OPERATING MANUAL
for
RAINSTAR A3
Version VII-2012
Art. No. 827 9978
Introduction
Thank you for buying BAUER RAINSTAR A3 !
The present manual is a very important document that describes how to operate and BAUER
RAINSTAR A3.
This manual describes the system as detailed as possible. If you need still more information, please
contact your dealer or turn directly to BAUER in Voitsberg/Austria.
Please note that the content of this manual neither constitutes part of nor alters in any way any
previous or existing agreement, promise or legal relationship. BAUER’s commitment is based solely
on the respective purchase contract which also contains the complete and only valid warranty
agreement. Said contractual warranty is neither extended nor limited by the content of this manual.
All information contained in the present manual is based on the latest product details available at the
time of printing.
BAUER reserves the right to change without notice without assuming any liability!
BAUER RAINSTAR A3 is designed for highest performance safety and reliability provided it is
operated in accordance with the present operating instructions.
Therefore you should study this manual thoroughly before starting your BAUER RAINSTAR A3 !
Strictly observe all instructions pertaining to system handling, operation and service!
On this condition, BAUER RAINSTAR A3 will operate to your satisfaction for many years!
Non-observance of this manual may cause personal injury or damage the equipment!
This manual is to be considered an integral part of BAUER RAINSTAR A3. Suppliers of both new
and used systems are advised to put down in writing that they delivered the manual together with the
system.
Please make this manual available to your sta ff. State the pump type and serial number of your
BAUER RAINSTAR A3 in all inquiries, correspondence, warranty problems, or parts orders.
We wish you a lot of success with BAUER RAINSTAR A3 !
II
Manual for BAUER RAINSTAR A3
Product details
Type designation:
Type number:
1
Serial number
:
Dealer:
Date of shipment:
Manufacturer:
RAINSTAR A3
Name:
Adresse:
ph./fax:
Röhren- und Pumpenwerk BAUER Ges.m.b.H.
Kowalds tr. 2
A - 8570 Voitsberg/Austria
Tel.: +43 3142 200 – 0
Fax: +43 3142 200 –320 /-340
www.bauer-at.com
e-mail: sales@bauer-at.com
Owner or operator:
Name:
Address:
ph. / fax:
Note: Please make a note of the type and serial number of your RAINSTAR A3 and accessories. Be sure to
specify these details every time you contact your dealer.
1
In all warranty claims and correspondence relating to this machine it is essential to specify the full serial number group including all letters.
This applies to both the machine and the components concerned. We cannot emphasise this point often enough.
Manual for BAUER RAINSTAR A3
III
General Safety Instructions
Symbols and terms
The CE symbol that has to be affixed on the machine by the manufacturer
outwardly demonstrates compliance of the machine with the directives for
WARNING!
machines and other relevant EU directives.
This “Warning” symbol refers to important safety instructions in this
manual. Whenever you see this sym bol be aware of possible injury
hazards. Read the note following the symbol very carefully and
inform the other operators accordingly.
CAUTION
Non-observance of this instruction may cause damage to or destroy
the machine or individual components.
NOTE
Qualified operators are persons who on account of their trai ning, experience and instruction as well as
their knowledge of relevant standards, rules, precautions to be ta ken for accident prevention, and
prevailing operating conditions, have been authorised by the person in charge of plant safety to perform
the respective tasks required, and in doing so are able to recognise and avoid potential hazards. Among
other things, knowledge of first-aid procedures is also required.
It is very important to observe this note or condition!
Product liability
As defined by the product liability law every farmer is also an entrepreneur!
According to §9 PHG (Product Liability Law), liability for damage to corporeal things caused by defective
products is expressly excluded. This exclusion of liability also applies to parts not manufactured by
BAUER itself but purchased from external suppliers.
Duty to furnish information
Even if the customer passes on the machine later-on he is obliged to hand the operating manual on to
the new receiver, too. The receiver of the machi ne must be instructed with reference to the mentioned
regulations.
Intended use
BAUER RAINSTAR A3 is built exclusively for normal agricultural applications (intended use).
Any use beyond this normal use is considered non-conforming. Manufacturer is not liable for damage
resulting from such non-conforming use, the sole li ability for damage from non-conforming use is with the
user.
Intended use also includes compliance with the manufacturer’s operating, maintenance and service
instructions.
The BAUER RAINSTAR A3 may be used and operated only by persons who are familiar with the
device and aware of the hazards involved.
All rules for accident prevention as well as any other generally valid specifications and regulations
relating to safety, work medicine and traffic law must be strictly observed.
Unauthorised modifications on the machine rel ease the manufacturer from liability for damage
resulting therefrom.
