Welger RP 302 SPECIAL, RP 320 FARMER, RP 320 MASTER, RP 320 PROFI, RP 220 MASTER Operating Manual

...

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1753-27

1742.99.03.05 02.04from year of manufacture 2004

WELGER

RP 320

MASTER

1741-113

www.welger.com

Operating manual

RP 202 / RP 302 RP 220 / RP 320

Contents

1. Model Overview................................................ 3

2. Your Safety.......................................................4

3. Component Overview.....................................16

4. Putting Into Operation ....................................17

5. Twine wrapping*............................................. 27

6. Net Wrapping*................................................32

7. Cutting Device*...............................................35

8. Field Use........................................................ 44

9. Wrapping ....................................................... 50

10. Overload protection / Reversing mechanism60

11. "BALERCONTROL"* ................................... 64

12. Maintenance / Settings ................................ 67

13. Technical Data ............................................. 86

The machine number is entered onto the data plate shown opposite and is located on the right hand side of the baler. Warranty claims and enquiries cannot be processed without this number. Please enter this number here below immediately after delivery:

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

Read the operating manual and safety instructions before putting the baler into operation. We have inserted a warning sign in this operating manual at points concerning your safety. Please also pass on all safety instructions to other users. The warning and instruction plates on the baler provide important information for safe operation. Paying attention to them is for your own safety!

* Please note that the features marked with a [*] in this operating manual are fitted only to some models as

standard or are only available for particular models as additional features. These features may also not be supplied to all export countries.

Reproduction prohibited - all rights reserved. Design and construction subject to alterations. The illustrations shown are non-binding for model, form and equipment.  2000 by 2004 by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany.

Maschinenfabrik GmbH

Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143 eMail: wmf@welger.com

Handover Declaration

Please fill in this form when the machine is handed over and return it to the distributor. No warranty applications can be

processed until this form is received.

Welger Maschinenfabrik GmbH

Abteilung T.S. (Technical Support)

Postfach 1965

D-38289 Wolfenbüttel

(1) Handover Date

(2) Type:

RP ................

Machine No.: (see data plate: #)

Equipment fitted:

 Pick-up unit 1.50 m  Pick-up unit 2.00 m  Pick-up unit 2.25 m

(3) Customer's address

Name:

Street:

Postcode: Place:

Country:

Phone: E-Mail:

(4) The baler entered in (2) was purchased/used by me.

When the baler was handed over, I was given the operating instructions No. ..................................

including the EU Conformity Declaration. The safety, operating and maintenance regulations contained therein were explained to me. All safety features for the correct functioning and handling were demonstrated to me.

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

Date Customer’s signature

(5) Marketing partner’s address Importer’s address

Company stamp/signature

(6) The machine was handed over to the customer in accordance with the manufacturer's guidelines.

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

Date Customer service specialist's signature

 Cutting unit  Twine wrapping  Net wrapping

WELGER RP 202 • RP 220 • RP 302 • RP 320 3

1. Model Overview

This Operating Manual describes the models RP 202, RP 220, RP 302 and RP 320

RP 202 CLASSIC

RP 302 CLASSIC

RP 202 SPECIAL

RP 302 SPECIAL

RP 220 FARMER

RP 320 FARMER

RP 220 MASTER

RP 320 MASTER

RP 220 PROFI

RP 320 PROFI

1,50 m



2,00 m

  

Pick-up unit width

2,25 m

  

MASTERCUT

12 blade

 

PROFICUT

23 blade

 

Cutting device

PROFICUT

25 blade

 

bolted



Conveyor bottom

HYDROFLEXCONTROL

spring loaded a. hydr. actuated

  

VARIOTWIN

Twine wrapping

    

Wrapping

VARIONET

Net wrapping

    

BALERCONTROL E

  

Control

BALERCONTROL III

 

Table 1

 = Standard equipment  = Special equipment

4 WELGER RP 202 • RP 220 • RP 302 • RP 320

2. Your Safety

• All the protective devices such as the safety covers, rubber aprons or safety brackets are provided for your safety! Never operate the baler with defective safety devices or if the safety devices have been removed!

• Always keep components which are relevant to safety in a suitable condition. All guards must be fitted and closed before putting the baler into operation!

• Never carry out adjustments, repairs or maintenance and service work on the baler while it is running.

• Always first stop the power take off (pto) shaft, detach the universal drive shaft from the pto shaft stub and

disconnect the electrical connection between the tractor and the baler prior to working on any of the baler’s moving parts.

• Never try to remove hay, straw or other harvested crop from the baler while it is running. Always first stop the pto shaft, and switch off the tractor engine.

• While work is in progress, only the driver should be on the tractor. Passengers are not allowed on the baler!

• Never step on the maintenance platform of the moving machine. Before you step on the maintenance platform: Stop the machine, switch off power take-off shaft and tractor engine and wait until the machine has stopped.

• Do not climb on the drawbar or other parts of the baler when it is in operation. Also, keep your distance from the pick-up unit. Do not reach into the working area of the transport units.

• Before threading in the binding material, switch off the baler drive and tractor engine and remove the ignition key

• All protective guards must be fitted to the baler and must be in sound condition. Before opening the guards, stop the pto shaft and the tractor engine, remove the ignition key and wait until the baler has stopped.

• Before detaching the baler from the tractor, secure it with the aid of the chocks to prevent it from rolling away. Carry the chocks with the baler when the baler is transported or used.

• Upon opening the tailgate, maintain at least 2 metres safety distance from the high voltage cables.

• Work on the magnets of the knife holders: The function of cardiac pacemakers may be impaired by

magnetic fields.

• Work on the magnets of the knife holders: Danger of injury by splinter – never strike the installed blades from the bottom with a striking tool. Magnets may be damaged!

• All maintenance and repair work beyond that described in the descriptions in these operating instructions must always be carried out by authorised persons. Wear parts of the brake system must always be replaced on both sides.

• Secure the baler from tipping backwards before detaching the complete pick up unit.

Warning! The baler is inherently dangerous even if all the points listed above are followed exactly. Therefore always take care when working with the baler to avoid endangering yourself or other people!

WELGER RP 202 • RP 220 • RP 302 • RP 320 5

2.1. Noise level of tractors and machines

EU Guideline 86-188 - EEC concerning noise at the workplace instructs employers and employees to measure and control the noise level at the workplace. The noise level during normal field work is subject to various fluctuations which depend on the noise level of the tractor, and also on the conditions under which the baler is being used.

The noise level generated by WELGER balers, measured at the driver's head height with the tractor window open, is less than 70 dB(A) under normal working conditions. The combined noise level generated by the baler and tractor primarily depends on the level of tractor noise (radios are an additional source of noise). We recommend that the tractor be driven with the cabin windows closed.

6 WELGER RP 202 • RP 220 • RP 302 • RP 320

2.2. Fire prevention

• Crop materials are very combustible.

• Always keep the baler free of crop remnants and oil

contamination.

• Should overheating of the baler components occur, determine the cause and resolve accordingly.

• Always keep the electrical circuits of the tractor and baler, as well as the tractor’s exhaust system in perfect working order.

• The supplied cabling may not be used for purposes other than for factory installed or approved electrical equipment. Overloading the electrical cables leads to excessive heating.

• Smoking is forbidden in the vicinity of the baler.

• Always keep a suitable fire extinguisher within easy reach.

2.3. Tailgate safeguard

If maintenance or installation/assembly work is performed with the tailgate open, it is essential to secure the tailgate to prevent it from falling.

Use the cut-off valve on the right side of the baler for this purpose. The shut-off valve may only be actuated from the right side of the machine.

Return the valve to its original position after completing maintenance and installation/assembly work (fig. 2).

fig. 1

fig. 2

0387-35

fig. 3

WELGER RP 202 • RP 220 • RP 302 • RP 320 7

2.4. Hydraulic system

Max. operating pressure of the hydraulic system

• 210 bar

When carrying out assembly work on the hydraulic system, particularly when using accumulators (fig. 4):

• Depressurise the hydraulic system (control valve set to “Lower”)

• Mechanically secure hydraulically operated components (pick-up device, cutting unit) to prevent uncontrolled movements.

According to DIN 20066, the period of use of a hose line, including any storage period, should not exceed six years.

2.5. Protective guards

In order to comply with European safety regulations EN 704, the manufacturer of machines is required since 01.01.95 to supply fixed partitioned protective guards that are self locking but require the use of a tool to be opened.

In order to open the protective guards on WELGER balers, turn the hexagon head of the lock anti-clockwise with a 13 mm spanner and pull the guard off the baler.

Observe the following order:

When opening: ................................. first the upper cover (fig. 5).

When closing:......................................first the side cover (fig. 6).

To close, push the guard cover against the baler until the lock is heard engaging.

The baler is never permitted to be operated with the

protective guards open!

2.6. Maintenance platform

Danger of falling! Never step on the maintenance platform of the moving machine. Before you step on the maintenance platform: Stop the machine, switch off power-takeoff shaft and motor engine and wait until the machine has stopped.

fig. 4

fig. 5

fig. 6

8 WELGER RP 202 • RP 220 • RP 302 • RP 320

2.7. Warning symbols

2.7.1. Explanation of the symbols

Danger areas which cannot be made safe by design measures are identified by yellow warning symbols. Since these are signs without texts in most cases, their precise meaning is described below.

The warning symbols must always be kept in a recognizable state. If there are no warning symbols on your baler or if they are damaged, replace them (see also Spare parts list, Section F).

Warning symbol Description/Spare part No.

Read and adhere to the operating manual and safety notes before starting up for the first time.

Spare part No.: 0388.11.00.00

Close protective guards before putting baler into operation!

