINK control box

= series equipment = variant = not available


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WELGER RP 405 RP 435 RP 505 RP 535 7

RP 505 SPECIAL RP 535 RP 535 MASTER

2.00 m

Pick-up width

2.25 m

NONCUT

Ring type rotor Rotor

PROFICUT


MASTERCUT13-knife

XtraCut 1717-knife

Cutting device

XtraCut 2525-knife

firmly bolted

FLEXCONTROL Bottom

HYDROFLEXCONTROL

Net tying

Tying

Twine tying

BALERCONTROL Ewith BCE control box

ControlBALERCONTROL IIIwith E-LINKControl box

= series equipment = variant = not available


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8 WELGER RP 405 RP 435 RP 505 RP 535

2 Safety

2.1 General safety instructions

Attention!Even if all instructions are observed the machine involvesresidual dangers. Always handle the machine with care to avoiddanger to yourself and others!

Before starting work perform a visual inspection of themachine. Check whether any device has been changed or ismissing and pay attention to any unusual noise or leakswhich occur during operation.

All protective devices, as for example casing sheets, rubberskirts or distance brackets are for your safety! Never operatethe machine with defective or removed protective devices e.

Keep all safety relevant parts always in correct function.Before commissioning all guard casings must be mountedand closed!

Never perform maintenance- and repair works duringmachine is in operation.

In case of all work on movable parts or in the range of actionof movable parts: Switch off power take-off shaft, switch offtractor engine, remove ignition key and disconnect driveshaft from power take-off shaft end. Interrupt electricalconnection between tractor and machine.

Bring no metal parts close to the machine, as long theelectric control is in operation (e.g. tools, safety boots with

metal caps). Reason: unintentional triggering of proximityswitches and thus unexpected machine moves.

When carrying out work on the opened tail gate: insert tailgate safeguard (chapter 2.4 Tail gate safeguard).

Never remove any crop material from the machine while thedrive is running, or while the disconnected machine is stillmoving. Always switch-off power take-off shaft and tractorengine first.

During work only the driver must be on the tractor. Riding onthe machine is prohibited!

Never step onto the maintenance platform during machine isin motion. Before stepping onto the maintenance platform:

stop machine, switch-off power take-off shaft and tractormotor, take out ignition key and wait for standstill of themachine.


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WELGER RP 405 RP 435 RP 505 RP 535 9

Do not step onto the drawbar or other parts of the machine,when the machine is in operation. Keep sufficient distance tobaler (pick-up, running gear, bale unloading area).

Before threading the tying material: stop machine, switch-offpower take-off shaft and tractor motor, take out ignition keyand wait for standstill of the machine. Make the controlpowerless (disconnect electrical connection to the tractor).

All protection devices must be mounted to the baler andmust be in correct state. Prior to opening the protectiondevices switch-off power take-off shaft and tractor motor andwait for standstill of the machine.

Block the wheels of the baler with wheel chocks whenmachine is parked. Carry the chocks on the machine whentransporting it or during field use.

When opening the tail gate keep a minimum distance of 2 mfrom 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 protectivegloves.

Works at the magnets of the knife holders: the function ofcardiac pacemakers can be interrupted by magnetic fields.

Works at the magnets of the knife holders: Danger of injuryby splinters never hit the inserted knives from below with astriking tool. Magnets could be damaged!

Maintenance work may be carried out by trained personsonly. All maintenance- and repair works that are not part ofthis operating instruction must be carried out by authorisedpersonnel only.

Replace wearing parts of the braking system only at both

sides.

Prior to disassembling the complete pick-up the machinemust be secured against backward tilt.

In case of locations on a slope: place the round bales alwaysso that they cannot move automatically.


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2.2 Noise level

The EC directive 86/188/EEC (or EC directive 2003/10/EC)concerning noise at the workplace instructs employers andemployees 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 tractorand on the other hand on the deployment conditions of thebaler.

The noise level generated by the WELGER balers, measured atthe head height of the driver with the tractor cabin windowopen, is, under normal operating conditions, less than 70 dB(A). The combined noise level of baler and tractor primarilydepends on the level of the noise from the tractor (radios are anadditional source of noise). We recommend that the tractor isoperated 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 themanually 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 theexhaust system of the tractor in proper condition.

The existing wiring must not be used for any otherconsumers than those installed in the factory or approved bythe manufacturer. Overloading the electrical lines leads toexcessive heating.

Do not smoke in the vicinity of the machine.

Keep fire extinguisher within reach.

Figure 1


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WELGER RP 405 RP 435 RP 505 RP 535 11

2.4 Tail gate safeguard

If any short-timemaintenance or assembly work is carried outwith the tail gate open, the tail gate must be hydraulicallysecured against lowering: use shut-off valve (on themaintenance 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 tailgate open, the tail gate must (in addition to the hydraulicsafeguard) be mechanically secured against lowering - usingsuitable means.

After completion of any maintenance and/or assembly workreset the valve to its initial position (along flow direction, Figure3) 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), whilethe machine is in motion. Before stepping on the maintenanceplatform: stop machine, switch-off power take-off shaft andtractor motor and wait for standstill of the machine.Climb and leave the maintenance platform exclusively via theladder [10]. Never step on the ladder when folded up alwaysfold down the ladder before using it.

(Figure 4) To climb the maintenance platform: fold down theladder [10].

(Figure 4) Before the machine can move on: fold up and lockthe ladder [10] again.

(Figure 4, Figure 5) For transportation the railing [15] isremoved from the maintenance platform in the factory andenclosed with the machine. The railing must be mounted againbefore commissioning of the machine:

Take the dismounted railing [15] out of the machine.

Mount the railing [15] to the maintenance platform using the6 enclosed screws [16] (Figure 5).