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Manual for BAUER RAINSTAR A3
Index
GENERAL INSTRUCTIONS FOR SAFETY AND ACCIDENT PREVENTION ......................... 2
GENERAL .................................................................................................................................. 6
1 SAFETY PRECAUTIONS FOR THE RAINSTAR A3 .......................................................... 7
2 DESCRIPTION .................................................................................................................... 8
3 PUTTING INTO OPERATION ............................................................................................. 9
3.1 STEPS TO BE CARRIED OUT ONCE OR FROM TIME TO TIME ................................................ 9
OPERATING MODE I: PE-PIPE PULL-OFF ........................................................................................... 10
3.2 OPERATING MODE II: Laying down the PE-pipe .................................................................... 15
4 MECHANICAL REGULATION .......................................................................................... 18
5 QUICK STOP .................................................................................................................... 19
6 WINDING MECHANISM .................................................................................................... 19
7 SHUT-OFF AND SAFETY EQUIPMENT .......................................................................... 19
8 CART ................................................................................................................................. 20
9 OVERPRESSURE SHUT-OFF VALVE ............................................................................. 20
10 WINTERIZATION – DRAINING ..................................................................................... 21
11 WINDING MECHANISM – STARTING POSITION ........................................................ 22
12 SETTING THE GEARBOX SHUT-OFF DEVICE ........................................................... 24
13 SPEEDOMETER ............................................................................................................ 26
14 SERVICE AND MAINTENANCE .................................................................................... 28
15 TROUBLE-SHOOTING .................................................................................................. 29
14. CONFORMITY CERTIFICATE ....................................................................................... 32
Manual for BAUER RAINSTAR A3
1
General instructions for safety and
accident prevention
Check the operational safety of the machine before every start-up.
1. In addition to the instructions contained in this manual, all specifications generally valid for safety
and accident prevention must be observed!
2. The warning and instruction signs affixed to the machine give very important instructions for safe
operation. Observing them serves your own personal safety!
3. Never put the machine into operation unless all guards and safety devices are completely
mounted and in their proper working position!
4. Acquaint yourself with all equipment components and controls as well as their respective functions
before starting to work. It is too late when the device is already running!
5. The operator’s clothes should fit tightly. Avoid wearing loose clothes!
6. When handling slurry always keep in mind that the gasses produced are highly toxic and extremely
explosive in combination with oxygen. Therefore, open fires, light tests, sparking and smoking are
strictly forbidden!
7. Utmost care is required with regard to gasses in slurry and dung channels at open valves to the
preliminary pit, before the main pit, or at cross channels. The same applies to mixing and
withdrawal points when mixers or pumps are running!
8. When handling slurry always ensure sufficient ventilation!
9. Keep the machine clean to avoid fire hazards!
Power take-off (applies only to PTO driven machines)
1. It is not allowed to use any other types of PTO drive shafts except the ones prescribed by the manufacturer!
2. Drive-shaft guard tube and guard cone as well as the PTO guard – also on the machine side must be mounted and in good working order!
3. When using a PTO drive shaft always observe the specified overlap in transport and working
position!
4. Never connect or disconnect the PTO drive s haft unless the PTO is stopped, the engine turned
off, and the ignition key pulled out!
5. Make sure the drive shaft is always connected and secured properly!
6. Attach the safety chain to keep the drive shaft guard from rotating with the shaft!
7. Before you turn on the PTO make sure that the selected tractor PTO speed corresponds with
the permissible implement speed!
8. Before starting the PTO make sure that nobody is standing in the danger zone of the machine!
9. Never turn on the PTO when the engine is turned off or during a transport drive!
10. When working with the PTO nobody is allowed near the turning PTO or drive shaft!
11. Warning! The PTO shaft may continue turni ng due to its centrifugal mass after the PTO has
been turned off! Keep clear of the machine duri ng this time and do not touch until the PTO
shaft stands absolutely still!
12. For cleaning, greasing, or adjusting the PTO driven implement or drive shaft, PTO and engine
must be switched off and the ignition key pulled out!
13. Place the disconnected drive shaft on the provided support!
14. When drive shaft has been removed put the guard on the PTO shaft!
15. If a defect occurs repair it immediately before starting to work with the machine!
Hydraulic system
1. Hydraulic system is under high pressure!
2. When connecting hydraulic cylinders and motors, make sure the hydraulic hoses are connected
as specified!
3. Before coupling the hydraulic hoses with the tractor’s hydraulic system make sure that the
entire hydraulic system is pressureless both on the tractor and implement side !
4. Inspect the hydraulic lines at regular interval s and replace them immediately in case of defects
or ageing. Replaced hoses must comply with t he technical specifications of the implement
manufacturer!
5. When looking for leaks use only suitable equipment because of the injury hazard involved!
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Manual for BAUER RAINSTAR A3
6. Liquids emerging under high pressure (hydraulic oil) may penetrate the skin and cause serious
injuries! An injured person must see a doctor immediately! Danger of infection!
7. Before working on the hydraulic system t he machine must be lowered, the system
depressurised and the engine turned off!
Electric-driven implements
1. All work beyond normal maintenance of the implement should be performed only by a professional
electrician!
2. Defective or broken plugs and sockets must be replaced by a professional electrician!
3. Never pull a plug out of the socket at the flexible electric cord!
4. Extension cables for power supply should be used only temporarily! Never use such lines
permanently as a substitute for the required fixed installations!
5. Flexible lines laid across traffic areas on the farm must have at least 5 m ground clearance!
6. Always turn off the power supply before you do any work on the machine!
7. Check all electric lines for visible defects bef ore you put the machine into operation! Replace
defective cables and do not start the machine before that!
8. Never use electric-driven implements in damp situations or locations exposed to fire hazard
unless they are adequately protected against moisture and dust!
9. Covering electric motors may cause heat c oncentration with high temperatures which could
destroy the operating equipment and cause fires!
Hand-operated devices (valves)
1. Because of the slurry gasses produced in the li nes, no slurry is allowed to remain in closed
pipelines – bursting hazard!
2. Lay the pipelines with sufficient inclination and ma ke sure that the selected closing order of valves
allows all lines to be drained completely!
