KUHN RW1600 Operation Manual
RW1600
Operatio n ma nual
Issue 04/2009
Date of printing 6.2009
Language EN
From machinenumber (PIN) VGEW000365
Serial number (PSN) 03EW01
Reference number ZNA012EN
Identifica ti on of the m achine
To support you as soon as possible your dealer requires several details of your machine.
Please enter the information here.
Designation
PIN
Software version
Assembled
options
Dealer's address
RW1600
VGEW........................
Manufacturer's
address
KUHN-GELDROP B.V., retains all copyrights and rights of usage. The contents of this operating manual are subject to change without notice. All
rights reserved. The right to technical revision is reserved.
KUHN-GELDROP B.V.
Nuenenseweg 165
5667 KP Geldrop
The Netherlands
Phone +31 40 2893300
Table of contents
Preface .............................................................5
Target group of this operation manual 5
Symbols used 6
Safety instructions .........................................7
For your safety 7
Safety decals at the machine 8
Who is allowed to operate the machine? 12
General 12
Hitching the machine 13
Road transport 14
Working with the machine 15
Unhitching the machine 16
Care and maintenance 17
Further prescriptions 18
Table of contents
Preparation at the field ................................ 46
Safety 46
Performing settings 46
Prior to wrapping 46
Placing into working position 47
Use at the field .............................................. 48
Safety 48
Checks before use 48
Film wrap recommendations 49
Start position mode 50
Wrapping 50
Loading a second bale during
wrapping 53
Emergency stop 54
Acquaintance with the machine .................19
Destination of the machine 19
Characteristics of the machine 19
Description of the components 20
Technical specifications 21
Delivery and preparation .............................25
Safety 25
Checking the delivery 25
Hitching the machine ...................................26
Safety 26
General 26
Hitching 27
Support jack 29
Installation cable control 30
Installation joystick control 31
Installation control box 32
Connections 33
Road lighting [+] 35
Preparation for use .......................................36
Safety 36
Table roller adjustment 37
Support roller 38
Loading arm width 39
Pre-stretcher 40
Film installation 41
Film overlap 42
Check at beginning of the season 43
Running 43
Road transport ..............................................44
Safety 44
Before road transport 44
Road transport 45
Wrap and bale counter ................................. 55
General 55
Wrap and bale counter box 55
Parameter change 56
Parameter settings 57
Joystick control ............................................ 59
General 59
Joystick control 59
Control mode 61
Parameter settings 62
Electronic control system ........................... 65
General 65
Control box 65
Control mode 68
Parameter change 70
Parameter settings 71
Cleaning and caring ..................................... 76
Safety 76
Cleaning 76
Caring 76
Storing the machine ..................................... 77
Safety 77
Unhitching and securing of the machine 77
After the season 77
Maintenance .................................................. 78
Safety 78
General 80
Attaching elements 82
Tightening torques 83
Pre-stretcher 84
Wheels/tyres 85
Hydraulics 86
Table 87
Applicutter 88
Lubrication 89
3
Table of contents
Optional equipment ......................................92
General 92
Film roll holder 92
Film roll magazine 92
Wheel chock set 93
Bale turner 93
Hydraulic bale turner 93
Bale stop arm 93
Drop mat 94
Drop plate 94
Road lighting set 94
Remote control 94
Troubleshooting ...........................................95
Safety 95
Electronic control system 95
Applicutter 96
Pre-stretcher 98
Hydraulics 98
Film 99
Bale 99
Disposal of the machine ............................100
EC Declaration of conformity .................... 101
Index ............................................................102
4
Preface
Preface
Target group of
this operation
manual
This operation manual is meant for those concerned with the control,
use and maintenance of the machine. It contains all data required for
a safe handling, use and maintenance of the machine.
For your safety
Before starting to adjust and use your machine, familiarise yourself
with this operation manual. By doing so your safety and the best
performance are assured. It is very important to read this manual
carefully before using the machine and to keep it handy. In this way,
you will
• avoid accidents
• respect the warranty conditions
• always have a functional machine in perfect working order
For the employer
All personnel are to be trained in the use of the machine regularly (at
least once a year) in accordance with employers’ liability insurance
association guidelines. Untrained or unauthorised individuals are not
permitted to use the machinery.
You are responsible for the safe operation and maintenance of your
machine. You must ensure that you and anyone else who is going to
operate, maintain or work around the unit be familiar with the
operating and maintenance procedures and related safety information
contained in this manual.