Figure 2

Figure 3

Figure 4

Figure 5


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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, tailgate, cutting device, HYDROFLEXCONTROL bottom door)mechanically against uncontrolled movement.

According to DIN 20066 hoses must not be older than six years,including storage time.

Figure 6


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WELGER RP 405 RP 435 RP 505 RP 535 13

2.7 Guard casings

To comply with the European safety regulations, since Jan. 1,1995 manufacturers of machines have been obliged accordingto EN 704 to design fixed, isolating guard casings in such a waythat 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 ofthe locking mechanism slightly in counterclockwise direction the casing engages in a safety catch.

(Figure 8): RP 405 / RP 435: Push safety catch up. Thecasing opens fully.

(Figure 9): RP 505 / RP 535: Push safety catch down. Thecasing 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 isavailable.Never operate the machine with defective or removed protectivedevices (e. g. guard casings and distance bracket). Beforeopening the protections: Switch off p.t.o. shaft drive and tractorengine, wait until machine has stopped, remove the ignitionkey.

Figure 7

Figure 8

Figure 9

RP 405 / 435

RP 505 / 535


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WELGER RP 405 RP 435 RP 505 RP 535 15

Warning symbols Meaning / Spare part No.

Read and heed the operating instruction and safetyinstructions prior to commission the machine.

Spare part no.: 0388.11.00.00

Close guard casings prior to commissioning the machine!

Spare part no.: 0389.92.00.00

Never reach into the pick-up section when the tractor engineis running and the power take-off shaft is coupled.

Spare part no.: 0389.94.00.00

Switch-off motor and take out the ignition key prior tomaintenance- and repair works.

Spare part no.: 0388.25.00.00

Switch-off motor and unplug the plug of the power supply priorto maintenance- and repair works.

Spare part no.: 0388.13.00.00

Stay clear of tail gate swinging area while in operation.

Spare part no.: 0389.93.00.00


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Riding on the machine, on treads or on the platform isprohibited.

Spare part no.: 0391.06.00.00

Handle cutting unit blades only with gloves and suitable tool

Spare part no.: 0387.33.00.00

The accumulator is under gas and oil pressure. Depressurise

hydraulic system prior to disassembling or repair.

Spare part no.: 0387.37.00.00

Activate tail gate safeguard prior to enter the roll chamber.

Spare part no.: 0394.98.00.00


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WELGER RP 405 RP 435 RP 505 RP 535 17

2.9 Symbolised operating instructions

The most important operating instructions are shown as symbols without text. The precise meaning isdescribed in the following.

Symbols Meaning / Spare part No.

The two lift eyes at the upper traverse are indicated by thissymbol.Other fastening points are not permitted for crane suspension.

Spare part no.: 0389.48.00.00

Note on crane loading

To ensure safe loading of the machine either a spreader mustbe used, or the transport chain must have a minimum lengthof 2.40 m.

Spare part no.: 0386.46.00.00

Tail gate locking device

If the lever is positioned at right angles to the flow direction,

the tail gate is secured against lowering.

Spare part no.: 0387.66.00.00

Maximum permissible hydraulic pressure

The machine may only be connected to a hydraulic systemproviding a maximum oil pressure of 210 bar.

Spare part no.: 0387.36.00.00

Adjusting the variable load valve

For driving on the road, the variable load valve of thecompressed-air brake must be set to "full brake force"

.

Spare part no.: 0385.01.00.00


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RP 405 / RP 435Locking of the belt lever for maintenance purposes

Spare part no.: 0386.45.00.00

RP 505 / RP 535Locking of the belt lever for maintenance purposes

Spare part no.: 0387.64.00.00

RP 405 / RP 435Opening of the lateral guard casings

Using a 13 mm spanner turn the hexagon head of thelocking mechanism slightly in counterclockwise direction the casing engages in a safety catch.

Push safety catch up. The casing opens fully.

Ersatzteil-Nr.: 0386.43.00.00 (linke Schutzverkleidung)Ersatzteil-Nr.: 0386.44.00.00 (rechte Schutzverkleidung)

RP 505 / RP 535Opening of the lateral guard casings

Using a 13 mm spanner turn the hexagon head of the

locking mechanism slightly in counterclockwise direction the casing engages in a safety catch.

Push safety catch down. The casing opens fully.

Spare part no.: 0387.81.00.00 (l.h. side guard casings)Spare part no.: 0387.80.00.00 (r.h. side guard casings)


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WELGER RP 405 RP 435 RP 505 RP 535 19

Guard lever for cutting unit blade

To unlock the cutting unit blades the lever must be turneddown through about 90.

Spare part no.: 0387.31.00.00 and 0387.32.00.00

Setting of the bale density

Spare part no.: 0387.65.00.00

Adjustment of the bale density for emergency operation

Spare part no.: 0387.96.00.00

Lubrication! 1 x per day, check lubrication and relubricate if

necessary.

Spare part no.: 0387.63.00.00

Thread scheme for net tying

Spare part no.: 0389.40.00.00

Thread scheme for twine tying

Spare part no.: 0386.79.00.00

Spare part no.: 0386.96.00.00


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WELGER RP 405 RP 435 RP 505 RP 535 21

2.10 Proper use

The machine is exclusively constructed for pressing balesfrom agricultural straw material lying on the floor (properuse). Using the machine for any other purposes does notconstitute proper use. The manufacturer cannot be held

liable for any damage resulting from such use; the risk ofimproper use lies entirely with the user.

Operating the machine within the limits of its proper use alsoinvolves complying with the operating, maintenance andservicing conditions prescribed by the manufacturer.

The bale weight must not exceed 1.5 t. I. e. the maximumbale size may not be available for silage bales (dependenton the quantity of moisture the bales must be smaller). Balesizes: See chapter "Technical Data".