Spare part No.: 0389.92.00.00

Never reach into the baler pick-up area as long as the tractor engine is running with the pto shaft connected.

Spare part No.: 0389.94.00.00

Always switch off the engine and remove the ignition key before starting any maintenance and repair work.

Spare part No.: 0388.25.00.00

WELGER RP 202 • RP 220 • RP 302 • RP 320 9

Switch off the engine and pull out the plug from the power supply before starting any repair, maintenance and cleaning work.

Spare part No.: 0388.13.00.00

Stay clear of tailgate swinging area while in operation.

Spare part No.: 0389.93.00.00

Do not ride on platform or ladder.

Spare part No.: 0391.06.00.00

Handle the cutting unit blades only if you are wearing gloves and using suitable tools.

Spare part No.: 0387.33.00.00

The accumulator is under gas pressure or oil pressure. Depressurise the hydraulic system before removal and repairs.

Spare part No.: 0387.37.00.00

Activate the tailgate safeguard before entering the roll chamber.

Spare part No.: 0387.34.00.00

10 WELGER RP 202 • RP 220 • RP 302 • RP 320

2.8. Symbols for the operation of the baler

The most important operating instructions are shown as symbols for the purpose of clarity. The exact descriptions are given below.

Symbol Description/Spare part No.

The two lifting eyes in the upper part of the baler are identified by this symbol. No other fixing points may be used for hooking up a crane.

Spare part No.: 0389.48.00.00

Locking lever for the cutter blades

To unlock the cutter blades, the lever must be swivelled down by approx. 90°.

Spare part No.: 0387.31.00.00 and 0387.32.00.00

Tailgate safeguard

If the lever is transverse with respect to the flow direction, the tailgate is secure against lowering.

Spare part No.: 0387.35.00.00

Maximum permissible hydraulic pressure

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

Spare part No.: 0387.36.00.00

WELGER RP 202 • RP 220 • RP 302 • RP 320 11

2.9. Proper Use

• The baler has been built exclusively for producing bales

compressed from agricultural straw material lying on the ground (proper use). Usage beyond this does not constitute proper use. The manufacturer is not liable for damage resulting from improper use; the user alone bears the risk.

• Proper use also includes compliance with the operating,

maintenance and servicing conditions specified by the manufacturer.

• The baler may only be used, maintained and repaired by

persons who are familiar with working with such machines and who have been informed of the dangers.

• The attachment of auxiliary equipment to the baler, other than

at the factory pre-set positions, is prohibited. Only auxiliary units approved by the manufacturer may be used.

• The relevant accident prevention regulations, regional safety

standards and other generally recognized safety regulations are to be observed.

• Unauthorized alterations and the installation of non-approved

parts and equipment on the baler exclude the manufacturer from any liability or damage resulting from this.

• Alteration of any of the safety relevant components invalidates

both the conformity declaration and the CE-symbol.

2.10. Electromagnetic compatibility (EMC)

The baler is equipped with electronic constituents and component parts whose function can be influenced by electromagnetic radiation from other appliances. Such influences can generate hazards for persons if the following safety precautions are not taken into account.

In the case of a supplementary installation of electrical and electronic appliances and/or constituents in the baler with a connection to the onboard system, the user has to verify whether the installation causes disturbances to the electronics of the vehicle or of other constituents.

In particular, it has to be taken into account that any additionally installed electrical and electronic components comply with the EMC Directive 89/336/EEC in the respective current version and that they are CE labeled.

12 WELGER RP 202 • RP 220 • RP 302 • RP 320

2.11. Precautions for driving on the road

Before driving on the road ...

… the baling chamber must be completely emptied (in

accordance with Road Traffic Vehicle Registration Regulations (RTVRR);

… the baler must be cleared of any harvested crop attached to

it;

… the universal drive shaft must always be fitted to the tractor

pto shaft;

… the tubes of the bale ejector* must be pushed in. … the lighting equipment of the attached machinery must be

connected to the tractor and its function checked (also in daylight);

… the support wheels of the pick-up unit must be detached

(working width 2.25 m) and placed in the park position.

… the parking brake must be fully released. Otherwise there is

danger of fire by brakes running hot (e. g. in the field).

… the power supply must be interrupted (pull plug), to prevent

uninterrupted roller lubrication.

Information shall be requested from the manufacturer before the baler is operated using attached machinery (e.g. bale wrapping device).

The wheel chocks, which are part of the safety equipment (two in number), are to be carried on the baler at all times.

The permissible maximum speeds for individual components (e.g. the drawbar or the axle) do not affect the maximum permitted speed limit for the entire baler (see Technical Data). Model-dependent maximum speeds limits have been exclusively specified in this operating manual. Current relevant national regulations, which may differ from manufacturers instructions, are always required to be observed.

WELGER RP 202 • RP 220 • RP 302 • RP 320 13

Pneumatic braking system*: Do not start driving with an attached baler until both coupling

heads (yellow and red) are connected to the tractor and the pressure gauge in the tractor cabin indicates the required operating pressure.

Hydraulic braking system *: Do not start driving with the attached baler until the appropriate

hydraulic hose is connected to the tractor.

Germany (StVZO): Agricultural equipment with a permissible total weight more than

3000 kg are required to have an operating permit. (Technical changes, e.g. fitting a trailer hook, result in the operating permit becoming void).

Before making intended changes to the attached working unit, it is essential to clarify whether the change is permissible without further requirements and can be entered in the vehicle’s documents following approval by an officially recognised expert.

Furthermore, the national regulations from the country of use are to be observed.

14 WELGER RP 202 • RP 220 • RP 302 • RP 320

2.11.1.Details on the rating plate

Item Meaning

1 ID number – individual machine number. Always quote in the event of queries

2 Permissible total weight for operation on public roads. The machine’s actual weight can be less.

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

3 Permissible axle load for operation on public roads

4 Machine’s year of construction

5 No applicable

6 Trade designation of the machine

7 Details of the systematic structure of the general operating permit (ABE)

8 Max. imposed load on the drawbar eye. The open-type hitch on the tractor must be approved for this

imposed load.

9 Permissible type-related maximum speed of the machine. National regulations can specify a lower

speed!

10 Internal control number

fig. 7

WELGER RP 202 • RP 220 • RP 302 • RP 320 15

2.11.2. Details on the rating plate of the drawbar

Item Meaning

1 Drawbar type (designation): D7 or D8

2 Official mark of conformity

3 Permissible, maximum total weight of the machine

4 Permissible maximum imposed load (D7: 400 kg; D8: 800 kg)

fig. 8

16 WELGER RP 202 • RP 220 • RP 302 • RP 320

3. Component Overview

12 V

23 7

145 108

1741-73

fig. 9

No. Component No. Component

1 Pick up unit 7 Net wrapping*

2 BALERCONTROL III - Control panel* 8 Bale ejector*

3 BALERCONTROL E - Control panel* 9 Tailgate

4 Cutting device* 10 Lock

5 Floor flap* 11 Chain wheels for roller drive

6 Twine wrapping*

WELGER RP 202 • RP 220 • RP 302 • RP 320 17

4. Putting Into Operation

When handling parts of the machine in the area of the drawbar, make sure that the machine is safeguarded from rolling away. Do not crank up the support foot until the baler is securely coupled to the tractor.

Do not disconnect the baler until:

• The surface is level and supports the road wheels and the

support foot

• The baler chamber is empty and the tailgate is closed

• The machine’s road wheels are blocked by chocks

• The hydraulic hoses are depressurised

• There is no load applied to the drawbar eye

Do not step between the tractor and baler until the vehicles are safeguarded from rolling away by means of the parking brake and/or the wheel chocks!

Children must be kept away from the baler at all times!

4.1. Attaching the baler

Correct baler attachment and drive shaft set up to the tractor is important to ensure trouble-free operation of the baler.

After attaching the baler, screw in the support foot with the hand crank until there is sufficient clearance from the ground.

Caution, danger of fire! Do not start driving with the machine attached unless the parking brake has been fully released. Otherwise there is danger of fire by brakes running hot (e.g. in the field).

• After attaching the machine to the tractor release the parking

brake (turn crank counterclockwise).

Caution, danger of accident! Any machines standing free, detached from the tractor, must be secured against accidental rolling away by applying the parking brake and by means of chocks.

• Apply the parking brake before detaching the machine from

the tractor (turn crank clockwise).

18 WELGER RP 202 • RP 220 • RP 302 • RP 320

4.1.1. Drawbar configuration

(all dimensions in [mm])

fig. 10

fig. 11

WELGER RP 202 • RP 220 • RP 302 • RP 320 19

4.1.2. Adjusting the trailer hitch

Any adjustment in the height set-up, and therefore a displacement in the drawbar eye position, shall only be carried out by the manufacturer or an approved specialist workshop.

• Position the baler on even ground.

• Screw out the support foot until the baler is standing level.

Use the flange plate on the stand as a reference.

• Measure the height of the tractor towing hitch;

• Measure the height of the baler drawbar eye.

• With reference to fig. 10 and fig. 11 align the drawbar with

the hole configuration that gives the closest fit to the desired dimension. The locking nuts must be replaced by new ones each time they are undone.

• After aligning the trailor hitch, the drawbar eye needs to be

brought into a horizontal position. Do this by undoing the fastening screws of the drawbar eye and correct the alignment of the drawbar eye with the help of the threaded pin.

• Firmly tighten all fastening screws and nuts.