5
Preface
Symbols used
In this operation manual the following symbols and terms are used:
• A bullet stands at enumerations
> A triangle stands at steps, which you must do
→ An arrow shows cross-references at other text passages
[+] The plus sign shows that it involves optional equipment, which
does not belong to the standard model.
Besides these symbols, pictograms are used, which will help you with
locating of text passages:
TIPThe word “Tip“ shows tips and advices to the use.
The triangle refers to danger at assembling or (adjusting) work.
The key refers to tips at assembling or adjusting work.
0
The star shows examples, which are needed for a better
understanding.
6
Safety instructions
Safety instructions
For your safety
This chapter contains all general safety instructions. Subject-specific
safety instructions are located per chapter. Take care of the safety
instructions
• because of your own safety
• because of the safety of your fellow man
• to guarantee the machine safety
When handling agricultural machinery, wrong behaviour can lead to a
lot of danger. Therefore work with special care and never under
pressure of time.
For the employer
Inform the one who works with this machine frequently about these
safety instructions and according to the legal regulations.
7
Safety instructions
Safety decals at
the machine
The installed warning and advisory signs give important hints for a
safe operation; adhering to serves your own safety. Keep safety
decals and signs clean and legible at all times. Replace safety decals
and signs that are missing or have become illegible. If original parts on
which a safety decal or sign was installed are replaced, be sure that
the replacement part also displays the current decal or sign.
8
Meaning of the safety
decals
Safety instructions
Read the operation manual carefully
Read the operation manual carefully before taking the machine into
operation. Read and obey the safety instructions.
Use the transport lock
Before road transport, the transport lock must be used to secure the
loading arm. A non-secured loading arm can cause serious or deadly
injuries or damages.
Stay clear of the pre-stretcher
Stay clear of the pre-stretcher area while the wrapper arms are
rotating. Serious injuries can occur.
Stay clear of the loading arm area
Stay clear of the moving loading arm area. A loading arm moving
down can cause serious personal injuries.
Stop the tractor engine
Prior to any maintenance, repair and adjustment work, stop the tractor
engine and remove the ignition key. Otherwise serious or deadly
injuries can occur.
9
Safety instructions
Pre-stretcher rotation 30 rpm
The prescribed pre-stretcher rotation of maximum 30 rpm may not be
exceeded.
Use ear protection
Use adequate ear protection during wrapping. Serious hearing injuries
can occur.
Never stay behind the machine while unloading
Stay clear of the table area while unloading a bale. An outcoming,
rolling bale has a heavy mass and a high speed. A rolling bale can
cause serious or deadly injuries.
Stay clear of pre-stretcher rollers
Stay clear of the pre-stretcher rollers. Hands can be squeezed
between the rollers. Personal injuries can occur.
Stay clear of the pre-stretcher area
Stay clear of the pre-stretcher area while the wrapper arms are
rotating. Serious injuries can occur.
10
Safety instructions
Use the table safety bar
Prior to any maintenance, repair and adjustment work on the tipped
table, place the table safety bar. A non-secured table can cause
serious or deadly injuries.
Stay clear of the applicutter rollers
Stay clear of the applicutter rollers. Hands can be squeezed between
the rollers. Personal injuries can occur.
11
Safety instructions
Who is al lo w e d to
operate the
machine?
General
Authorised people only
The machine may only be used, maintained or repaired by authorised
people who have been informed about the dangers when handling the
machine.
Usually such persons have an agricultural or equal intensive
education.
Safety is your responsibility
Apply and insist upon application of the safety instructions. Most
accidents are avoidable. Do not run the risk of serious or fatal
accidents through ignorance of these safety instructions.
Wear close fitting clothing
Avoid wearing loose fitting clothing.
Loose clothing can get stuck between rotating parts. Danger of
serious injury.
Keep the machine clean
Always keep the machine clean to avoid fire risk. Equip the machine
with a 10 litre pressurised water fire extinguisher to be prepared in
case of fire.
Running in an enclosed area
Do not run the machine in an enclosed area. Exhaust fumes can be
dangerous.
Never work on a running machine
Never work on the machine while it is running. Severe injuries can
occur.
No modification of the machine
Do not modify the machine in any way. Unauthorised modifications
may impair the function and/or safety and could affect the life of the
machine.