The machine may only be used, serviced and repaired bypersons who are familiar with such work and instructed onthe dangers involved.

Attachment of additional equipment other than at thepositions provided by the factory is prohibited. Onlyadditional equipment must be used that is allowed by themanufacturer.

The relevant accident prevention regulations and all othergenerally accepted safety rules must be observed.

Unauthorised modifications and installation of non-approvedparts and equipment on the machine preclude any liability ofthe manufacturer for any damage resulting therefrom.

Any changes to safety-relevant parts will invalidate theconformity declaration and the CE marking.

2.11 Electromagnetic compatibility

The machine is equipped with electronic components andmodules; the function of these electronic components andmodules can be influenced by electromagnetic emissions ofother equipment. Such influences can cause risks to persons, ifthe following safety instructions are not observed:

In case of subsequent installation of electrical and electronicequipment and/or components into the machine, it is the user'sresponsibility to check whether the installation impairs thevehicle electronics or any other components.

Ensure above all that the electrical and electronic componentssubsequently installed are in conformity with the EMC directive89/336/EEC as amended, and that they are provided with theCE.


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2.12 To heed in the road traffic

Attention!Prior to driving on the road ...

... the roll chamber must be completely emptied (acc. to roadtraffic regulations).

... remove any crop material hanging loosely from the baler.

... connect the drive shaft to the tractor power take-off shaft;

... insert the spars of the bale ejector *.

... the ladder of the maintenance platform must be turned upand locked.

... connect the lighting set of the machine to the tractor andcheck function (also at daylight).

... insert and secure the pick-up guide wheels* in upperposition (pick-up width 2.25 m).

... fully release the manually operated brake. Otherwisethere is danger of fire by brakes running hot (e. g. in thefield).

Prior to operate the baler with connected machine (e.g. roundbale wrapper), obtain information from the manufacturer.

The wheel chocks (2 in number) which are part of the safetyequipment are to be carried on the baler at all times.

Permitted maximum speeds of individual assembly groups (e.g.drawbar or axis) do not count for the allowed maximum speedof the total machine. In this document only type relevant

maximum speeds are listed. Any deviating national regulationsmust always be observed.

The following regulation applies in Germany:

Machine Equipment perm. maximum speed

with pneumatic brake system 40 km/hRP 405

RP 435 brakeless 25 km/h

with pneumatic brake system 40 km/hRP 505

RP 535 with pneumatic brake systemwith 500/60-22.5 tire equipment

25 km/h


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WELGER RP 405 RP 435 RP 505 RP 535 23

2.12.1 Pneumatic brake system*:

Do not begin a journey with the baler attached unless bothcoupling heads (yellow and red) are connected to the tractorand the pressure gauge in the tractor cabin shows the requiredoperating pressure.

Attention, danger of accident!Prior to each journey pay attention to the lever position of thevariable load valve of the pneumatic brake system. Wrongsetting reduces the traffic safety (see chapter 4.5.1 Adjustvariable load valve*).

Start driving on the road with connected baler only when thevariable load valve is set to full load (see chapter 4.5.1 Adjustvariable load valve*).

2.12.2 Hydraulic brake system*:

Start driving on the road only when the according hydraulic tubeis connected to the tractor.

2.12.3 Germany (StVZO road traffic regulations):

Agricultural machines with permitted total weight of more than3,000 kg need a type approval. (Technical changes such asattaching a trailer coupling will invalidate the type approval)Prior to changes at the machine it must be solved, if thechanges are permitted or if they can added to the documents by

an expert.Further heed the national regulations of the country where themachine is in use.


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2.12.4 Data plate specifications

Item Meaning

1 Trade name of the machine

2 Ident no. individual machine number, please state in case of inquiries.

3 Machine type, machine version

4 Permissible total weight for operation on public roads.The actual weight can be less according to the equipment.

Exception (only in field use):The actual weight of the machine plus bale in the chamber can be higher.

5 Maximum support load of the machine, that acts at maximum load of tying material* to the hitch.The open-type towing fixture of the tractor must be registered for this support load.

6 Permitted axle load for operation on public roads.

7 Year of construction of the machine

8 Internal batch number

9 Manufacturer's name and address

Figure 10


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WELGER RP 405 RP 435 RP 505 RP 535 25

2.12.5 RP 405 / RP 435 only: Specifications on the dataplate of the drawbar head

Note!

RP 505 and RP 535 have no data plates on the drawbar heads.

Item Meaning

1 Drawbar type

2 official mark of conformity

3 Permitted maximum total weight of the machine

4 Permitted maximum support load

Figure 11


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26 WELGER RP 405 RP 435 RP 505 RP 535

2.13 Environment/Disposal

2.13.1 Lubricants

Dispose of lubricants properly and do not pollute the

environment. Observe the safety data sheets of the lubricantsused. Dispose of biodegradable lubricants separately.

1 litre of oil pollutes 1 million litres of water.

1 litre of oil pollutes 10 million cubic meters of soil.

2.13.2 Consumables

Twines, nets, foils and machine parts thrown away pollute theenvironment. They endanger in particular the animal world.

Therefore: dispose of twines, nets, foils and machine parts in aprofessional manner.


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WELGER RP 405 RP 435 RP 505 RP 535 27

3 Assembly groups

Item Assembly group Item Assembly group

1 E-LINKcontrol box* 8 Bale ejector

2 BALERCONTROL E control box* 9 Guide roller

3 ELS ("Easy-Load-System" for net rolls) 10 Catch

4 Net tying or twine tying 11 Bottom door*

5 Belt 12 Pick-up

6 Rocker arm 13 Cutting device*

7 Tail gate

Figure 12


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28 WELGER RP 405 RP 435 RP 505 RP 535

4 Start Up

Attention, danger of injury!During handling in the area of the drawbar ensure that the

machine is secured against moving. Do not raise the supportfoot before the baler has been safely coupled to the tractor.