RP 202 CLASSIC

fig. 12

RP 202 SPECIAL • RP 220 RP 302 • RP 320

fig. 13

20 WELGER RP 202 • RP 220 • RP 302 • RP 320

Important: Depending on the equipment configuration, a rigid

or rotatable drawbar eye can be fitted. (observe local regulations!) The drawbar eye [3] can be rotated about its longitudinal axis, but has to be locked for a open-type hitch attachment

For open-type hitch (high hitch) attachment, prevent drawbar eye [3] from turning by fitting parts 4, 5 and 6.

For tow hitch (low hitch) attachment, do not prevent drawbar eye [3] from moving, i.e., parts 4 - 6 not be fitted. Parts 4 – 6 are included loose with the delivery of balers having rotating drawbar eyes.

The horizontal protective bracket underneath the drawbar must be set for a minimum ground clearance of 50 cm.

Note: All fastening screws and nuts must be done up tightly:

Component see… Tension

moment

Bracket RP 202 CLASSIC

fig. 12 450 Nm

Bracket RP 202 SPECIAL

RP 220 RP 302 RP 320

fig. 13 450 Nm

Drawbar eye fig. 14, item 1 400 Nm

Table 2: Tension moment

RP 202 CLASSIC

1725-159

2654

fig. 14

WELGER RP 202 • RP 220 • RP 302 • RP 320 21

4.1.3. Configuration of the tow hitch

If the baler is attached to the tractor tow hitch, compliance with the following dimensions is necessary: (Table 3).

Correspond-

ing category

Catch opening dimensions Catch

opening

outer radius

Position Vertical

support load

ISO 730-1 d b r1) c

l F

-0

min. max. min. ±10 kg

33 60 70 220 400 1200

33 70 80 250 500 1500

Various configurations for the tow hitch are permissible if the external radius

r is complied with. (see fig. 11)

The upper part of the tow hitch can be dismantled to comply with dimension

Dimensions are in millimetres

Table 3: Dimensions, location and support load of the tow hitch

1246-154

fig. 15

Tow hitches other than as shown in fig. 15 and Table 3

are not permitted! Danger of breakage!

22 WELGER RP 202 • RP 220 • RP 302 • RP 320

4.2. Universal drive shaft

4.2.1. Connecting the cam-type cut-out clutch*

Depending on the model, the universal drive shaft is fitted with an automatic overload safety cut out (cam-type cut-out clutch).

• Clean and grease the splines of the connecting shaft before

installation.

• Undo and pull out the clamping cone [1]

• Open the maintenance hole in the protective cone. Push the

clutch unit onto the connecting shaft until the locator hole [2] points to the maintenance hole.

• Position the locator hole for the clamping cone above the

snap ring groove [3] of the connecting shaft.

• Turn the clamping cone within the locator hole and gently

move the hub backwards and forwards lengthways to seat it securely (approx. 70 Nm).

• Check that the clutch hub is properly located and securely

fixed by pushing and pulling on it. During this process, the proper location of the clutch should be checked at regular intervals.

4.2.2. Removing the cam-type cut-out clutch*

Undo the clamping cone and pull it out of the clutch hub. If that cannot be done by hand, the clamping cone can also be driven out from the other side with the help of a pin punch.

1742-2

fig. 16

1742-3

fig.17

1742-4

fig.18

WELGER RP 202 • RP 220 • RP 302 • RP 320 23

4.2.3. Adjusting the universal drive shaft

Pay attention to the maximum operating length L

max

and

minimum operating length L

min!

Aim for the greatest possible

overlap.

a) Shortest operating length, i.e., fully covered

b) During normal operation, the overlap of the tube section

should be at least 2/3 of the overlap L

c) The universal drive shaft can be operated with length L

max

for short periods, i.e., with a tube section overlap of 1/3 LU.

If necessary, adjust the length. To do this, hold the drive shaft tubes next to each other in the shortest operating position and mark them. Saw off the inner and outer tubes by equal amounts so that a sliding travel of 40 mm is retained in the shortest operating position.

Prevent the protective tube of the universal drive shaft from rotating by fastening the retaining chain.

Check the universal drive shaft each time before start-up to ensure that the locks are properly engaged.

Important: When turning around sharp bends, ensure that the

angle at the wide-angle joint (at the tractor) does not exceed the maximum value quoted by the manufacturer of the universal drive shaft.

Pay attention to the operating instructions from the universal drive shaft manufacturer as well as to country-specific approved product labels for the protection of universal drive shafts.

Warning: Only universal drive shafts approved by the

manufacturer may be used. A wedge-type freewheel device that is an integral part of the universal drive shaft protects the machine drive against follow-on weights.

When the machine is disconnected, always deposit the universal drive shaft on the universal drive shaft support (Fig. 23). In the case of attachment below, swivel the support upwards as appropriate.

The protective tube and cone of the universal drive shaft and the pto protection device must be fitted and must be in sound working order. Before starting the pto shaft, ensure that the selected rpm of the tractor is in accordance with the permissible rpm and direction of rotation of the machine (540 min-1).

Only start the pto shaft at idling speed!

Lmin

2/3 LU

1/3 LU

Lmax

1246-162

fig. 19

40 mm

1721-207

fig. 20

fig. 21

24 WELGER RP 202 • RP 220 • RP 302 • RP 320

4.3. Hydraulic hoses

Symbol on

hydraulic hose

Baler Function

Tractor

connection

Colour

identification

RP 202 RP 220 RP 302 RP 320

Open and close tailgate

single-acting yellow

RP 202 RP 220 FARMER RP 302 RP 320 FARMER

Raise and lower pick up

single-acting red

OIL

RP 220 FARMER RP 320 FARMER

Activate floor flap and cutting knife

double-acting

green

OIL

RP 220 w. CD RP 320 w. CD

Hydraulic switch with the functions

• floor flap*

• pick up unit

• cutting device*

double-acting red

CD = Cutting Device*

WELGER RP 202 • RP 220 • RP 302 • RP 320 25

Note: In order to find the correct oil coupling sleeves quickly

when hooking up the baler on later occasions, it is advisable to transfer the colour identification used for the hydraulic hoses to the couplings at the tractor end.

Clean the coupling parts of the hydraulic pipes with a clean cloth and plug in to the sockets at the tractor.

Check hoses and pipelines regularly for damage, deterioration and safe functioning. Defective parts are to be replaced immediately by original WELGER replacement parts. Hoses and hose lines are subject to natural deterioration even under normal operating loads. As a result, the useful service life is limited.

According to the "Safety Regulations for Hydraulic Hoses", a service life of six years should not be exceeded!

26 WELGER RP 202 • RP 220 • RP 302 • RP 320

4.4. Electrical system

4.4.1. Lighting

To connect the lighting system, insert the 7-pin plug into the corresponding socket on the tractor. Before travelling on the road check that the lighting system functions correctly (also in daylight).

4.4.2. "Balercontrol" Electronic Controller

Read and follow the separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“.

The control panel is provided with a plate which should be fastened within easy reach of the tractor driver.

The control panel of the “Balercontrol” control system is also provided with a magnetic plate on the rear and can be attached to a metallic surface within easy reach of the driver.

Once the plug is inserted in the socket, power is supplied to the unit and a short sequence of beeps is heard.

Note: When connecting the “Balercontrol” electronic controller,

a power socket conforming to DIN 9680 must be fitted on the tractor. (Supplied with the baler.) The fuse rating must be 30 A. (For baling without twine wrapping a fuse rating of 16 A is sufficient.)

The socket with connecting cable and fuse can be supplied under WELGER part No. 0972.20.40.00 as a retrofit part for an additional tractor.

The correct polarity of the power supply on the tractor must not be changed, since otherwise the electronic control unit might be damaged (fig. 24).

Balercontrol E

RP 202 RP 302 RP 220 FARMER RP 320 FARMER

1742-37

12 V

fig. 22

fig. 23

fig. 24

WELGER RP 202 • RP 220 • RP 302 • RP 320 27

5. Twine wrapping*

5.1. Threading the baling twine

Insert and thread new twine spools only when the baler is switched off. Remove the ignition key

Use good quality baler twine. Refer to technical data at the end of this operating manual. The use of plastic twine is recommended. Place the spools upright into the twine box. If the spools are inserted the wrong way up, the twine tends to form loops and leads to breakage.

Twine A

(Shown as a continuous line

in fig. 26 to fig. 28) Guide the start of the twine from the inside of spool A1 (inner diameter) upwards to the guide eye and then out of the twine box. Tie the end of the twine (outer diameter) of spool A1 to the start of the twine of spool A2.

Twine B

(Shown as a dashed line - - - - - - in fig. 26 to fig. 28) Guide the start of the twine of spool B1 similarly upwards through the guide eye and then out of the twine box.

1. Guide the twines A and B through the twine brake (1).

2. Only in the case of Balercontrol “E”: Wrap both twines

around the deflection rollers (2).

3. Thread in both twines upwards to the pair of eyes (3) on the

binding bar.

4. Only in the case of RP 302 / RP 320 with Balercontrol “E”:

Use the additional guide eyes between the deflection rollers (2) and the pair of eyes (3).

5. The twines shall not touch each other.

6. For continuation go to fig. 27.

28 WELGER RP 202 • RP 220 • RP 302 • RP 320

Threading-in diagram for machines with BALERCONTROL “E”

RP 202 / RP 302 CLASSIC and SPECIAL RP 220 / RP 320 FARMER

Threading-in diagram for machines with „

BALERCONTROL III”

RP 220 / RP 320 MASTER / PROFI

fig. 25

fig. 26

A = B =

WELGER RP 202 • RP 220 • RP 302 • RP 320 29

5.1.1. Cross Support

1. Guide twines A and B through to the guide rollers [8] as

shown in fig. 27.

2. Loop twine A anticlockwise once around the variable

diameter disc [9].

3. Finally locate each twine at the entry to their respective guide

roller.