3. Protect the valves against unauthorised handling!
4. If a valve gets jammed do not apply force! Us e only the operating levers supplied with the
implement!
5. Observe the permissible maximum operating pre ssure of valves and pipelines when pumps are
operated!
6. Service only when the tanks are empty!
Maintenance
1. Never perform any maintenance, service or cleani ng work or fault elimination steps unless the
drive is turned off and the engine is standing still!
2. Check proper fit of all nuts and bolts regularly and tighten them, if necessary.
3. If maintenance work is required on the lifted mach ine always secure it by means of appropriate
supports!
4. When exchanging tools with cutting edges always use proper tools and wear safe protective
gloves.
5. Dispose of oil, grease and filters according to local laws and regulations!
6. Always turn off power before working on the electric system!
7. Before electric welding on the tractor and mounted machines the generator and battery cables
must be disconnected!
8. Spare parts must meet manufacturer’s minimum te chnical specifications! This is the case for
instance with original spare parts for instance!
Manual for BAUER RAINSTAR A3
3
Safety distances Z from electric lines at:
IRrigation = ZR e. g.: with drinking water, ground water (e. g. well) or running
water (e. g. river)
SlurryG = ZG e.g.: with liquid manure or slurry
H = minimum distance between sprinkler upper edge and conductor cable when
crossing beneath an electric line
The safety distance when crossing beneath an electric line, is reached when the distances as per the
below chart are kept. The water beam may touch the conductor cable but it may not be higher than the
conductor cable.
Sprinkler with rubber wheels Sprinkler with skids
Running direction
Pump tanker on rubber wheels Sprinkler jet pipe directed by hand
ATTENTION: DO NOT SPRAY SLURRY ON INSULATORS AND MASTS!
Type and operation mode of
the sprinkler
Jet type Spray F ull Spray F ull Spray F ull Spray Full
Up to 1.000 V
H = 1 m
Up to 30.000 V
H = 2,5 m
Up to 110.000 V
H = 3 m
Up to 220.000 V
H = 4 m
Up to 380.000 V
H = 5 m
4
ZR 1 5 1 5 1 5 1 5
ZG 1 8 1 8 1 8 1 8
ZR 3 9 5 21 3 7 4 9
ZG 5 11 7 23 5 9 6 11
ZR 3 12 5 24 3 9 4 15
ZG 5 14 7 26 5 11 6 17
ZR 4 14 6 26 4 12 6 22
ZG 6 16 8 28 6 14 8 24
ZR 5 16 7 26 5 14 6 22
ZG 7 18 9 28 7 16 8 24
With rubber wheels or directed by hand
With metal or synthetic pipes
26 mm ≙ 50 m3/h 36 mm ≙ 100 m3/h 26 mm ≙ 50 m3/h 36 mm ≙ 100 m3/h
Safety distance Z in m, measured on the ground
With skids or stationary/fixed
With metal cart and metal pipes
Nozzle diameter in mm or flow in m³/h
Manual for BAUER RAINSTAR A3
The safety distances indicated in the above chart are valid for a nozzle diameter of 26 mm and/or 36 mm at an
operating pressure of 5 bar. For higher operating pressures the safety distances have to be increased by 2 m.
The safety distances are not valid when standardized jet pipes like those of fire brigades are being used.
When applying polluted water or slurry, note that a conductive layer can build up on the insulators. Therefore do
not spray on the insulators! Flashovers and insulator damage can otherwise cause power failure.
If metal sprinkler pipes are laid in parallel to a high voltage power line, this can lead even without irrigation to a
perceptible contact voltage because of the electric influence. Touching the pipes is not dangerous but can be
unpleasant and painful. This is why it should be avoided to lay metal pipes in parallel to high voltage lines or only
over the shortest distances possible. When using synthetic pipes, you will not encounter any of these problems.
Note! Do not put pipeline pieces into a vertical position in the range of high voltage lines! Only transport
them horizontally!
WARNING SIGNS
The hazard points of the RAINSTAR A3 are marked by special safety labels on the machine. These
labels must be affixed well visibly to the points i ndicated and they serve to protect persons staying
around the machine.
1.
WARNING !
2.
3.
Study and observe carefully the operating manual and the safety hints
before starting the machine.
WARNING!
Stop the machine and read the operating manual before carrying out
maintenance jobs and repairs.
WARNING!
1. The working range of the RAINSTAR A3 always must be at a safe
distance from electric high-voltage lines.
2. This applies to both the use of wide-range sprinklers and boom carts
AS 26 / 32.
The water jet of the nozzles and the sprinkler must not reach any
electric lines.
Manual for BAUER RAINSTAR A3
5
4.
WARNING!
Safety covers must not be removed during operation.
For repairs, make sure that the reel of the RAINSTAR A3 cannot move.
Slacken the PE pipe.
5.
WARNING!
1 Do not stay at rear of the RAINSTAR A3 !
Operator is in danger of being crushed by the retracted sprinkler cart. Keep
the distance !
GENERAL
BAUER products are designed and manufactured carefully, subject to a system of continuous quality
control. The BAUER RAINSTAR A3 is a turb ine-driven machines designed for fully mechanised and
labour-saving irrigation. Individual pipe sets are no longer laid down by hand; system set-up,
repositioning, and operation are all done with the tractor only.
The BAUER RAINSTAR A3 is a universal machine su itable of covering fields of varying lengths and
widths. There is no need for supervision while the system is operating.