12
Safety instructions
Hitching the
machine
Hydraulics
Increased danger of injury
While hitching the machine onto the tractor an increased danger of
injury occurs. Therefore:
• prevent the tractor from rolling away, shut down the engine and
remove the ignition key
• never stay between tractor and machine during hitching
In case of negligence damages to the machine or serious personal
injuries can occur.
Hydraulic couplings only pressureless
Only couple the hydraulic hoses to the tractor when both tractor and
machine hydraulics are pressureless. Hydraulics under pressure can
cause accidental movements of the machine.
High pressure in the hydraulic system
The hydraulic system is under high pressure. All tubes, hoses and
couplings must be controlled regularly for leaks and external
damages. Only use suitable tools when searching for leaks.
Immediately repair damages. Leaking oil can cause injuries and fire.
When having injuries visit a doctor immediately.
13
Safety instructions
Road transport
Pay attention to a road-safe condition
When driving on the local roads, the machine must correspond to the
current traffic prescriptions. To which e.g. belongs:
• mounting of lighting, warning and protection installations
• comply with the permittable transport dimensions and weights,
maximum permittable axle loads, tyre carrying capacity, total
weights and national speed limits
• taking care of the maximum permitted speed of 25 km/h
In case of negligence, driver and owner of the machine are fully liable.
Prohibition of transporting people on the machine
Nobody and nothing shall be transported on the machine during
transport. Transporting of people or objects on the machine is perilous
and prohibited.
Changed driving and braking handling
Because of the hitched machine the driving and braking handling
changes. Especially when driving curves the dimensions and mass of
the machine have to be taken into account. A not adapted driving style
can lead to accidents.
Adapted driving speed
Under bad road circumstances and at high driving speeds very high
crafts can appear, which load or overload the tractor and machine to
much. Adapt the driving speed according to the road circumstances.
A not adapted driving speed can lead to accidents.
14
Safety instructions
Working with the
machine
First use only after instruction
The machine may at the first time of use only be brought into use by
employees of the dealer, factory representatives or employees of the
manufacturer. False use after bringing the machine into use without
instructions can cause damages to the machine or accidents.
Take care of technical correct condition
Only bring the machine into use in a technical correct condition. Check
all important parts and replace defective parts before use. Defective
parts can cause material or personal damages.
Do not remove protective covers
The protective covers should not be removed or evaded. Check all
protective covers before using. Unprotected machine parts can cause
heavy or deadly accidents.
Prohibition of transporting people on the machine
Nobody and nothing shall be transported on the machine during
transport. Transporting of people or objects on the machine is perilous
and prohibited.
Check the direct surroundings
Before driving and bringing into use of the machine the direct
surroundings must be checked. Take care of sufficient view. Only start
driving when no persons or objects are in the direct surroundings.
Perilous injuries can occur.
Tighten bolts and nuts
Check bolts and nuts regularly for being tight and tighten if necessary.
Because of using the machine bolts can get loose. Damages to the
machine or accidents can be caused.
Behaviour at troubles
At functional troubles stop and secure the machine immediately.
Remedy the trouble immediately or commission a workshop.
Continuing working with the machine cause accidents or damages.
Blockage or operation of a security device
In case of a blockage or operation of a security device, never work on
the machine without
• stopping the engine and
• removing the ignition key
Never be tempted to hand feed or unblock the machine while it is
running. Serious or deadly injuries can occur.
15
Safety instructions
Unhitching the
machine
Increased danger of injury
While unhitching the machine from the tractor an increased danger of
injury occurs. Therefore:
• prevent the tractor from rolling away, shut down the engine and
remove the ignition key
• never stay between tractor and machine during unhitching
• take care of a level and secure surface for the machine
• take care of a secure lock of the support jack
• only detach the hydraulic hoses when the hydraulic system at both
tractor and machine is pressureless
In case of negligence heavy or deadly injuries can be the
consequence.
16
Safety instructions
Care and
maintenance
Observe the care and maintenance intervals
Observe the prescribed intervals and those stated in the operation
manual for recurring checks and inspections. In case of negligence of
the intervals damages to the machine or accidents can be caused.
Use original parts only
Lots of components have special properties which decides for the
stability and the function of the machine. Only the parts and options
delivered from the manufacturer have been tested and released.
Other products can interrupt the function of the machine or can harm
the security. When using not original parts the warranty and liability of
the manufacturer reduces to nil and void.