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

securely grasped.

Note:

The clamping and cutting devices [10] have been factory set so that the driving twine (shown as a continuous line ) must be guided through the guide roller on the left-hand side, as seen from the direction of travel.

5. Tension both sets of twine once they have been threaded.

fig. 27

A = B =

30 WELGER RP 202 • RP 220 • RP 302 • RP 320

5.1.2. Setting the twine brake

Basic set up

Spring length at the twine brake (fig. 28)

BALERCONTROL E

(fig. 25)

BALERCONTROL III

(fig. 27)

Twine A

(shown as continuous line )

39 mm 33 mm

Twine B

(shown as dashed line - - - - - - )

37 mm 28 mm

The twines brakes [1] (fig. 25 and fig. 27) must hold the twines as taut as possible for the twine to be tight around the bales.

Note:

The permitted thread tension is exceeded when the twine breaks in the vicinity of the guide rollers [8] (fig. 27).

fig. 28

WELGER RP 202 • RP 220 • RP 302 • RP 320 31

5.1.3. Setting the edge clearances

In order to limit the twine wrapping on the ends of the roll bale, the edge clearance retainers [1] are adjustable (the right side of the baler is shown in fig 30 and fig. 31, but the same applies to the left side):With very dry and brittle crops it is better if the retainers are located more towards the middle of the baler.

5.1.4. Setting the distance between twine wrappings

The distance between the wrappings is given by the diameter used for the variable diameter disc [9] (fig. 27). The smaller the effective diameter of the disc, the greater the distance between the wrappings.

On the far right-hand edge of the cross-support is a lever [2] (fig. 29 and fig. 31), which is used to set the distance between the wrappings.

Setting

Position 1 .............................................greatest winding distance

Position 7............................................. smallest winding distance

5.1.5. Setting the edge wrappings

In order to ensure that the high density bales remain well compressed, the twine wrappings are automatically laid closer together near the edge of bales.

In order to achieve this, the right-hand shuttle [4] presses the variable diameter disc closer together when reaching the end zone. The working diameter of the variable diameter disc increases and the distance between wrappings is reduced towards the edges.

An adjustable arm [3] (fig. 29) is installed in the right-hand shuttle, which is attached by two screws in a unit with a set of holes. There are four different installation settings available.

Setting

Switching angle (3) towards the variator disk → more end windings on the edge of the bale

Switching angle (3) towards the machine centre → less end windings on the edge of the bale

fig. 29

fig. 30

fig. 31

32 WELGER RP 202 • RP 220 • RP 302 • RP 320

6. Net Wrapping*

6.1. Inserting the net

In order to handle the net roll safely, insert it together with

the help of a second person!

• Open all protective covers.

• If a wrapping process has not been completely executed

(e. g. because the net roll depleted during the wrapping process): pull the grip of the knife carrier strongly forward against the spring tension (fig. 32). The counting segment for the net length is reset to its starting position.

• Release the handwheel [1] on the disk brake in

counterclockwise direction

• Withdraw support pipe [2] from the holder.

• Remove empty hard paper core.

• Push net tensioner [3] to the rear and secure with cotter pin.

• Insert the net roll at first angularly above the two net roll

grooves from the left side in the direction of motion (fig. 33).

• Slide the net roll onto the mandrel (on the right in the

direction of motion) (fig. 34).

• Lift net roll on the left in direction of motion, push in and lock

support pipe [2] (fig. 34).

• Align net roll laterally to the effect that it is positioned

centrally to the roll chamber.

• Remove cotter pin from net tensioner and pull net tensioner

to the front again.

• Tighten handwheel [1].

fig. 32

fig. 33

fig. 34

fig. 35

WELGER RP 202 • RP 220 • RP 302 • RP 320 33

• Guide the net from the roll around the upper deflection roller

[4] and finally around the net tensioner [3].

• Place the beginning of the net over the sideways tensioner

[5] and then between the rubber roller [6] and steel roller [7].

• Turn the rubber roller manually until the net is caught. So

that the net does not prematurely enter the roll chamber during baling operation, the start of the net must not project more than approx. 10 cm.

• Move the net tensioner [3] forward into its working position.

1721-111

fig. 36

fig. 37

fig. 38

34 WELGER RP 202 • RP 220 • RP 302 • RP 320

6.2. Tensioning the net cutting knife

The net cutting knife is automatically tensioned (reset) each time the tailgate is opened. If a new net wrapping is required without opening the tailgate while the bale chamber is full, due to a net changeover or fault, the tensioning process can be done manually.

This is done by pulling the knife holder forwards against the spring (fig. 39). It can be released as described in the Section “Wrapping.”

6.3. Setting the net wraps

With help from the scale (fig. 40), a variable number of net wraps around the roll bales can be set.

After loosening the wing nut, the net length can be set by moving the nut within the slot.

Tip:

First, select the setting in the centre of the slot. To save binding material, adjust stepwise in the ( - ) direction for the following bales.

However, the bales must still be held together securely. With very smooth material and a high pressing density, a greater amount of net may be needed.

fig. 39

fig. 40

WELGER RP 202 • RP 220 • RP 302 • RP 320 35

7. Cutting Device*

RP 220 • RP 320

Depending on the model, the baler can be fitted with a 12-blade cutting device (MASTERCUT) or with a 23-blade cutting device (PROFICUT) or with a 25-blade cutting device.

It can be used for silage, hay and straw. The cutting device is hydraulically moved in and out.

7.1. Cutting device operation

RP 220 • RP 320 MASTER / PROFI

Read and observe the separate operating manual

„BALERCONTROL III with Graphic Display for RP 220/RP 320“.

1. Press the button on the BALERCONTROL panel.

The symbol „cutting device“ appears in the display field of the control panel (fig.43).

2. Activate the attached tractor control valve. (The actuating

direction can be changed by swapping the connected hydraulic hoses.)

3. When the blades are in the cutting position, the symbol

“cutting device” also appears in the display field of the control panel. Or: When the blades are not in cutting position, the symbol „cutting device crossed out“ appears in the display field of the control panel (fig.44).

4. In order to fill the hydraulic accumulators, operate the

control valve for at least another 2 seconds.

5. In order to ensure free movement of the individual blades, it

is recommended to move the cutting device in and out several times each day.

Note:

The cutting device is safeguarded from being overloaded by a single hydraulic pressure switch serving the cutter blades. This activates at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked.

1724-36

fig.41

1742-40

fig.42

fig.43

fig.44

36 WELGER RP 202 • RP 220 • RP 302 • RP 320

Remedy:

1. Keep the button

depressed, while at the same time:

2. Activate the control valve for at least 3-4 seconds.

3. Repeat points 1 and 2 as needed until the blades are in the

cutting position.

Warning: The common protection for the cutter blades has been disabled by pressing the button !

Finally, the blades must definitely be once again moved completely in and out without having to depress the

cutting device button . Otherwise, the machine overload will result in a cancellation of the warranty!

WELGER RP 202 • RP 220 • RP 302 • RP 320 37

RP 220 FARMER - RP 320 FARMER

with cutting unit, with swivel floor

Pick-up unit width 2.0 metres

Activating the cutting device:

1. Open the shut-off valve on the left side of the baler

(fig. 45), i.e. move the lever into the vertical position.

2. Activate the "raise" function on the connected tractor valve

until the cutting device moves into its working position. (If the swivel floor (HYDROFLEXCONTROL) was open, it will also move upwards.

3. In order for the hydraulic accumulators to fill, continue to

activate the control valve for another 5 seconds after the cutter blades have moved in.

4. Close the shut-off valve (fig. 45), i.e. move the lever into the

horizontal position.

Deactivating the cutting device:

1. Open the shut-off valve on the left side of the baler (fig. 45),

i.e. move the lever into the vertical position.

2. Activate the "raise" function on the connected tractor control

valve for about 5 seconds. Blades and conveyor channel floor will move downwards one after the other.

3. Close the shut-off valve (fig. 45), i.e. move the lever into the

horizontal position.

4. Activate the "raise" function on the connected tractor control

valve until the conveyor channel floor is completely closed.

Tip:

In order to ensure free movement of the individual blades, move the cutting device in and out several times each day.

The shut-off valve (fig. 45) is only opened for moving the blades in and out.

During normal operation the shut-off valve must always remain closed (position “0” in fig. 46).

fig. 45

0387.67.00.00

fig. 46

38 WELGER RP 202 • RP 220 • RP 302 • RP 320

Hydraulic protection of the cutter blades

Note:

The cutting device is safeguarded from being overloaded by a single hydraulic pressure valve serving the cutter blades. This activates at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked.

Remedy:

1. Move the ball valve under the left protective guard towards

the back (shown in fig. 47 without the protective guards).

2. Move the shut-off valve, on the left side of the baler, into a

vertical position (fig. 48).

3. Activate the "raise" function on the connected tractor valve

until the cutting device moves into its working position.

4. Once again activate the "lower" function on the connected

tractor control valve until the cutting device and the conveyor channel floor are located in the lowest position.

5. Repeat points 3 and 4 as needed until the blades are

operating smoothly.

6. Move the ball valve again towards the middle of the baler

(fig. 47 and fig. 49).

7. Activate the "raise" function on the tractor control valve until

the cutting device is in its working position.

8. Close the shut-off valve (fig. 48), i.e. move the lever into the

horizontal position.

Warning: If the ball valve lever (fig. 47) is pointing towards the

back, the common protection of the cutter blades is deactivated!