Do not uncouple the baler, unless:

the bottom for wheels and support foot is even and bearing.

the baling chamber is empty and the tail gate closed.

the wheels of the machine are blocked by means of wheelchocks.

the hydraulic tubes have been depressurised.

the hitch is released.

Nobody must be between tractor and baler as long as the

vehicles are not secured against moving by manually operatedbrake and/or wheel chocks!

Always keep children away from the machine!

4.1 Coupling the baler

Note!Dependent on the equipment variant, a rotary or a rigid hitchcan be installed (observe national regulations!).

For trouble-free operation of the baler correct coupling of themachine (with adjustment of the drive shaft) is of decisiveimportance.

After coupling of the baler:

fully retract the support foot using the crank handle.

release the bolt.

push support foot fully in and lock it with the bolt.


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WELGER RP 405 RP 435 RP 505 RP 535 29

4.1.1 Manually operated brake (according to version)

Attention, danger of burning!Do not begin a journey with the machine attached unless the

manually operated brake [20] has been completely released.Otherwise there is danger of fire by brakes running hot (e. g. inthe field).

After coupling the machine to the tractor: Release manuallyoperated brake [20] (turn crank to the left).

Attention, danger of accident!Machines not coupled to the tractor must be secured againstaccidental rolling away by applying the manually operatedbrake [20] and by means of wheel chocks.

Before uncoupling the machine from the tractor: Apply the

manually operated brake [20] (turn crank to the right).

4.1.2 Drawbar positions

(all measures in [mm])

Figure 13

1753-29

1

5

2

6

3

7

4

120

100

115

250

100

130

1357

246

Figure 14


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30 WELGER RP 405 RP 435 RP 505 RP 535

4.1.3 Adjusting the drawbar

Attention!The height adjustment and thus the adjustment of the hitch may

be changed only by the manufacturer or an authorised specialworkshop.

Place the baler on a horizontal ground.

Turn out the support foot so far that the machine standshorizontally (axle plates horizontal, support foot vertical).

Measure the height of the drawbar on the tractor.

Measure the height of the hitch on the machine.

Using the dimensions stated in Figure 14 adjust the drawbarto the pair of holes approximating the desired value mostclosely. After each loosening of the safety nuts these mustbe replaced.

After alignment of the triangular draw system, position thehitch horizontally: loosen the fastening screws of the hitchand correct the position of the hitch by means of thethreaded rod.

Firmly tighten all fastening screws and nuts:

4.1.4 Tow hitch version

In case of tractor's tow hitch coupling of the baler thefollowing dimensions must be observed, at all costs:(see Table 1).

Category in

conformity

with

dimensions of the catch

opening

catch

opening-

outline

layout max.

permissible

vertical

support load

ISO 730-1 d B r1) c2) l F+1

-0

min. max. min. 10 kg

2 33 60 70 220 400 1200

3 33 70 80 250 500 15001) Provided the outer radius ris adhered to, different designs of tow hitch are permissible (see Figure 16).

2) To adhere to the dimension c, the upper part of the tow hitch can possibly be removed.

Dimensions in millimetres

Figure 15

Figure 16

Attention!

Other tow hitches than showed in Figure 16 or Table 1 are notpermitted! Danger of breaking!

Table 1: Dimensions, position and support load of the tow hitch


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WELGER RP 405 RP 435 RP 505 RP 535 31

4.2 Drive shaft

4.2.1 Coupling the cam-type cut-out clutch*

Depending on the version, a drive shaft with automatic safetyclutch (cam-type cut-out clutch) is installed.

Clean and grease the profile of the machine sidedconnecting shaft prior to assembling.

Loosen and turn out clamping cone [1].

Open maintenance hole in the guard cone on the machineside. Slide the clutch onto the connecting shaft so that thelocation hole [2] points towards the maintenance hole.

Position the location hole for the clamping cone above thering groove [3] of the connecting shaft.

Turn clamping cone into location hole and tighten firmly(approx. 70 Nm) while moving the hub slightly to and fro inlongitudinal direction.

Check tight and firm seat of clutch hub by compression andtensioning movements. During work, check clutch for correcttightening at regular intervals.

4.2.2 Uncoupling of the cam-type cut-out clutch*

Loosen and remove clamping cone from clutch hub. If thiscannot be done by hand, drive out clamping cone from theopposite side by means of a pin punch.

Figure 17

Figure 18

Figure 19


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32 WELGER RP 405 RP 435 RP 505 RP 535

4.2.3 Adjusting the drive shaft

(Figure 20) Pay attention to maximum operating length Lmaxand minimum operating length Lmin! Aim at maximum

overlap possible.

a) Shortest operating length, i. e. complete overlap.

b) During normal operation, the overlap of the sliding tubesshould be a least 2/3 of the profile overlap LU.

c) For a short time, the drive shaft can be operated withthe length Lmax , i. e. the profile overlap is 1/3 LU.

If necessary: adjust length. Hold the drive shaft halves next

to each other in the shortest operating position and markthem. Shorten inner and outer tubes by equal amounts sothat a sliding travel of 40 mm is retained in the shortestoperating position.

Secure the protective tubes of the drive shaft by retainingchain against revolving.

Before the starting the drive shaft, check whether the lockshave properly engaged.

When driving through narrow bends ensure that the wideangle joint (on the tractor side) is not bent more thanpermitted by the manufacturer of the drive shaft.

Heed the operating instructions of the drive shaft'smanufacturer as well as national relevant signs with typeapproval for drive shaft protection.

Only the drive shafts prescribed by the manufacturer may beused!