Strict observance of all operating and service instructions in this manual is the basic prerequisite for
many years of trouble-free operation. Therefore please make sure that all operators on your staff are
familiar with the instructions given in this manual.
The model number as well as the serial number (V ehicle identification numbe r) are stamped into the
nameplate. In addition, the serial number is stam ped into the frame of the undercarriage. Please state
these data in all your inquiries, correspondence, warranty matters and parts orders.
We warrant according to our General Terms of Sale.
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Manual for BAUER RAINSTAR A3
1 SAFETY PRECAUTIONS FOR THE RAINSTAR A3
1. Read this manual before putting the system into operation for the first time.
2. Never handle the PE-pipe near the machine or the machine itself during pull-off or pull-in.
3. During PE-pipe rewind with the trac tor's PTO or during pipe pull-off, always make sure that the
shifting lever is in the proper position. Mor eover, the maximum permissible speed must not be
exceeded. Max. speed: 200 rpm
WARNING!
4. Never carry out service- or setting jobs (except speed settings) while the machine is operating.
5. Keep clear of all moving parts.
6. Never expose any moving parts by removing protective elements.
7. Keep a safe distance from the sprinkler during operation.
8. Be careful in case of high connecting pressure!
9. Make sure that the water jet from spray nozzles does not hit public roads.
10. The RAINSTAR A3 is licensed for transport in agricultural operation only. For transportation on
public roads, all applicable traffic requirements must be strictly observed.
WARNING!
11. When loading the machine on a trailer, note that the water remaining in the pipe shifts the
system's centre of gravity upward.
12. When driving in curves with the RAINSTAR A3 loaded on a trailer, the permissible maximum
driving speed is reduced considerably in dependenc e on the position of the RAINSTAR A3's
centre of gravity!
13. Always make sure that the locks and stops are secured according to the machine's general
conditions for transport.
14. Before starting irrigation near electric power lines, you should contact your local power supply
company regarding the safety distances to be observed.
15. Maximum permissible speed: 10 km/h.
Danger by improper handling!
For safety reasons, it is not allowed to tr ansport the RAINSTAR A3 by pulling it with
a fork-type drawbar (OPTIONAL) nor with the toolbar!
Manual for BAUER RAINSTAR A3
7
2 DESCRIPTION
The RAINSTAR A3 is a universal irrigation machine for varying lengths and widths of fields and it is best
suited for sprinkling seed crops and horticultures, par ks, vegetable plantations as well as any kind of
grassland.
The main components are a two-wheel undercarriage, the swiveling turntable and the reel with the
special PE-pipe, the compact gearbox and the Ti 7-A turb ine as well as the high-rise cart that is ideal
particularly for high crops with the BAUER wide-range gun.
The material of the PE-pipe corresponds to the late st state-of-the-art. One end of the pipe connects to
the reel drum and to the water supply through its axle. The other end of the pipe is coupled with the
high-rise cart. The cart's track width is infinitely adjustable (see technical data).
The heart of the RAINSTAR A3 is the Ti 7-A turbine. This is a full-flow turbi ne, nearly insensitive to
soiled water and offers maximum efficiency. The driv e shaft is made of stainless steel. The regulating
flap inside the turbine is coated with a wear-proof rubber lining.
The lifetime lubricated drive shaft bearing is sealed by a maintenance-free rotating mechanical seal.
The Ti 7-A turbine is designed for water flow rates from 4,8 to over 20 m³/h and features a wide control
range. Impeller speeds range from 200 to 1000 rpm.
The system's connecting pressure should not exceed 8 bar.
Power is directly transmitted from the turbine to the change-speed gearbox as well as from the chain
drive onto the reel. A reel brake prevents fast revers e rotation of the reel in the final shut-off position
when the PE-pipe is stretched.
The reel brake and the gearwheels in the change-speed gearbox filled with oil, act as brake and prevent
the PE-pipe windings on the reel from loosening during pipe pull-out.
For safety reasons, the drive is fitted with an emergency stop and a reversing stop. With this emergency
stop device, the drive can be stopped immediately by hand.
WARNING!
A winding carriage moved by a helically grooved spi ndle ensures that the PE-pipe is wound up properly
on all layers.
8
Never remove the drive cover before you have turned off the water supply
to the machine and slackened the stretched PE-pipe.
Manual for BAUER RAINSTAR A3
Mechanical regulation: To keep the retraction speed constant on all layers independent of the pipe
length still lying on the field, the RAINSTAR A3 is equipped with a layer compensating device. It is
actuated by the shut-off frame that is always re sting against the PE-pipe and acts on the regulating flap
of the turbine via control rods.
At the end of the irrigation strip, t he cart is lifted automatically to transport position. Thereby the drive is
shut-off automatically by rods.
After shut-off, the cart lifted automatically, is locked through the transport lock. If the machine is
equipped with a shut-off valve (mechanical regulation) , the water supply will be shut off simultaneously.
After shut-off, apply the reel brake (see item 5 "Quick Stop"). Now the RAINSTAR A3 can be
transported to its next setting-up position immediatel y. Pull-off or lay down the PE-pipe, connect the
water supply and the machine is ready for the next run.
When driving on public roads, the reel must be turned into driving direction and secured with the lock
bolt. The PE-pipe must be fully wound up on the reel, t he cart must be lifted and the reel brake must be
applied. The jack and both rear machine supports must be withdrawn to their top position.