After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler! (fig. 49)

After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty!

fig. 47

1724-29

fig. 48

0387.16.00.00

o. k.

fig. 49

WELGER RP 202 • RP 220 • RP 302 • RP 320 39

RP 220 FARMER • RP 320 FARMER

with cutting unit, with swivel floor

Pick-up unit width 2.25 meters

Attention:

For daily operation the two ball valves must be positioned in parallel (see fig. 50)!

Switching the cutting device on:

1. (Left machine side, fig. 50 and fig. 51:) Left ball valve of the

hydraulic block must be set to position „35 bar“. Right ball valve of the hydraulic block must point towards the machine.

2. Set the connected tractor control valve to „Raise“ and leave

it in this position until the cutting device moves to working position.

3. To enable the hydro accumulators to fill: continue to actuate

the control valve for another 5 s approx. after the cutter blades have moved in.

Switching the cutting device off:

1. (Left machine side, fig. 50 and fig. 51:) Left ball valve of the

hydraulic block must be set to position „35 bar“. Right ball valve must point towards the machine.

2. Set the connected tractor control valve to „Lower“ for 5–10 s

approx..

Tip:

In order to ensure free movement of the individual blades, switch the cutting device on and off several times each day.

fig. 50

fig. 51

40 WELGER RP 202 • RP 220 • RP 302 • RP 320

Hydraulic protection of the cutter blades:

Note:

To safeguard the cutting device from overload the cutter blades are protected in common by a hydraulic pressure valve. This pressure valve responds when a factory-set pressure is reached.. I. e. this is also the only pressure which is available for switching on the blades. Depending on the conditions, the hydraulic pressure may be insufficient if the blade slots are clogged.

Attention:

For daily operation the two ball valves must be positioned in parallel (see fig. 52)!

Remedy:

1. (Left machine side, fig. 52 and fig. 53:) Left ball valve must

be set to position „180 bar“. Right ball valve of the hydraulic block must point towards the machine.

2. Set the connected tractor control valve to „Raise“ and leave

it in this position until the cutting device moves to working position.

3. Set the connected tractor control valve to „Lower“ and leave

it in this position until the cutting device disappears again in the swivel floor.

4. Repeat points 2 and 3 as needed until the blades are

operating smoothly.

5. (Left machine side, fig. 52 and fig. 53:) Reset left ball valve

of the hydraulic block to position „35 bar“.

6. Set the connected tractor control valve to „Raise“ and leave

it in this position until the cutting device moves to working position.

7. Set the connected tractor control valve to „Lower“ and leave

it in this position until the cutting device disappears again in the swivel floor.

Attention: If the ball valve lever (fig. 54) points to the position

„180 bar“, the common protection of the cutter blades is deactivated!

After raising of the cutter blades, the lever of the ball valve must be reset to the „35 bar“ position!

It is absolutely necessary that finally the cutting device is once

again lowered and raised (see points 2 and 3). Otherwise machine overload will result in cancellation of the warranty!

fig. 52

fig. 53

fig. 54

WELGER RP 202 • RP 220 • RP 302 • RP 320 41

RP 220 FARMER • RP 320 FARMER

with cutting unit, without swivel floor

The cutting device is directly actuated with the double-acting tractor control valve. (The actuating direction can be changed by swapping the connected hydraulic hoses.)

In order to ensure free movement of the individual blades, it is recommended to move the cutting device in and out several times each day.

Note: The cutting device is safeguarded from being overloaded

by a single hydraulic pressure valve serving the cutter blades. This responds at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if the blade grooves are blocked.

Remedy:

1. Move the ball valve under the left protective guard towards

the back (fig. 55).

2. Activate the control valve until the blades are in the cutting

position.

3. Move the ball valve once again towards the middle of the

baler.

4. Move the blades once more in and out. Only after this

process can the baler be brought into normal operation.

Warning: If the ball valve lever (fig. 55) is pointing towards the

back, the common protection of the cutter blades is deactivated!

After the blades have been moved upwards, the lever must once again be brought back towards the middle of the baler! (fig. 56)

After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty!

1724-30

fig. 55

0387.16.00.00

o. k.

fig. 56

42 WELGER RP 202 • RP 220 • RP 302 • RP 320

7.2. Brittle crops

It is recommended when baling brittle crops to hydraulically move the cutting device out of the cutting position before wrapping. The bales are then enclosed by long material and crumbling losses are avoided to a large extent.

7.3. Installation and removal of the cutter blades

The cutting length for the pressed material can be adjusted by removing individual blades. All of the blades can be removed if the cutting function is not needed for a longer period of time:

Warning: Danger of injury! Wear protective gloves when handling blades.

If maintenance or assembly work is to be performed when the tailgate is open, then for safety reasons it is absolutely necessary that the tailgate be secured from lowering.

• Move the cutting device into the cutting position.

• Lower the HYDROFLEXCONTROL bottom flap* approxi-

mately halfway (fig. 57).

• Open the tailgate and secure it by using the cut-off valve

(see chapter 2.3. Tailgate safeguard).

• Pull down the blade lock lever on the conveyor housing on

the right-hand side (in the driving direction) by approx. 90° until it stops.

• From the roll chamber, pull out the blades using pliers

diagonally up from the blade axle and remove it from the slot.

Once removed, the blades can be stored behind the right door panel and secured in place with a plug-in split pin and a lever. (fig. 58).

Note: Removed blades should be replaced by dummy blades*

in order to prevent the slots from becoming blocked. (Part no. 1724.55.12.37)

fig. 57

fig. 58

WELGER RP 202 • RP 220 • RP 302 • RP 320 43

7.4. Sharpening the cutter blades

In order to ensure an optimum throughput of crops, it is recommended that the cutter blades be sharpened after 500 bales have been cut at the latest. Depending on the operating conditions, sharpening may also be required sooner.

Attention, danger of injury during work on the magnets of the knife holders!

The function of cardiac pacemakers can be impaired by magnetic fields. Danger of injury by splinter: Never strike the installed blades from the bottom with a striking tool - magnets may be damaged!

As described above, remove the blades and grind the cutting edge from the smooth side. Pay attention that the hardened cutting edges are not drawn when grinding.

A grinder is available as a spare part. (Part no. 0980.70.14.00)

44 WELGER RP 202 • RP 220 • RP 302 • RP 320

8. Field Use

The roll baler is safeguarded against foreseeable accidents. In spite of this, necessary precautions must still be taken when working. Each time before use, check that all safety devices on the roll baler are in proper working order. Never attempt to correct malfunctions while the machine is in operation. Take special care when opening and closing the tailgate. Stay clear of swing area of the tailgate at all times. Before entering the bale chamber, lock the tailgate (fig. 3).

8.1. Driving on the road

Lift the pick-up unit to its highest position. Close the shut-off valve on the hydraulic hoses for the pick-up unit. The pick-up unit is now hydraulically secured in the transport position.

For pick-up units with 2.25 m* width: Also move the pick-up unit support wheels into the park position (fig. 59).

In order to avoid any danger to other road users, both rectangular tubes of the bale ejector must be pushed in and secured (fig. 60).

8.2. Bale ejector*

In order to prevent bales that have already been tied from remaining within the swing area of the tailgate, a bale ejector is mounted underneath the baling chamber. Prior to field use, both rectangular tubes should be pulled out from the parking position and secured with bolts and split pins.

When working on a sloped surface the bale ejectors should remain in the park position.

8.3. Windrowing

The full capacity of the baler and good bale formation can be only achieved by careful windrow preparation. Therefore the windrows should be laid down uniformly.

The windrow width should be as follows:

Pick-up unit width 1.50 m 2.00 m 2.25 m

Optimal windrow width (approx.)

1.30 m 1.40 m 1.50 m

fig. 59

1724-32

fig. 60

WELGER RP 202 • RP 220 • RP 302 • RP 320 45

8.4. Pick-up unit

RP 202 • RP 302 CLASSIC / SPECIAL RP 220 • RP 320 FARMER

The pick-up unit is raised and lowered by operating the tractor control valve.

Read and observe the separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“.

RP 220 • RP 320 MASTER / PROFI

An electro-hydraulic manifold block (Hydraulic switch*) makes it possible to operate a number of different hydraulic functions with a single control valve.

In order to raise or lower the pick-up unit, press the button (shown opposite) on the “Balercontrol” control panel (fig. 61). The symbol “Pick-up” appears in the display field of the control panel (fig. 62).

The connected tractor control valve can now be used to actuate the pick-up lifting mechanism.

8.4.1. Support wheels*

When on the field, set the pick-up unit support wheels to give the tines a ground clearance of at least 2 cm. To set the support wheels, raise the pick-up unit. Pull out the spring retainer [1] and align the bracket [2] with the desired hole (fig. 63); secure the support wheels once again with the spring retainer. Provide the same setting on both sides.

1742-41

fig. 61

fig. 62

fig. 63

46 WELGER RP 202 • RP 220 • RP 302 • RP 320

8.4.2. Hold-down device / Pick-up unit short crop guard*

For all types of pick-up unit, the hold-down device is movable and hangs over the pick-up drum. The height of the hold-down device rake can be adjusted by using the chain to allow for various windrow thickness.

The upper end of the chain must always be hung on the hook in order to prevent it from being caught up in the pick-up unit.

Special Notes:

RP 202 CLASSIC / RP 302 CLASSIC

Pick-up unit width 1.50 m (fig. 64) As an optional feature, a pick-up unit short crop guard can be supplied (not shown). It prevents short baling crops from falling away ahead of the pick-up unit.

For installation, locate both brackets of the pick-up short crop guard onto the inside of the hold-down device and secure on each side by using a spring pin. Adjust the setting by using the chain with swivel hooks. Set high or remove the pick-up unit short crop guard for long crops.