Support drive shaft always with the drive shaft support whenmachine is uncoupled (Figure 22). In case of bottomcoupling swivel up the support accordingly.

Attention, danger of injury!

Protective tube and guard cone of the drive shaft, and thepower take-off shaft protection, must be fitted and be in proper

condition. Ensure before switching on the power take-off shaft

that the selected speed of the tractor is in conformity with the

permissible speed and direction of rotation of the machine (540

rpm).

Switch power take-off shaft only during idling!

Figure 20

Figure 21

Figure 22


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WELGER RP 405 RP 435 RP 505 RP 535 33

4.3 Hydraulic System

4.3.1 Hydraulic connections for machines with E-LINK

Symbol on hydraulic tube Function Tractor connection Colour of marking

Tail gateopen and close

single acting yellow

Hydraulic switch with thefunctions

open and close

conveyor bottom raising and lowering the

pick-up

move cutting device inhome- and in operatingposition

double actingwith floating position

red


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34 WELGER RP 405 RP 435 RP 505 RP 535

4.3.2 Hydraulic connections for machines with BALERCONTROL E

Symbol on hydraulic tube Function Tractor connection Colour of marking

Tail gateopen and close

single acting yellow

Pick-uplift and lower

single acting red

move bottom door in home-and in operating position(for machines withoutcutting device)

double acting green

move cutting device inhome- and in operatingposition(for machines with fixedbottom door)

double acting green


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WELGER RP 405 RP 435 RP 505 RP 535 35

Note!For easier assignment of the correct oil connecting bushing incase of future coupling of the baler, transfer the colour marks ofthe hydraulic tubes to the connections of the tractor.

Clean the coupling parts of the hydraulic hoses with cleancloth and plug them into the bushings at the tractor.

Caution!Check hoses and tubing regularly for damage, ageing andoperating reliability. Defective parts must immediately bereplaced by original WELGER spare parts. Even in case ofpermissible stress, tubes and hoses are subject to naturalageing. They can therefore be used only for a limited period oftime.

The period of use for hydraulic tubing should not exceed sixyears!

4.3.3 Prior to first commissioning: open hydraulic valve

RP 405 SPECIAL and RP 435RP 505 SPECIAL and RP 535For transportation the bottom door is hydraulically blocked inthe factory, i. e. the bottom door valve on the hydraulic system

control block is closed. (See also: chapter 7.4 Lock bottomdoor.)

Prior to first commissioning: open hydraulic valve.

Using appropriate tool: set the right ball valve 90counterclockwise (Figure 23).Figure 23


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36 WELGER RP 405 RP 435 RP 505 RP 535

4.4 Electrical system

4.4.1 Lighting set

To connect the lighting system, insert the 7-pin plug(ISO 1724) into the corresponding socket on the tractor.

Before travelling on the roads, check that the lighting systemfunctions correctly (also at daylight).

4.4.2 Control electronics

The machine will be delivered according to the version withthe following control:

"Balercontrol E"(with control box for "Balercontrol E" Figure 24)

"Balercontrol III"(with control box for "E-LINK" Figure 25)

Note! Read and heed the separate operatinginstruction "E-LINK for RP 435/535 MASTER".

For attaching the corresponding control box a bracket isdelivered with, that must be mounted nearby the tractordriver.

The respective control box is equipped with a magnetic plateat the back and can be fixed onto a metallic surface into thetractor's cabin.

Connecting the control box: To connect the control box to

the control system plug the small 7-pole plug (with screwcoupling) into the corresponding 7-pole socket on themachine.

Connecting the power supply: A load socket according toDIN 9680 is required on the tractor for connecting the controlelectronics "Balercontrol". (Part of the delivery of the baler).Fuse protection must amount to 30 A. (For balers withouttwine tying a fuse protection of 16 A is sufficient.) Plug the 2-or 3-pole plug of the machine into the load socket(DIN 9680) of the tractor.After connecting the plug supply voltage is available and ashort series of beeps can be heard from the control box(only if the load socket of the tractor is permanently

connected or if the ignition of the tractor is actuated)..

To equip another tractor the plug socket with connecting cableand fuse is available under the WELGER part no.0972.20.40.00.

The correct polarity of the power supply of the tractor must notbe changed, otherwise the electronic control could be damaged(Figure 26).

Figure 24

Figure 25

Figure 26


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WELGER RP 405 RP 435 RP 505 RP 535 37

4.5 Compressed-air braking system

4.5.1 Adjust variable load valve*

Attention, danger of accident!Prior to each journey pay attention to the lever position of thevariable load valve (Figure 27). A wrong setting reduces thetraffic safety.

Symbol Brake power

No brake power!Not for road driving!Not for field use!

Low brake power!Not for road driving!Restricted for field use!

Medium brake force!Not for road driving!Permitted for field use!

Full brake force!Permitted for road driving!Permitted for field use!

Table 2

Brake released (no brake power)The machine has not sufficient braking power for driving on the road.This lever position may only be used for moving the uncoupledmachine. This setting is not permitted for moving the machine with a

tractor.

Empty load (low brake power)The machine has not sufficient braking power for driving on the road.This lever position should not be used for field use of the machine.When using this setting the tractor must have sufficient brake power.For this heed the nature of the ground and of the site.

Half load (medium brake power)The machine has not sufficient braking power for driving on the road.This lever position can be used for field use of the machine. Whenusing this setting the tractor must have sufficient brake power. For thisheed the nature of the ground and of the site.

Full load (full brake power)This lever position must be set for driving on public roads.This lever position can be used for field use of the machine.

Figure 27


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38 WELGER RP 405 RP 435 RP 505 RP 535

4.5.2 Connecting the pneumatic system (pneumaticbrake system)

Attention, danger of injury!