On public roads, the drawbar must be hitched to the tractor's yoke. Without administrative authorization,
the driving speed must not exceed 10 km/h.
Basically it is possible to transport the machine betw een hydrants in the field wi th the cart lifted on the
side. In this configuration, the driving speed al ways must be adapted to the existing conditions and it
should never exceed 5 km/h.
3 PUTTING INTO OPERATION
Before and during the first start-up, grease a ll bearings, chains and guide parts of the winding
mechanism. Use normal ball bearing grease for all bearing assemblies with grease nipples and a
viscous and durable type of grease for chains, guide rods and joints.
Tighten the wheel nuts before the first starting and check the tires on the specified pressure (see
technical data).
Tighten also the connecting bolts, the ball race on the undercarriage and turntable according to the
"Service and Maintenance" table.
3.1 STEPS TO BE CARRIED OUT ONCE OR FROM TIME TO TIME
Set the required track width on the cart depending on the
existing type of crop.
Manual for BAUER RAINSTAR A3
9
OPERATING MODE I: PE-PIPE PULL-OFF
3.1.1 Transport of Machine to Set-up Position
During transport, the reel should be turned into the driving
direction and secured with the lock bolt. The reel brake must
be applied. Cart, jack and both rear support legs must be lifted
or retracted. For lateral PE-pipe pull-off, set up the RAINSTAR
A3 on the headland at right angles to the selected irrigation
strip and detach it from the tractor.
When positioning the RAINSTAR A3, make sure that t he machine's vertical axis of rotation is in the
middle of the driving lane or centered between two crop rows.
Adjust the undercarriage in a level position with the jack.
For lateral pull-off of the PE-pipe, remove the lock bolt, turn
the reel into the direction of the driving lane and secure it
again with the lock bolt.
On very hard soil, the supports must be extended into holes dug into the ground for this purpose.
10
Extend the supports into the ground by means of a winch.
Manual for BAUER RAINSTAR A3
3.1.2 LOWERING THE CART
Unlock the cart mechanically in working position. Pull up the
locking lever.
Now loosen the reel brake.
SWITCHING POSITIONS OF THE SHUT-OFF LEVER
834 9274
Working position
PE-pipe retraction
PE-pipe pull-off
Tractor rewind
Manual for BAUER RAINSTAR A3
11
3.1.3 PULLING OFF THE PE-PIPE
Hitch the toolbar on the pulling hook and pull the cart into the
field.
Do not stop abruptly but slow down gradually at an intermediate stop or at the end of the pull-off.
WARNING!
If the PE-pipe was exposed to the sun fo r a longer period or if its surface
temperature rose above 35°C, you will have to cool the pipe by water flow before
rewinding it.
The standard wheel cart need not be lifted (therefore 1 pulling
hook is sufficient).
Pull-off speed
Couple the pressure hose. Open the water supply.
: Do not exceed 5 km/h!
12
When the full operating pressure has been reached and clear
water is discharged at the sprinkler's nozzle in a full jet without
air bubbles, push the gear shift lever to the "PE-pipe
retraction" position.
Manual for BAUER RAINSTAR A3
The reel starts to rewind the PE-pipe.
3.1.4 SPEED ADJUSTMENT w i th mechanical regulation
IMPORTANT!
Slower Faster
Adjust the speed only when the PE-pipe already has been rewound by half a
winding and/or when it is stretched.
Loosen the knurled nuts (for fixation of the adjusting lever).
Set the retraction speed which can be read on the
speedometer (optional) by means of the adjusting lever. Then
lock the adjusting lever again with the knurled nuts.
Retractionspeedm/h 10 20 30
Waterflow10m³/h 2 1‐
14m³/h 2 1 1
18m³/h 2 2 1
In the table you find the hole position.
Hole 1 is the bottom hole.
Note:
Smalls corrections deviating from the chart could be necessary, because the friction resistance of the
Pipe on the ground is equal.
Manual for BAUER RAINSTAR A3
13
At the end of irrigation, the ca rt is lifted automatically and the
drive is shut off by means of rods.
The water supply is stopped by the optional "overpressure
shut-off valve".
Once the PE-pipe retraction has been finished, withdraw the
supports by means of the winch.
14
Move in the reel brake before the transport.
Manual for BAUER RAINSTAR A3
3.2 OPERATING MODE II: Laying down the PE-pipe
In addition to the pull-off method, the PE-pipe also can be laid down on the ground. This method is
mostly used in situations where heavy soil makes it im possible to pull the cart across the field or where
the field is longer than once the PE-pipe length. Moreover, the laying down method allows to use
smaller tractors because no pulling forces are applied on the pipe.
Drive into the field with the RAINSTAR A3 taking into consideration the sprinkler's distance of throw.
*) W = distance of throw of the sprinkler
Lower the cart as described under Operating Mode I, item
"Lowering the Cart" and anchor it slightly. Now move the
machine across the field.
Carry out the next steps as already described.
3.2.1 FUNCTIONAL DESCRIPTIONOF THE MAIN COMPONENTS
3.2.1.1 MACHINE DRIVE – FULL-FLOW TURBINE
The full-flow turbine Ti 7-A is a drive turbine of specific design
with large cross sections and minimum pressure loss.
Therefore they are also suited for high retraction speeds at
very low flow rates. They provide the energy needed for the
PE-pipe retraction. The turbine speed is directly taken off the
impeller shaft and transmitted via a three-step V-belt drive to
the BAUER change-speed gearbox.