RP 202 SPECIAL / RP 302 SPECIAL

Pick-up unit width 2.00 m (fig. 65) The hold-down device rods [1] should be parallel to the pick-up unit bottom plate. For adjustment, use the connecting bar [2] on the left side of the baler.

RP 220 and RP 320

Pick-up unit width 2.00 m and 2.25 m (fig. 66)

For pick-up units with pick-up width of 2.25 m, both support wheels cover the sides of the rotating tines and therefore also form part of the installed safety equipment.

When using the baler, both support wheels must be installed at all times.

1742-42

fig. 64

1724-34

fig. 65

fig. 66

WELGER RP 202 • RP 220 • RP 302 • RP 320 47

8.5. Feed guide plate

The streamlined feed guide plate [1] is factory installed in the roll chamber.

Should material become jammed due to unusual crop conditions, then the feed guide plate may be removed. To do this, take out screws (arrow in fig. 67) on the right side (in the driving direction) and remove the plate from the roll chamber.

8.6. Pto shaft speed

Operate the baler with a standard pto shaft speed of 540 min-1. For extremely short or brittle crops, the baler can also work at lower pto shaft speeds (350 – 450 min

-1

Only universal drive shafts approved by the manufacturer may be used. The protective tube and cone of the universal drive shaft and the pto shaft protection device must be fitted and must be in sound working order.

Always check that the universal drive shaft is correctly installed and well secured! Secure the universal drive shaft guard by attaching the chain to prevent it from turning! Before starting the pto shaft, ensure that no person is within the danger zone of the machine!

8.7. Driving with the baler

To obtain high output and well-shaped round bales, an appropriate driving style is required so that the roll chamber is evenly fed with material over the entire baler width.

For narrow windrows - i.e. the width of the windrow is narrower than the pick-up unit width - uniform feeding of the bale chamber can be achieved by driving into the left and right side of the windrow in an alternating fashion (fig. 68).

When turning around sharp bends, ensure that the angle at the wide-angle joint (at the tractor) does not exceed 80°. Otherwise there is a danger of breakage during operation and at rest.

1742-51

fig. 67

richtig correct correct

falsch wrong

faux

10 - 20 m

1742-19

fig. 68

48 WELGER RP 202 • RP 220 • RP 302 • RP 320

8.8. Setting the bale density

RP 202 • RP 302 CLASSIC / SPECIAL RP 220 • RP 320 FARMER

There is a lever on the right-hand side of the baler to set the density.

1. With the side panel open, loosen the wing nut.

2. Shift the pointer to set the desired baling density within the range between “+” and “-”.

3. Finally, screw on the wing nut once again.

RP 220 • RP 320 MASTER / PROFI

(See separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“)

fig. 69

WELGER RP 202 • RP 220 • RP 302 • RP 320 49

8.9. Locking the tailgate

Before picking up the crop and after each bale ejection, the tailgate must be locked properly. To do this, keep the tractor control valve for tailgate actuation in the "lower" position. This will automatically lock the tailgate.

For balers with net wrapping, the tractor control valve must be kept in the "lower" position for a further few seconds after the locking of the tailgate. This will reactivate the net wrapping.

Note: So as not to place any unnecessary load on the hydraulic

pump, leave the control valve in the “floating position” during pressing.

RP 202 • RP 302 • RP 220 FARMER • RP 220 FARMER

The white pilot lamp (right front side of the machine) lights for as long as the tailgate is not locked.

RP 220 • RP 320 MASTER / PROFI

A short signal tone informs the tractor driver that the tailgate is fully locked.

50 WELGER RP 202 • RP 220 • RP 302 • RP 320

9. Wrapping

The following wrapping modes* can be selected

• manual wrapping (twine and net)

• automatic twine wrapping

• automatic net wrapping

• automatic combined wrapping

(only for MASTER and PROFI)

9.1. "BALERCONTROL E Control Panel“

RP 202 • RP 302 CLASSIC and SPECIAL RP 220 • RP 320 FARMER

The BALERCONTROL E control panel contains the following functions and displays. (fig. 70):

No. Component Function

1 Green LED Correct power supply

2 Red LED Set bale density reached

3 Yellow LED Automatic net wrapping selected.

(Flashes when the net clutch is in operation)

4 Yellow LED Automatic twine wrapping selected.

(Flashes when the twine motor is in operation)

5 Button Changes between manual and

automatic wrapping (manual: lights [3] and [4] go out).

Depress for 5 seconds: resets the bale counter (DLC

) to zero.

6 Button Trigger the net wrapping by hand

7 Button Trigger the twine wrapping by hand

8 Display Top row: non-resetting life time

counter (LTC

);

Bottom row: daily counter (DLC) can be reset;

9 buzzer

(on back side)

Pre-selected bale density reached

DLC = Daily Counter

LTC = Life Time Counter

12 V

1742-43

fig. 70

WELGER RP 202 • RP 220 • RP 302 • RP 320 51

9.1.1. Triggering the wrapping (BALERCONTROL E)

When the pre-selected bale density is reached, the tractor driver is notified by the red LED [2] and the buzzer [9].

Depending on the selected wrapping mode, the wrapping is triggered either automatically or manually from the appropriate button (net [6] or twine [7]).

Manual twine wrapping

• Selection: Depress button [5] several times until both yellow LED's go out.

• Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds.

• While driving, depress the twine button [7]; the corresponding yellow LED flashes simultaneously.

• Stop driving the tractor approx. 5 to 10 seconds after depressing the twine button [7]. With normal P.T.O speed, allow the twine to wrap the bale.

• Check the twine is running by the detection pulleys (fig. 71). As soon as the detection pulleys stop, the wrapping process is finished

• Open the tailgate and eject the bale.

Manual net wrapping

• Selection: Depress button [5] several times until both yellow LED's go out.

• Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds.

• Stop driving the tractor and allow the pick up unit to clear.

• Depress the net button [6] for approx. 5 seconds; The

corresponding yellow LED flashes.

• With normal P.T.O. speed allow the net to wrap the bale

• Check the net is running by the detection pulley (fig. 72). As

soon as the detection pulley stops the wrapping process is finished.

• Open the tailgate and eject the bale.

1741-97

fig. 71

1742-44

fig. 72

52 WELGER RP 202 • RP 220 • RP 302 • RP 320

Automatic twine wrapping

• Selection: Depress button [5] (fig. 70) several times until the right yellow LED lights up.

• Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on.

• The twine is automatically guided into the roll chamber. The corresponding yellow LED flashes simultaneously.

• The buzzer sounds about 4 seconds after triggering the twine wrapping. Stop driving the tractor at this point. With normal speed, allow the twine to wrap the bale.

• Check the twine is running by the detection pulleys (fig. 71). As soon as the detection pulleys stop, the wrapping process is finished.

• Open the tailgate and eject the bale.

Automatic net wrapping

• Selection: Depress button [5] (fig. 70) several times until the left yellow LED lights up.

• Once the pre-selected bale density is reached, the red LED initially begins to flash and then remains continually on. The buzzer sounds.

• Immediately stop driving the tractor and allow the pick up unit to run clear.

• About 4 seconds after the sounding of the buzzer, the net is automatically driven into the roll chamber. The corresponding yellow LED flashes simultaneously.

• With normal P.T.O. speed allow the net to wrap the bale.

• Check the net is running by the detection pulley (fig. 72). As

soon as the detection pulley stops, the wrapping process is finished.

• Open the tailgate and eject the bale.

Note: Should very brittle crops be wrapped with twine, the

following procedures have shown to be advantageous:

• In order to tightly bind the start of the twine, quickly supply

extra crop shortly after the wrapping process begins.

• After finishing the wrapping process, eject the bales at

normal speed.

WELGER RP 202 • RP 220 • RP 302 • RP 320 53

Combined net / twine wrapping

In order to minimise crumbling losses and keep net consumption low, it is possible to use both types of wrapping simultaneously.

• Activate the baler for automatic twine wrapping (see page 44).

• Allow the twine wrapping to be triggered automatically.

• As soon as the yellow LED stops flashing, depress the net

wrapping button.

For combined wrapping it is sufficient to select a lower number of net wrappings and a larger distance between twine wrappings.

9.2. "BALERCONTROL III" Control Panel“

RP 220 • RP 320 MASTER / PROFI

Read and observe the separate operating manual

„BALERCONTROL III with Graphic Display for RP 220/RP 320“.

For wrapping operations, the BALERCONTROL III control panel contains the following functions and displays (fig. 73):

No. Component Function

1 Display Display: Wrapping type, bale density,

a.s.o.

2 Button

Alternate between various wrapping types

3 Button <NET> Trigger the net wrapping by hand

4 Button

<TWINE>

Trigger the twine wrapping by hand

5 Buzzer (on

back side)

Pre-selected bale density reached

1724-37

fig. 73

54 WELGER RP 202 • RP 220 • RP 302 • RP 320

9.2.1. Wrapping the bale

Repeatedly depress the button <AUTO/MAN> on the control panel until the desired wrapping type is selected. The following sequence appears:

Set to: manual wrapping (twine and net possible)

Set to: automatic twine wrapping

Set to: automatic net wrapping

Set to: automatic combined wrapping

Set to: manual wrapping (start setting)

The selected setting is stored and will be used again automatically when the electronics are switched on.

The following two pages show the relevant operating steps and the associated display on the control panel for each type of wrapping:

fig. 74

WELGER RP 202 • RP 220 • RP 302 • RP 320 55

9.2.2. Twine wrapping, manually triggered:

Audible (3 sec.) signal when reaching the preselected baling density (visual: bar graph display of bale density raised to preset level).