Pneumatic braking system: Before any work is carried out onthe pneumatic system, the system must be depressurised.

Caution, danger of injury!Do not begin a journey with the machine attached unless thepressure gauge in the tractor cabin shows 5.0 bar. Otherwisethere is the risk of the brakes running hot.

Remove dirt, if any, from the sealing washers of the couplingheads on the tractor and on the connecting tubes of themachine.

Connect coupling heads for reservoir (red) and brake(yellow) with the corresponding connections of the tractor.

Drain the compressed-air tank (left machine side) and checkfor damage and tight seat daily.

To enable manoeuvring of the machine without connection tothe compressed air system:

lever of load apportioning regulator to:

machine manoeuvring.

Before the beginning of the next journey, or in order to brakethe machine again: Set lever of load apportioning regulatoraccording to demand or or (seechapter "Adjust variable load valve*").

4.6 Hydraulic braking system

4.6.1 Connect hydraulic system (hydraulic brakingsystem)

Attention, danger of injury!Hydraulic braking system: Before any work is carried out on the

hydraulic system, the system must be depressurised.

The machine can be equipped with a hydraulic brake accordingto the legal regulations of the delivery country. Thecorresponding hydraulic coupling is different from the otherhydraulic couplings in that the sleeve of the quick-actioncoupling is fitted to the machine.

Please observe in this context the national regulations of thecountry in which the machine is to be used.


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WELGER RP 405 RP 435 RP 505 RP 535 39

5 Twine tying*

5.1 Threading the twine

Attention, danger of injury!Prior to inserting of new spools of twine and threading thetwine: stop machine, switch-off power take-off shaft and tractormotor, take out ignition key and wait for standstill of themachine. Make the control powerless (disconnect electricalconnection to the tractor).

Note!Optimum results in production during use of our machinesdepend of multiple factors. Therefore:

The threaded twines must not contact each other or runcrosswise.

Use high-grade twines (recommendation: plastic twines).Place the twine spools upright side by side in the twine box.If the spools are inserted the wrong way round, the twine willtend to loop and break.

Heed and follow the instructions given in the operatinginstructions.

For working in extreme ambient conditions: request to ourcustomer service. Heed the technical data at the end of thisoperating instruction.

Twine A(Shown by continuous line in Figure 28 and Figure 29.)

Twine B(Shown by dotted - - - - - - line in Figure 28 and Figure 29.)

Twine A (Figure 28): Feed the beginning of the twine fromspool A1 upwards through the guide eye and then out of thetwine box. Knot end of twine of spool A1 with the beginningof the twine of spool A2. Important: The knot must be verysmall!

Twine B (Figure 28): Feed the beginning of the twine ofspool B1 upwards through the guide eye and then out of thetwine box. Knot end of twine of spool B1 with the beginning

of the twine of spool B2. Important: The knot must be verysmall!

Thread the twines A and B each through the twine brake [1].

Wrap both twines around the guide rollers [2].

Thread in both twines upwards to the pair of eyes [3] on thebinding bar.

(Continued on the page after next.)


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40 WELGER RP 405 RP 435 RP 505 RP 535

Thread scheme: from the twine box to the variable diameter disc

Thread scheme: from the variable diameter disc to the guide rollers

Figure 28

Figure 29


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WELGER RP 405 RP 435 RP 505 RP 535 41

(Figure 29) Feed twines A and B through to the guide rollers[8].

Loop twine A anticlockwise once around the variablediameter disc [9].

Finally locate each twine at the entry to their respective

guide roller. Turn the roller pair by hand until the thread has been

securely grasped.

Note!The clamping and cutting devices [10] have been factory set sothat the driving twine (twine A) must be guided through theguide rollers on the left-hand side, as seen from the direction oftravel.

After threading: tighten the two twine ropes towards the

twine spool.


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42 WELGER RP 405 RP 435 RP 505 RP 535

5.2 Adjusting the twine brake

The twine brakes [1] (Figure 28) must hold the twines as taut aspossible for the twines to be tight around the bales.

(Figure 30) Adjust dimension "X" of the twine brake

according to the following table.

Basic settingLength "X" of the spring

(Figure 30)

Twine A 39 mm

Twine B 37 mm

Note! The permitted thread tension is exceeded when the twine

breaks in the vicinity of the guide rollers [8] (Figure 30).

The dimension "X" is measured between: washer bottomedge and the bottom surface of the cranked plate.

Figure 30


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WELGER RP 405 RP 435 RP 505 RP 535 43

5.3 Setting the edge clearances

For lateral limitation of the twine wrapping at the ends of thebale:

adjust the left and right range spacer [1] (only the rightmachine side is shown in Figure 31 and Figure 32).

With very dry and brittle crop materials select the retainersin the middle of the baler.

5.4 Adjusting the wrapping distance

The distance between the wrappings is given by the diameterused for the variable diameter disc [9] (Figure 29). The smallerthe effective diameter of the disc, the greater the distancebetween the wrappings.

A lever [2] used to adjust the wrapping distance is located onthe far right-hand end (in travelling direction) of the binding bar[2] (Figure 31 and Figure 33).

Swivelling the lever towards the machine centre will movethe two halves of the variable diameter disc apart, reducethe effective diameter of the variable diameter disc andresult thus in a larger twine distance. Setting:

Position 1: maximum wrapping distancePosition 7: minimum wrapping distance

Figure 31

Figure 32

Figure 33


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5.5 Edge wrapping adjustment

In order to ensure that the high density bales remain wellcompressed, the twine wrappings are automatically laid closertogether near the edge of bales.

In order to achieve this, the right-hand shuttle [4] presses thevariable diameter disc closer together when reaching the endzone. The working diameter of the variable diameter discincreases and the distance between wrappings is reducedtowards the edges.