Manual for BAUER RAINSTAR A3
15
The change-speed gearbox consists of toothed wheels that
reduce the turbine speed. Reel drive stop at the end of the
irrigation strip is ensured by disengagement of the toothed
clutch.
The gearbox in connection with the belt steps adapt perfectly to existing operating conditions. As a
result the following retraction speeds (m/h) can be reached:
12 m/h 8 - 25 m/h 18 m/h
834 9277
16
WARNING!
Removal of the drive cover for servic e jobs or change of transmission only is
permitted when the PE-pipe has been slackened completely! Move the gear shift
lever to shut-off position! This shut-off position also must be used for the transport of
the machine on the roads!
Manual for BAUER RAINSTAR A3
PTO REWIND:
If required, you can rewind the PE-pipe also with the tractor's
PTO system. Push the shifting lever to "Tractor retraction"
position.
Winding up the PE-pipe with the PTO will become necessary when there is no need to continue
irrigation due to natural rainfall.
WARNING!
Retract the PE-pipe at lowest possible PTO speed – start slowly and
smoothly and avoid jerks.
Highest PTO speed = 200 rpm
Avoid strain by excessive articulation of the PTO shaft.
If the PE-pipe is covered with mud, it should be loosened and lifted off the
ground to reduce the retraction forces before rewinding it.
If the soil is deep and heavy, the PE-pipe must be wound up more slowly
to make sure that the permissible loads on PE-pipe and machine are not
exceeded.
If you disengage the PTO shaft during PE-pipe retraction, make sure that
the pipe reel stands still when you re-engage the PTO shaft. Double
motion may cause severe damage!
When driving the reel with the PTO, the automatic shut-off system is
inactive. Therefore you must stop the PTO shaft in time.
When driving the reel with t he PTO, the automatic shut-off
system is inactive. Therefore you must stop the PTO in time
and wind up the end of the PE-pipe with the hand wheel. This
will prevent damage to cart, shut-off system, gearbox etc.
Manual for BAUER RAINSTAR A3
17
4 Mechanical Regulation
The retraction speed is steplessly adjustable and it is set by
means of the adjusting lever which is fixed with the knurled
nuts after adjustment. The speed is nearly constant from the
first to the last layer as well as within one layer. This is
achieved by means of the laye r compensating lever resting
against the PE-pipe in any position ….
... It actuates via control rods the regulating flap mounted on
the turbine and it regulates hence the turbine speed.
Varying conditions of ground as well as low water flow may
lead to inconstant retraction speeds despite of the layer
compensating device. This c an be remedied by fixing the
control rod one hole up or down when PE-pipe retraction
becomes faster or slower.
The exact setting of the regulation also depends on the PE-pi pe diameter and it is different for PE-pipes of 55 –
63 mm.
By fixing the bolt of the control rod one hole up, regulation will be reduced so that the retraction speed increases
up to the last layer.
By fixing the bolt of the control rod one hole down, regulation will be increased so that the retraction speed is
reduced up to the last layer.
18
Manual for BAUER RAINSTAR A3
5 QUICK STOP
Apply the reel brake. Now the PE-pipe retraction can be
stopped immediately by actuati ng the shut-off frame or the
gear shifting lever. Thereby the gearbox is disengaged.
Slacken the PE-pipe slowly by opening slightly the reel brake.
6 WINDING MECHANISM
The winding mechanism operates synchronously with the
winding or unwinding of the PE-pipe. Starting from the reel, it
is operated through a chain and the helically grooved spindle
that transports the winding carriage of the PE-pipe. The
winding mechanism ensures that the PE-pipe is guided
properly winding for winding. When you put the machine into
operation for the first time, pull off the full length of the PEpipe to let it take a circular shape under pressure and
eliminate ovality. This step is essential for trouble-free
operation of the winding mechanism.
7 SHUT-OFF AND SAFETY EQUIPMENT
Unattended operation of the RAINSTAR A3 is ensured by a
final- and safety shut-off device. The final shut-off device is
actuated when the sprinkler cart pushes against the shut-off
frame which in turn operates the gearbox shut-off lever
through a system of rods stoppi ng thus the drive. To avoid
troubles caused by faulty windi ngs of the PE-pipe on the reel,
the shut-off device also is ac tivated by the shut-off frame
when faulty pipe windings build up on the reel.
Manual for BAUER RAINSTAR A3
19
8 CART
The high construction of the cart provides maximum crop
protection. With infinitely vari able track width, the cart adapts
to any crop row s pacing. For eas ier PE-pipe pull-off, the c art
is equipped with a draw-out hook.
For retraction, the cart is lifted automatically.
You pick up this hook with the tractor's toolbar and pull-off the
PE-pipe.
To turn the pipe reel and to reposition the RAINSTAR A3 to a
new set-up position, the cart must be pulled back to its end
position.
9 OVERPRESSURE SHUT-OFF VALVE
With an overpressure shut-off valve, the water
supply to the machine is interrupted completely at
the end of the irrigation run. When the valve
closes, pressure rises in the supply line.
20
Manual for BAUER RAINSTAR A3
10 WINTERIZATION – DRAINING
In areas where frost is likely in winter after the irrigation season, the machine must be drained in time. A
compressor with a minimum air capacity of 500 l/min. at 1 bar overpressure is best suited for this purpose. The
small amount of water remaining in the PE-pipe after the draining will not do any harm.