While driving depress button

<TWINE>

Twine motor is switched on for 8 sec. after depressing button. Stop driving tractor After completion of the twine wrapping (twine movement sensors indicate stoppage):

A signal sounds. Then: Open tailgate with tractor control valve.

As soon as lock opens:

After bale ejection: Close tailgate again using the tractor control valve. After locking of the tailgate a signal sounds.

The bar graph display for the bale density has dropped to „0“.

More crop can be once again added.

56 WELGER RP 202 • RP 220 • RP 302 • RP 320

9.2.3. Net wrapping, manually triggered:

Audible (3 sec.) signal when reaching the selected baling density (visual: Bar graph display for bale density raised to preset level).

Stop driving the tractor and allow the pick up unit to operate freely.

Depress button <N

ET>

until the net is grasped by the bale.

After completion of the net wrapping (net cutting knife was operated):

A signal sounds, Then: Open the tailgate using the tractor control valve.

As soon as lock opens:

Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. The net cutting knife is automatically tensioned (reset) again when the tailgate is closed.

The bar graph display for the bale density has dropped to „0“.

More crop can be once again added.

WELGER RP 202 • RP 220 • RP 302 • RP 320 57

9.2.4. Twine wrapping, automatically triggered:

Wrapping starts without any action from the driver on reaching the pre-selected baling density.

The driver will be signalled to stop driving by a continuous tone lasting for 3 seconds.

This signal begins 2.5 sec. or 5 sec. after the start of wrapping. The delay can be adjusted in the set-up menu.

After completion of the twine wrapping (twine movement sensors indicate stoppage):

A signal sounds. Then: Open tailgate with tractor control valve. As soon as lock opens:

Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate.

The bar graph display for the bale density has dropped to „0“.

More crop can be once again added.

9.2.5. Net wrapping, automatically triggered:

Wrapping starts without any action from the driver on reaching the pre-selected baling density.

The driver will be signalled to stop driving by a continuous tone lasting for 3 seconds. This signal begins 2.5 sec. or 5 sec. before

the start of wrapping. The delay can be adjusted in the set-up menu.

The net clutch is activated for a period of 5 seconds.

After completion of the net wrapping (net cutting knife was operated):

A signal sounds. Then: Open tailgate. As soon as lock opens:

Close tailgate after bale ejection. Buzzer sounds briefly after locking the tailgate. Activate the control valve for a further 5 sec. so that the net cutting knife* is fully tensioned.

The bar graph display for the bale density has dropped to „0“.

More crop can be once again added.

58 WELGER RP 202 • RP 220 • RP 302 • RP 320

9.2.6. Combined wrapping, automatically triggered:

The "automatic twine wrapping" and the "automatic net wrapping" are started within 3 sec. of one another. (Twine wrapping first).

Stop driving the tractor after the tone ("density reached")

9.2.7. Multiple triggering of the wrapping:

Automatic wrapping can only be triggered once. To reactivate, the tailgate must be once again opened.

Manual wrapping can be triggered as often as desired without having to open the tailgate.

When net wrapping is manually triggered for the second time, the following query appears

“Net cutting

knife tensioned?”

If the button <NET> is depressed once more, wrapping starts again.

Before beginning a new wrapping, check whether the net cutting knife has been reset.

WELGER RP 202 • RP 220 • RP 302 • RP 320 59

9.3. Ejecting the bale

After completing the wrapping process, open the tailgate hydraulically so that the bale rolls out. Keep the tractor control valve on "raise" until the tailgate has completely opened.

If no bale ejector* (see fig. 9, No. 8) is fitted, then reverse by approx. 3 m before ejecting and then drive forward again up to the windrow before closing the tailgate.

To close the tailgate, keep the tractor control valve on "lower" until the tailgate has been securely locked and when required, until the net wrapping* is once again tensioned.

If possible move the tractor control valve into the floating position after actuation (only if “floating position” is available).

For balers fitted with BALERCONTROL III there is also an audible confirmation tone. The control panel display again shows the initial start-up condition.

The tailgate is now locked on both sides and collecting the crop can begin again for the next bale.

Take special care when opening and closing the tailgate.

Stay clear of swing area of the tailgate at all times.

If the ground is uneven, the bale may start to roll or tip over onto its side. Employ suitable measure to eliminate this risk.

All persons must move away from the bale’s possible movement area.

60 WELGER RP 202 • RP 220 • RP 302 • RP 320

10. Overload protection / Reversing mechanism

10.1. Universal drive shaft with shearing bolt clutch*

A shearing bolt clutch is installed in the universal drive shaft on the baler side. In the event of overloading, the bolt [1] will shear and must be subsequently replaced by a new one. Only put the machine into operation again when the cause for the overload has been resolved.

Use original replacement parts only:

Shearing bolt with nut............................................ 0930.84.53.00

10.2. Universal drive shaft with cam-type cut-out clutch*

The cam-type cut out clutch limits the drive torque in the event of overload. Switch off the pto shaft and remedy the cause of the overload. After switching on the pto shaft, the torque increases once again, so that the baler can be put into operation.

Avoid long and frequent overloading. Ensure that only the appropriate universal drive shaft is used.

10.3. Reversing the main drive

RP 220 / RP 320 without HYDROFLEXCONTROL*

Should the inlet section become blocked for balers without hydraulic bottom flaps (HYDROFLEXCONTROL), the main drive can be manually rotated backwards (fig. 77):

• Switch off the pto shaft

• Switch off engine and remove the ignition key

• Apply the crank lever delivered with the baler (46 mm jaw

width) and rotate the drive backwards far enough so that the blockage in the inlet section can be removed;

Before restarting the baler, remove the crank lever and

close up all protective guards!

1741-81

fig. 75

1741-82

fig. 76

1724-38

fig. 77

WELGER RP 202 • RP 220 • RP 302 • RP 320 61

10.4. Hydraulic bottom flap*

(HYDROFLEXCONTROL)*

The hydraulically hinged conveyor channel floor has two hydraulic cylinders which help in extending the conveyor channel through to the roll chamber.

Any congested material is thereby easily pulled through, grasped by the lower pressing roller and transported into the roll chamber.

What to do if material jams:

RP 220 • RP 320 MASTER / PROFI

Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed!

Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves!

1. Stop driving and switch off pto shaft.

2. If the cutting device was used, first press the button

<CUTTING DEVICE> (fig. 79) and use the tractor control valve to swing the cutter blades away from the conveyor

channel. The symbol for „cutting device inactive“ appears in the display.

3. Press the button <BOTTOM FLAP> (fig. 80) and use the

tractor control valve to open the conveyor channel floor. The

flashing symbol for „bottom flap open“

appears in the

display.

4. Engage the universal drive shaft.

5. Return the bottom flap to the working position once the

blockage has been removed (symbol „bottom flap open“ disappears).

6. If the cutting function is required, the blades must be swung

in once again. The symbol for „cutting device active“ appears in the display.

fig.78

fig. 79

fig. 80

62 WELGER RP 202 • RP 220 • RP 302 • RP 320

What to do if material jams:

RP 220 FARMER / RP 320 FARMER

Only rectify functional faults at inlet elements (such as pick-up unit, augers and rotor) when the tractor engine is turned off and the ignition key has been removed!

Cutting device: There is also a danger of injury in handling the inlet section when the cutting device is lowered. Always wear protective gloves!

If the cutting device was used:

1. Stop driving and switch off the pto shaft.

2. (Left machine side, fig. 81 and fig. 82:) The right ball valve

of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine.

3. Set the connected tractor control valve to „Lower“ and leave

it in this position until the blades move into the bottom flap.

4. Reengage the pto shaft. The material jam is automatically

removed by the running conveying elements.

If the material jam has been removed, see work steps 5 and 6.

If swivelling-back of the cutting device is not sufficient to remove a material jam: open and close the bottom flap (please continue on the next page now).

5. Set the connected tractor control valve to „Raise“ and leave

it in this position until the blades move to working position.

6. To enable the hydro accumulators to fill: actuate the control

valve for another 5 s. approx. after the blades have moved in.

fig. 81

fig. 82

WELGER RP 202 • RP 220 • RP 302 • RP 320 63

Opening the bottom flap:

1. Stop driving and switch off the pto shaft.

2. (Left machine side, fig. 81 and fig. 82:) The right ball valve

of the hydraulic block must point towards the tail of the machine. The left ball valve of the hydraulic block must point towards the machine.

3. Set the connected tractor control valve to „Lower“ and leave

it in this position until the bottom flap moves down and opens completely.

4. Engage the pto shaft: The material jam is automatically

removed by the running conveying elements.

Then close the bottom flap.

Closing the bottom flap:

1. Set the connected tractor control valve to „Raise“ and leave

it in this position until the bottom flap moves up and closes completely.

2. To enable the hydro accumulators to fill: actuate the control

valve for another 5 s. approx. after the bottom flap has closed.

Attention:

For daily operation the two ball valves must be positioned in parallel (see fig. 81)!

3. (Left machine side, fig. 81 and fig. 82:) The right ball valve

of the hydraulic block must point again towards the machine. The left ball valve of the hydraulic block must point towards the machine.

Attention:

When the bottom flap is being closed, the blades move automatically to working position. If you want to work without blades, they must subsequently be moved to home position again: see chapter 7. Cutting Device!

64 WELGER RP 202 • RP 220 • RP 302 • RP 320

11. "BALERCONTROL"*

Not only the control unit (only with BALERCONTROL III), but also the operating control panel, as well as the associated program, all have their own serial numbers.

In order to process future enquiries, it is necessary to state the serial / version numbers. Therefore please enter these numbers below upon delivery:

BALERCONTROL E

Component Version number How do I find the version number?

Control panel program (Software)

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

By switching on the power supply before the counters are displayed.