At all care and maintenance work:
• make the hydraulics pressureless
• switch off the engine and remove the ignition key
• make sure the tractor and machine are positioned on a firm and
level area, support if necessary
• unhitch the tractor if possible
• do not use parts of the machine as climbing help, use suitable
climbing helps on the contrary
Only when observing these prescriptions a secured working during
care and maintenance work is guaranteed.
Interrupt electric power supply
Before working on the electrical device, separate this from the electric
power supply. Supplies being charged can cause material or personal
damages.
Exchange hydraulic hoses
Hydraulic hoses can age without external recognizable indications.
We therefore recommend to exchange all hydraulic hoses every six
years. Defective hydraulic hoses can cause heavy or deadly injuries.
Careful when cleaning with high-pressure cleaner
The machine can partly be cleaned with water or steam. Clean
bearings, plastic parts and hydraulic hoses with low pressure only. Too
high pressure can damage these parts.
17
Safety instructions
Careful when cleaning with compressed air cleaner
The machine can partly be cleaned with compressed air. Clean
electric parts and the hydraulic valve block with low pressure only. Too
high pressure can damage these parts.
No aggressive wax additives
When cleaning do not use aggressive wax additives. Bright metal
surfaces can get damaged.
Before welding work
Before welding to the hitched machine, untie the tractor’s battery and
the dynamo. Therefore you will avoid damages to the electrical
installation.
Tighten bolted links
After care and maintenance work all loose bolted links must be
tightened. Because of loose bolted links material damages can be
caused.
Further
prescriptions
Observe the prescriptions
Please observe besides these safety instructions
• the accident prevention prescriptions
• the general accredited safety-technical, industrial medicinal and
road traffic law rules
• the tips in this operation manual
• the work, care and maintenance prescriptions
18
Acquaintance with the machine
Destination of the
machine
Intended use of the
machine
Characteristics of
the machine
This chapter contains general information about your machine and
information about:
Acquaintance with the mach ine
• characteristics
• technical specifications
This machine is exclusively appropriate designed for film wrapping of
round bales of ligneous plants, mainly grasses, taking into account all
prescriptions, procedures, etc. as stated herein and/or through decals
or other signs on the machine.
This machine shall be exclusively used for the normal agricultural
work.
Any use beyond the one stipulated above requires written
authorization of the manufacturer, this may be required for film
wrapping unusual, non-grass plants as well.
The loading arm picks up, lifts the bale and puts it onto the table. The
table starts rotating. The bale is being wrapped with film. When the
desired number of film wraps is reached, the table stops rotating. The
bale will be unloaded by tipping backward the table. During unloading
the film is cut by the applicutter.
19
Acquaintance with the machine
Description of the
components
Table
Loading arm
Applicutter
Film roll storage [+]
Pre-stretcher
Drawbar
20
Acquaintance with the machine
Technical
specifications
Dimensions / weight
Weight
Maximum weight (kg) 1,550
Length (m)
Overall length 4.20 (L)
Width (m)
Overall width 2.69 (W)
Height (m)
Overall height with loading arm folded out 2.58 (H)
H
L
W
L
21
Acquaintance with the machine
Bale require m ents
Round bales
Minimum diameter (cm) 100
Maximum diameter (cm) 150
Maximum width (cm) 120
Maximum weight (kg) 1.200
Maximum
150 cm
22
Optional equipment
Film roll holder
Road lighting set
Film roll magazine
Film end kit (for manual control only)
Drop mat
Bale turner
Additional counter weights
Adapter for 500 mm film rolls
Remote control
Adapter belt drive sprocket
Gear kit pre-stretcher
Wheel chock kit
Acquaintance with the machine
Bale wrap counter
Filmend sensor kit (for electronic con-
trol only)
Hydraulic tip arm for bale turner
Stop arm for bale turner
23
Acquaintance with the machine
Tractor requirem e nts
Tractor requirements
Electronics 12 V (DC) coupling for control box
(DIN 9680)
12 V (DC) coupling for road lighting
(DIN ISO 1724) [+]
Hydraulics 1 single acting control valve with pres-
sureless return
with hydraulic bale turner [+] 1 single acting control valve with pres-
sureless return
Pump capacity (l/min) 26
Pressure (bar) 160
Machine
requirements
Tyres
standard 15.0/55-17 10PR-AW
Maximum transport speed (km/h) 25
Maximum table rpm 30
Film requ ire m ent
Film width (mm) 750
Alternative film width (mm) 500
Film thickness (μm) minimum 25
Quality 3-layer blown film
24
Delivery and preparation
Delivery and preparation
Safety
Checking the
delivery
Wear safety shoes
During all work at the machine never bring your feet under the
machine and always wear safety shoes. Wearing safety shoes
prevents or decreases the risk of serious injuries.