Turn out the drain plug on the bottom of the Ti 7 turbine. We recommend to turn it in again only when you start
up the machine again at the beginning of the next season.
From 2012:
Open the ball cock at the bottom of the Ti 7 turbine. We recommend closing the ball cock only when you start
up the machine at the beginning of the next season.
Clean the RAINSTAR A3 and regrease all appropriate points. The machine should preferably be stored in a
roofed shelter where it is protected from direct exposure to the weather.
Red plug with ventilation mounted on top
Filling screw for gear oil ( 0,9 liters )
Drain screw for gear oil
Grease the jack.
Grease the support.
Manual for BAUER RAINSTAR A3
21
11 WINDING MECHANISM – STARTING POSITION
Step 1:
Pull off the PE-pipe and adjust the connecting bend (7) in a vertical position pointing down.
Step 2:
Loosen the winding chain (1) between the reel and the helically grooved spindle (2).
Step 3:
By turning the helically grooved spindle (2), the winding carriage (3) is moved to the right outer reversing point
of the groove value: 13 mm.
13 mm
1
22
2
3
Manual for BAUER RAINSTAR A3
Step 4:
By turning the helically grooved spindle, move the right guide bar to the value of
wall.
1
"0" towards the inner reel side
Thereby the spindle must be turned in the direction of winding (counter-
Step 5:
Mount the winding chain (1), the reel remains
unchanged with the inlet bend pointing down.
Tighten the winding chain (1).
WARNING!
clockwise, see sketch).
At this point, the winding carriage moves from the reversing point to the left
(direction A).
Manual for BAUER RAINSTAR A3
23
12 SETTING THE GEARBOX SHUT-OFF DEVICE
2
Turn the drive shaft at the gearbox (pulley). With the value of 2 mm at the gearbox and the value of "X"
at the shut-off frame, the PTO must not turn anymore. (Put a hand wheel on the PTO for easier
checking of the turning movement.)
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Manual for BAUER RAINSTAR A3
The shut-off frame (13) is set at
The hex nut (15) on the shifting rod (16) is approached to the lever (14) of the shut-off frame. Secure the nut.
X mm off the reel (17) ( see below table ).
Machine X mm Y mm
RAINSTAR A3 45 75
17
Y
13
14
15
X
16
18
Set the adjusting screw (18) to the shut-off frame (13) at the value of "Y" and secure it.
12.1 TESTING THE SHUT-OFF DEVICE
Put the shut-off frame (13) against the PE-pipe (last layer).
Move the shut-off lever (9) to position "PE-pipe retraction".
Pull the shut-off frame (13) to shut-off position (=
The shut-off lever must jump to shut-off position!
Manual for BAUER RAINSTAR A3
X mm off the reel).
25
12.2 ADJUSTUNG REEL BRAKE
1. Open brake shoe (A) --> no tension on spring (B)
2. Adjust brake shoe so that is touching the reel at the biggest (outher) diameter --> no tension on spring (B)
3. Put tension on to spring (B) by turning one rotation on the nut --> fix with second nut.
4. Adjust spring (C) to a distance (X) between 115 and 130mm by using different chain links.
A
B
X
C
13 SPEEDOMETER
Programming the Computer
CHOOSE MILES OR KILOMETERS
The A4 allows to display the speed and the distance in kilometers or miles. You may always change between
these units whereby all values will be converted automatically.
STEP 1 Open „TRP“ on the display. Keep the SET key pressed for approximately 3 seconds.
STEP 2 km or m is blinking on the right top of the display. Change to "
STEP 3 Press the SET key to confirm your selection. Now A4 changes automatically to the setting mode for the
radius factor.
km" by means of the MODE key.
26
Manual for BAUER RAINSTAR A3
8
8
PROGRAMMING THE RADIUS FACTOR
After selecting the unit – m or km – and pressing t he SET key for confirmation, the computer changes
automatically to the setting mode for the radius factor. Factory setting is 2155 mm and/or 84.8 inches.
STEP 1 Set the blinking figure by means of the MODE key.
Radius factor with kilometers „
STEP 2 Confirm the setting by means of the SET key. ===> The next figure is blinking.
STEP 3 Repeat the setting until all figures are set correctly.
STEP 4 Press the SET key for approximately 3 seconds in or der to finish the setting procedure and to return to
the TRP display.
728 „
SETTING THE TIME
The VDO A4 has got a 24 hours time display.
STEP 1 Press the SET key in CLK mode for 3 seconds. Now your computer changes automatically to the time
setting mode.
STEP 2 Set the blinking hours by means of the MODE key. Confirm your setting by means of the SET key.
===> The minute figures are blinking.
STEP 3 Set the blinking minutes by means of the MODE key. (Keep the key pressed for fast run).
STEP 4 Keep the SET key pressed for approx. 3 seconds in order to finish the setting procedure and to return
to the CLK display.
CONVERSION TABLE FOR DISPLAYED SPEED
8349278 Lage/Layer1 Lage/Layer2 Lage/Layer3 Lage/Layer4
Einzugs‐
geschwindigkeit
Retraction
Speed
Tachoanze ige/DisplayedSpeed
m/h ft/h
5 15
10 30
15 45
20 60
25 75
30 90
35 105
40 120
Manual for BAUER RAINSTAR A3
5
10
15
20
25
30
35
40
4,4
8,9
13,3
17,
22,2
26,7
31,1
35,5
4,0
8,0
12,0
16,0
20,0
24,0
28,0
32,0
3,6
7,3
10,9
14,5
18,1
21,
25,4
29,0
27
14 SERVICE AND MAINTENANCE
We cannot emphasise often enough that proper service at the right time is e ssential for the operating reliability
and service life of a machine. At the end of every irrigation season, t he RAINSTAR A3 should be checked and
cleaned thoroughly and all parts should be greased carefully.