A switching angle [3] (Figure 34) is installed in the right-handshuttle, which is attached by two screws in a unit with a set ofholes. Four different installation positions are available.

By displacing the angle towards the variable diameter disc, thevariable diameter disc is pressed closer together for the area ofthe edge wrappings. The effective diameter increases and more

edge wrappings are applied to the edge of the bale. Setting:

Displace switching angle (3) towards the variable diameterdisk: more end windings on the edge of the bale.

Or:

Displace switching angle (3) towards the machine centre:less end windings on the edge of the bale.

Figure 34


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WELGER RP 405 RP 435 RP 505 RP 535 45

6 Net tying*

6.1 Inserting the net

Attention, danger of injury!Prior to inserting new net rolls and threading the net: stopmachine, switch-off power take-off shaft and tractor motor, takeout ignition key and wait for standstill of the machine. Make thecontrol powerless (disconnect electrical connection to thetractor).In order to handle the net roll safely, insert it together with thehelp of a second person!

Attention, danger of injury by cutting!There is danger of injury by cutting during work on the net knife(Figure 48, item 10). Wear protective gloves.

Open left-hand side cover.

Attention, danger of injury by net knife turning downautomatically!Only if the last wrapping process has not been completelyexecuted (e. g. because the net roll depleted during thewrapping process): (Figure 35) Pull the handle of the knifecarrier hard to the front against the spring tension (the triangularcounting segment for the net length returns to its startingposition).

This prevents unexpected activation and automatic drop-downof the net knife during threading of the net.

Figure 35


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46 WELGER RP 405 RP 435 RP 505 RP 535

(Figure 36) Open safety chain [1].

(Figure 37) Pull out handle [5] of the crank handle. Crankback the tensioning spindle [4] until the lock plate with thecrank handle.

Open upper hood.

(Figure 38) Slide net tightener [8] back and secure withcotter pin.

Figure 36

Figure 37

Figure 38

4

5

1

8


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WELGER RP 405 RP 435 RP 505 RP 535 47

(Figure 39) Depending on the diameter of the net rolls in usethe height of the net roll plate [10] must be set accordingly:

Net roll with net length 3,000 m: Mount net roll plate in lowerposition (bottom thrill hole in Figure 40).

Net roll with net length 2,000 m: Mount net roll plate inmedium or upper position (centre or top thrill hole in Figure40).

(Figure 41) Dependent on the width of the net rolls used an

extension tensioning spindle (16) can be mounted on theoriginal tensioning spindle (15):

Width of the net roll more than 1.23 m: extension tensioningspindle not necessary.

Width of the net roll 1.23 m or smaller: Unscrew extensiontensioning spindle (16) and attach to the tensioning spindle[15].

Figure 39

Figure 40

Figure 41

16

15

10


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48 WELGER RP 405 RP 435 RP 505 RP 535

(Figure 42) Depending on the width of the net rolls in use thecomplete net holder [21] must be moved horizontally and fastenagain:

Width of the net roll 1.23 m: move complete net holder [21]in the slotted holes to the left until the lock plate and fastenit.

Width of the net roll 1.30 m: move complete net holder [21]in the slotted holes [20] to the right until the lock plate andfasten it.

According to the width of the net rolls a position between the leftand the right lock plate can be selected for the net holder.

(Figure 43) Slide net roll until the lock plate into the tiltableauxiliary net holder.

Note!Watch wind-off direction of the net roll! The net must enter themachine beneath the net roll (see Figure 48).

(Figure 44) Tilt net roll into the net holder.

Note!(Figure 45) The tips of both tensioning spindles must point intothe sleeve of the net roll.

If the tips of the two tensioning spindles do not point into thesleeve but onto the net material the height of the net roll platemust be corrected accordingly (Figure 39 and Figure 40).

Figure 42

Figure 43

Figure 44

Figure 45

20

21


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WELGER RP 405 RP 435 RP 505 RP 535 49

(Figure 46) Pull out handle of the crank handle. Cranktensioning spindle with crank handle into the sleeve of thenet roll.

(Figure 47) Crank tensioning spindle so far until between thebushing (25) and the crank handle (26) is only a gap ofapprox. 2 mm left.

Fold back the crank handle again.

Note!Before closing the side cover: Turn crank back into machine.Fold back the crank handle.

The net roll must rotate free and easy. If not: Check andrepeat the setting described in this chapter "6.1 Inserting thenet", if necessary.

Figure 46

Figure 47

25

26


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50 WELGER RP 405 RP 435 RP 505 RP 535

(Figure 48) Feed the net from the roll (11) around the upperguide tube [4] and subsequently around the net tightener [3].

(Figure 48 and Figure 49) Feed the net across theexpanding device [5] and place its front end between rubberroller [6] and steel roller [7].

(Figure 50) Turn the rubber roller [6] by hand until the net isgrasped. To prevent the net from getting into the rollchamber too early during the baling process, the front end ofthe net must not project more than approx. 10 cm beyondthe rubber roller.

(Figure 38) Remove cotter pin from the net tightener and

swivel net tightener to the front. (Figure 43) Insert an auxiliary net roll into auxiliary net

holder.

(Figure 36) Close safety chain.

Figure 49

Figure 50

Figure 48


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WELGER RP 405 RP 435 RP 505 RP 535 51

6.2 Tightening the net knife

Normal case: the net knife is tensioned automatically wheneverthe tail gate is opened.

Special case: if, while the baling chamber is filled, new net tying

is necessary without opening of the tail gate (e. g. because of anet roll change or a fault), the net knife can be tensioned byhand:

(Figure 51) Pull the knife carrier against the spring tension tothe front. Triggering is effected as described in the chapter"Operation / Tying".