Completely delivered
The machine is delivered completely. In case parts are not present,
please contact your dealer.
The machine must be checked after delivery. The machine is
equipped with:
• Operation manual
• Spare parts manual
• Hydraulic hose with coupling
• Electronic control system (control box / joystick, fixing brackets,
power cable)
25
Hitching the machine
Hitching the machine
Safety
General
Increased danger of injury
• Prevent the tractor from rolling away
• Never stay between the tractor and the machine during hitching
• Operate the three-point hitch slowly and carefully
In case of negligence serious or deadly injuries can occur.
Use a proper tractor
Make sure the tractor
• is in safe operating condition
• has adequate braking capabilities for this machine
• is suitable for carrying and transporting this machine
Using a tractor which is not suitable can cause serious personal and
material damages.
Fix the tractor lower links
Fix the tractor lower links after hitching of the machine. Lateral
movement of the lower links causes leads to unstable driving
characteristics during road transport and can cause accidents.
The machine is ex works provided for hitching onto the tractor towing
hook.
To prepare the machine for hitching, the following items are
necessary:
• Both tractor and machine must be placed on a firm level
• The machine must be levelled
• The electronic control box must be installed
• The hydraulic hoses must be coupled
• The lighting cables [+] must be coupled
26
Hitching the machine
Hitching
Drawbar adjustment
Drawbar
Hitch eye Handle
Remove tractor lower links
Remove the tractor lower links to avoid them touching the drawbar.
During turning, the lower links can touch the drawbar and the machine
can tip over. Personal or machine damages can occur.
The machine is ex works provided for hitching to the tractor towing
hook.
Before the machine can be hitched onto the towing hook, the correct
height of the hitch eye to the towing hook must be determined.
> Place both tractor and machine in line on a firm level, with a
distance between the towing hook and the hitch eye of about 15 cm
The drawbar can be turned upside down. Doing this the drawbar can
be set for high and low attachment.
Four types of drawbars exist:
• standard drawbar
• drawbar with eye
• drawbar with double tongue
• high drawbar
The machine must be placed in a horizontal position:
> Turn the handle to the left: drawbar goes upwards
or
> Turn the handle to the right: drawbar goes downwards
> Check the height of the towing hook of the tractor
The drawbar height can be changed by moving the drawbar. The
drawbar can be placed into six positions.
Select the correct position in accordance with your tractor in order to
have tractor and machine lined up correctly.
→ Moving the drawbar, page 28
27
Hitching the machine
Moving the dra w bar
Towing hook height (cm) Cm
69
36
> Secure the drawbar by placing it in a well suited hoist
Drawbar
> Loosen the bolts and nuts
> Move the drawbar to the desired position
The drawbar must always be fitted with 3 bolts and nuts per side.
> Tighten the bolts and nuts
> Torque the bolts and nuts to 220 Nm
> Remove the hoist
> Hitch the machine to the towing hook of the tractor
Minimum 36
Maximum 69
BoltsNuts
28
Support jack
Pin /
spring clip
Handle
Support jack
Hitching the machine
> Fully retract the support jack using the handle
> Remove the spring clip
> Remove the pin
> Lift the support jack completely
> Place the pin
> Lock the pin with the spring clip
29
Hitching the machine
Installation cable
control
Connection
Cable control
Check correct lying of the cables
Cables may not get stretched or get trapped. Take care of sufficient
free space. Torn or trapped cables can lead to unpredictable
movements of the machine and can lead to serious damages and
injuries.
The cable control must be installed on a support or holder in the tractor
cab.
Take care of the following:
• Ensure the cable control is installed in good manual and visible
reach of the operator
• Do not mount the cable control onto a part that is subject to strong
vibrations
• Ensure the cable control is in an area with less dust
• Avoid sharp bends in the cables
> Place the cable control at the tractor
Rotation and bale
counter
Rotation and
bale counter
30
The rotation and bale counter must be mounted.
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