Machine part Service interval Lubricant, grease, oil
1. Helically grooved spindle of
the winding mechanism
2. Drive chain of winding
mechanism
3. Driver (spindle nut) of
winding mechanism
4. Driving chain as required Alvania Grease 3
5. Change-speed gear
6. Ball race every 500 service hours through greasing nipple
7. Jack as required through greasing nipple
8. Screwed joints Tightening torques
Ball race on turntable and
undercarriage
every 250 service hours Alvania Grease 3
every 250 service hours Alvania Grease 3
every 250 service hours,
replacement recommended after
2500 service hours
First oil change after 500 service
hours and then after 500 – 800
service hours or once a year
48 Nm
Alvania Grease 3
0,9 l of oil SAE 90 EP
Alvania Grease 3
Alvania Grease 3
28
Manual for BAUER RAINSTAR A3
15 TROUBLE-SHOOTING
FAULT CAUSE REMEDY
The PE-pipe cannot be pulled
off.
Brake shoe sticks to the reel. Loosen the brake shoe.
PE-pipe retraction stops before
the final shut-off is actuated
Pressure drop in supply line. Check pumping station and
Overwinding of PE-pipe activates
Repair broken winding chain.
The final shut-off is activated but
the shut-off valve does not
close.
The reel overwinds or the
windings become loose when
the PE-pipe is pulled off.
No oil in the change-speed gear. Refill oil.
Incorrect gear shift lever position. Put it into the pull-off position.
Brake shoe has been applied Loosen the brake shoe.
Turbine blocked by a foreign
body.
the safety shut-off.
Values for the shut-off valve
activation are not set correctly.
Tractor stopped abruptly. Slow down gradually.
Remove the foreign body.
hydrant connections.
Adjust the winding mechanism.
Adjust the settings according to
the manual.
The retraction speed is not
constant from PE-pipe layer to
PE-pipe layer.
The selected retraction speed is
not reached.
Blocked sprinkler nozzle. Remove blockage.
General: Compare connecting pressure and water flow with
Cart is not lifted. Incorrect belt transmission. Select proper belt transmission
Varying conditions of the ground Adjust the regulation to the
conditions of the ground (adjust
the rods at the layer
compensating lever).
Incorrect drive transmission. Select proper gear transmission.
performance chart values.
Manual for BAUER RAINSTAR A3
29
K
R
H
P
Q
L
I
M
30
A PE-pipe diameter x length
B Max. strip length
C Flow
D Connecting pressure
E Nozzle range
F Weight incl. PE-pipe with water
G Weight incl. empty PE-pipe
H Overall length incl. cart
I Max. width of largest track
K Overall height
L Length of machine without cart
M Track width of undercarriage
N Tires of undercarriage
O Tire pressure of undercarriage
P Ground clearance
Q Hitch height - standard
R Cart track width
S Cart tires
T Cart tire pressure
Manual for BAUER RAINSTAR A3
Type
55 - 170 63 - 125 63 - 150
A
B
C
D
E
F
G
H
I
mm x m 55 x 170 63 x 125 63 x 150
m 195 150 175
m³ 4,8 - 20
bar 3,2 - 8
mm 8 - 16
kg 792 778 855
kg 515 512 537
mm 3550
mm 1730
RAINSTAR A3
K
L
M
N
O
P
Q
R
S
T
mm 1690
mm 2890
mm 1250
18x9.50-8 4PR
bar 1,6
mm 180
mm 290
mm 1000 - 1500
13x5.00/6
bar 1,3
Manual for BAUER RAINSTAR A3
31
14. CONFORMITY CERTIFICATE
EC Declaration of Conformity
according to EC Directive 2006/42/EC
The manufacturer
Röhren- und Pumpenwerk BAUER Gesellschaft m.b.H.
Kowaldstraße 2, 8570 Voitsberg, Austria
phone +43 3142 200-0; fax: +43 3142 200-320/-340
herewith confirms that the machine mentioned below
Designation of machine RAINSTAR
Machine type / basic units A3
Consists of Irrigation machine with cart
corresponds analogously to the requirements of the Machinery Directive 2006/42/EC.
In case of a modification of the machine not accorded with FAN GmbH, this declaration will cease
to be valid.
The following standards as amended have been applied analogously:
DIN EN ISO 12100-1 Safety of machines – Basic concepts, general principles for design,
Part 1: Basic terminology, metodology
DIN EN ISO 12100-2 Safety of machines – Basic concepts, general principles for design,
Part 2: Technical principles and specfications
DIN EN 60204-1 Safety of machines - Electrical equipment of machines,
Part 1: General requirements
EN ISO 14121-1 Safety of machines – Risk assessment
Norms related to products
DIN EN 908 Irrigation machine with hard hose reel
Person in charge of documentation: Thomas Theissl, Kowaldstraße 2, 8570 Voitsberg, Austria,
Technical Designer in Charge Commercial Manager
Voitsberg, 26.7.2010
32
Manual for BAUER RAINSTAR A3
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