Figure 51


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52 WELGER RP 405 RP 435 RP 505 RP 535

6.3 Adjusting the net length

6.3.1 BALERCONTROL E

Using the scale (Figure 52) the net length (i.e. the number ofnet wraps around the bale) can be adjusted continuously:

Slacken the wing nut. Displace the wing nut in the slotted hole to adjust the desired

net length.

Retighten the wing nut.

Note!First select a setting in the middle of the slotted hole. To savenet material change the setting step by step towards ( ) forsubsequent bales.Do not use too little net material: The bale must still be heldtogether. For very smooth bales and high baling densities a

larger amount of net material must be adjusted.

Note!If the bale diameter changes the net length must be adjustedaccordingly.

6.3.2 E-LINK

Via the E-LINK control system the net length can be adjusted inincrements of 0.5 from 1.5 to 5 net layers (net layers are thenumber of net wraps around the bale).

Note!In case of E-LINK machines the wing nut must be installed inthe separate square hole of the scale (Figure 52) (not in theslotted hole).

Note!Read and observe the separate operating manual:E-LINK for RP 435 MASTER / RP 535 MASTER.

Figure 52


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WELGER RP 405 RP 435 RP 505 RP 535 53

7 Cutting device*The cutting device (Figure 53) can be used for silage, hay andstraw. The knifes of the cutting device are swivelled in and outhydraulically.

Attention, danger of injury!Prior to any work on the cutting device of the machine: Switchoff power take-off shaft, switch off tractor engine, removeignition key and disconnect drive shaft from power take-off shaftend. Make the control powerless (disconnect electricalconnection to the tractor).

7.1 Equipment

The machines can be equipped as follows:

machine withcontrol box:

can be equipped with:

Balercontrol E

BALERCONTROL E


MasterCut (13 knives)

XtraCut 17 (17 knives)

E-LINK

E-LINK without cutting device

MasterCut (13 knives)



7.2 Knife groups

To change the cut length of the material to be pressed, knifegroups can be selected (that means, not all knives of the cuttingdevice are in use):

The cutting device XtraCut 17 (17 knives) contains an 8-knife group and a 9-knife group (8 + 9 = 17). Both knifegroups can be used in the following combinations:0 knives 8 knives 9 knives 17 knives

The cutting device XtraCut 25 (25 knives) contains a 12-knife group and a 13-knife group (12 + 13 = 25). Both knifegroups can be used in the following combinations:0 knives 12 knives 13 knives 25 knives

Figure 53


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54 WELGER RP 405 RP 435 RP 505 RP 535

7.2.1 Select knife group (E-LINK)

Note!

Read and heed the separate operating instruction "E-LINK forRP 435 MASTER / RP 535 MASTER".

Caution!Before a knife group can be selected, all knives that can be incutting position must be totally moved into home position. seechapter 7.3 Moving in and out the cutting device.

To move a knife group by means of the tractor's distributionvalve it must have been selected:

In the menu "MONITOR": Repeat pressing the centre key

until the symbol for the selected knife group appears inthe display (above the centre key).

For example: for a machine with 17-knife cutting device thefollowing selection is possible:

(8-knife group)

(9-knife group)

(8- and 9-knife group together)

The selected knives can be moved now:see chapter 7.3 Moving in and out the cutting device.


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WELGER RP 405 RP 435 RP 505 RP 535 55

7.2.2 Select knife group (Balercontrol E)

Caution!Before a knife group can be selected, all knives that can be in

cutting position must be totally moved into home position. seechapter 7.3 Moving in and out the cutting device.

To move a knife group by means of the tractor's distributionvalve it must have been selected by means of the hydraulicvalves [1] and [2] (Figure 54 and Figure 55). The hydraulicvalves are located on the left machine side, seen drivingdirection.

Attention, danger of injury!The hydraulic valves are located in the range of action of thepick-up and of the cutting device. Prior to operate the hydraulicvalves: Switch off the power take-off shaft, switch off the tractorengine, remove the ignition key.

Desired knife groupAdjust hydraulic valves(according to Figure 54)

no knivesValve 1 Position 0

Valve 2 Position 0

8 KnifeValve 1 Position "I"

Valve 2 Position 0

9 KnifeValve 1 Position 0

Valve 2 Position "I"

17 Knife



Adjust hydraulic valves according to the table.

The knives can be moved, now: see chapter 7.3Moving inand out the cutting device.

1 2

Figure 54

Figure 55

1

2


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56 WELGER RP 405 RP 435 RP 505 RP 535

7.3 Moving in and out the cuttingdevice

7.3.1 General

On the following pages the conditions "Knives in cuttingposition" and Knives in home position" are mentioned. Now, thedefinition of the states:

"Knives in cutting position" means:The knives are totally moved out of the knife bottom plate(Figure 56). Straw conveyed through the machine is cut bythe moved out knives.

"Knives in home position" means:The knives are totally inserted into the knife bottom plate(Figure 57). Straw conveyed through the machine is not cutby the inserted knives.

7.3.2 Prior to first commissioning: open hydraulic valve

RP 405 SPECIAL and RP 435RP 505 SPECIAL and RP 535For transportation the bottom door is hydraulically blocked inthe factory, i. e. the bottom door valve on the hydraulic systemcontrol block is closed. (See also: chapter 7.4 Lock bottomdoor.)

Prior to first commissioning: open hydraulic valve.

Using appropriate tool: Set the right ball valve 90counterclockwise (Figure 58).

Figure 56 (Pictures from open bottom door) Figure 57Knives in cutting position Knives in home position

Figure 58


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WELGER RP 405 RP 435 RP 505 RP 535 57

7.3.3 E-LINK control box13-knife cutting device17-knife cutting device25-knife cutting deviceHYDROFLEXCONTROL bottom door

lely baler

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