BALERCONTROL III

Component Serial number How do I find the serial number?

Control panel (hand set)

SW.Rev ...........................

dd ...........................

By switching on the power supply while keeping any control panel buttondepressed.

Control unit

Serial No. ...........................

SW version ...........................

SW date ...........................

Memory ...........................

Press button several times until "Systeminfo" appears in the display.

WELGER RP 202 • RP 220 • RP 302 • RP 320 65

11.1. Your Safety

The "Balercontrol" control system was designed and manufactured with utmost attention to details and maximum precision. Each unit has been checked and tested for correct functioning before delivery. Despite all the precautions, a malfunction can still occur. Therefore, the "Balercontrol" control system and associated baler should be always operated in such a manner that prevents damage to person or property.

Never carry out adjustments, repairs, maintenance and service work on the "Balercontrol" while the machinery is running. Always first stop the pto shaft and detach the universal drive shaft from the power take off stub before working on the baler or near moving baler components. A safety clearance from the machine must be maintained during baler control diagnosis.

11.2. Protection of the electronic control system

• All assembly and maintenance work (connection and

disconnection of sensors, valves, control panels etc., replacing of fuses) must be carried out with the power supply disconnected.

• "Balercontrol" is designed to operate with a 12 volt power

supply. The system must not be connected to other on-board power supplies!

• The "Balercontrol" control panel should at all time be in a

position where it is protected from water spray (tractor cab or the baler twine compartment, with the cable outlet pointing downwards).

• When welding on the baler:

- Do not allow the welding current to pass through the

control unit.

- Disconnect the power supply between the tractor and

baler.

- Be careful of heat generated at welding points; detach

any potentially sensitive components (cables, sensors etc) before welding.

66 WELGER RP 202 • RP 220 • RP 302 • RP 320

11.3. The "BALERCONTROL III" Control Panel

RP 220 • RP 320 MASTER / PROFI

Important baler functions can be controlled and monitored with the control panel remotely from the tractor.

Read and observe the separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“.

The control panel (fig. 83) consists of:

• LCD graphic display

• Keypad with 9 buttons

• Audible buzzer on the back side of the panel

After connecting the power supply the signal sounds and various information about the system appears on the display one after the other. After approx. 4 seconds the final display appears.

11.4. Menu structure

(See separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“)

fig. 83

WELGER RP 202 • RP 220 • RP 302 • RP 320 67

12. Maintenance / Settings

12.1. General instructions

After about the first 20 operating hours: tighten all fastening screws, wheel nuts, drawbar screws and nuts, including those inside the machine. When doing so, do not change adjustment screws, e.g. on the twine guide or the net brake.

12.2. Environment/Disposal

Lubricants

Always dispose of lubricants properly and do not allow them to pollute the environment. Observe the safety data sheets of the lubricants used. Biologically degradable lubricants must be disposed of separately.

1 litre of oil contaminates 1 million litres of water. 1 litre of oil contaminates 10 cubic metres of soil.

Consumables

Any twines, nets, foils and machine parts thrown away are polluting. They particularly endanger the animal world.

Therefore: Dispose of twines, nets, foils and machine parts properly!

12.3. Clamping elements

(fig. 84) The gear wheels [2] of the main drive roller [1] are installed on the roller end by means of clamping elements. Any work on the clamping elements [3] may only be carried out by instructed expert personnel.

fig. 84

68 WELGER RP 202 • RP 220 • RP 302 • RP 320

12.4. Maintenance of the net wrapping system*

Setting the disc brakes

In order to prevent the net roll from running on, the disc brake must be set such that the brake disc can no longer be turned by hand when the lever [1] is vertical.

In order to do this, undo screw [2] on the lever [1], tighten up knurled nut [3] until the brake linings lie snugly on the disc. Tighten up screw [2] once again

If there is excessive wear on one side of the brake disc lining [4], undo the lock nut [5], turn the screw [6] until the brake linings are parallel again and re-apply the lock nut [6].

1721-50

fig. 85

1742-54

fig. 86

WELGER RP 202 • RP 220 • RP 302 • RP 320 69

Setting the oscillation damper

The motion of the net tensioner [12] is braked with an oscillation damper on the left side of the baler.

Two wing nuts (arrows in fig. 87) press the friction pads against the net tensioner from both sides. To set the net tensioner, first of all move it into its highest position and do up the wing nut "finger-tight". Do the same for the lowest position. The setting is correct when the net tensioner can still just be moved up and down by hand between the two limiting positions.

When operating the net wrapping system, the net tensioner should move slowly enough between the two end positions so that the net always remains tensioned.

Danger of injury! Never reach into the cutting knife area.

12.5. Standby wrapping operation

In the event of a defect in the electronic control system, the twine or net wrapping unit can be operated using the electric lighting system. The plug-in connection [1] that protrudes from the cable harness on the right side of the baler is used for this.

12.5.1. Emergency operation of the net wrapping unit (BC III and BC E)*

The black connection plug [1] of the electrical net clutch is simply plugged into the free white plug connection [2]. To trigger the net wrapping process, briefly switch on the parking light (or the passing beam or full beam) until the net is caught by the bale (recognisable by the faster rotation of the net roll).

12.5.2. Emergency operation of the twine wrapping unit (BC III only)*

The red connection plug [3] for twine wrapping is simply plugged into the free white plug connection [2]. To trigger the twine wrapping process, briefly switch on the parking light (or the passing beam or full beam) until the twine is caught by the bale. This emergency operation requires that the main power supply system between tractor and machine works properly.

Note:

• Interrupt the provisional electrical connection for the net or

twine wrapping unit if the vehicle lighting is to be switched on for a long duration, e.g. when driving on the road.

1742-21

fig. 87

fig. 88

70 WELGER RP 202 • RP 220 • RP 302 • RP 320

12.6. Balercontrol components

RP 220 • RP 320 MASTER / PROFI

No. No.

1 Control unit 10 Magnet, net wrapping* (N)

Sensor cutting device (S)

11 Motor, twine wrapping* (G)

Pressure switch (D)

, opener at 35 bar

Hydraulic switch1) A (0)

4 Sensor, right lock (R) Ø 30 mm 13

Hydraulic switch

A1 (1)

5 Sensor, left lock (L) Ø 30 mm 14

Hydraulic switch

A2 (2)

6 Sensor, bottom flap (G) 15

Hydraulic switch

A4 (4)

7 Sensor, right twine run (1) 16 Left clearance sensor, yellow (L)

8 Sensor, left twine run (2) 17 Right clearance sensor, yellow (R)

9 Sensor, net cutting knife (N)

1) Only for models with a cutting device

fig.89

WELGER RP 202 • RP 220 • RP 302 • RP 320 71

12.7. Hydraulic diagrams

RP 220 • RP 320 MASTER / PROFI

Circuit Logic

Solenoid valve Control valve Blade Bottom

Switch position A A1 A2 A4 P P2

Cutting

Pressure switch closed

open

closed

closed open

➜

Cutting

position

Rest position

closed

device

Pressure switch open

closed closed

closed open

Bottom flap

closed closed

open open

➜

Rest position

open

closed

Pick-up unit

closed open closed closed

➜

Symbol:

= voltage at solenoid valve

➜ = line is pressurised

BALERCONTROL

Cutting position Rest position

1742-58

Screw valves must be closed

0,7 mm

Cutting device

2x 0953.22.01.00 20 bar

Hydraulic switch 0952.58.22.00

openclosed

Release valve opens at 35 bar

Pick up

Bottom flap

fig. 90

72 WELGER RP 202 • RP 220 • RP 302 • RP 320

RP 220 FARMER • RP 320 FARMER

with cutting unit and without swivel floor

Note: During baler operation, the changeover valve "U" must

always point towards the machine centre.

fig. 91

WELGER RP 202 • RP 220 • RP 302 • RP 320 73

RP 220 FARMER • RP 320 FARMER

with cutting unit and swivel floor

2.00 m pick-up unit only (see Table 1)

Note:

• During operation, the shut-off valve [1] must be closed, otherwise the floor may lower itself.

• During baler operation, the changeover valve "U" must always point towards the machine centre.

fig. 92

74 WELGER RP 202 • RP 220 • RP 302 • RP 320

RP 220 • RP 320 FARMER / MASTER / PROFI

with cutting unit and swivel floor

2.25 m pick-up unit only (see Table 1)

Note: During baler operation, the changeover valve "U" must

always point towards the machine centre.

fig. 93

WELGER RP 202 • RP 220 • RP 302 • RP 320 75

12.8. Sensor settings*

There are three types of sensors installed:

No. Designation

Application

RP 220

RP 320

RP 202 RP 302

Setting

Sensor

M 12

∅ 12 mm

• Cutting Device*

• Bottom flap*

• Right twine run

• Left twine run

MASTER

PROFI

0,5 - 2,0 mm

Sensor

M 30

∅ 30 mm

• Lock, right

• Lock, left

• Net cutting knife*

MASTER

PROFI

5 mm

1742-24

• Basic density setting

FARMER CLASSIC

SPECIAL

only possible using special tools

Part No.: 0980.70.01.00 and: 1740.82.14.10

Clearance sensor (yellow)

∅ 20 mm

• Tailgate clearance, right

• Tailgate clearance, left

MASTER

PROFI

- only possible using special tools

Part No.: 0980.70.01.00 and: 1740.82.14.10

76 WELGER RP 202 • RP 220 • RP 302 • RP 320

12.9. BALERCONTROL III - Quick check

RP 220 • RP 320 MASTER / PROFI

Step 1

⇒ Plug in the power supply connector;

• ........ The control panel sounds a bleeps ..........................................................................

• ........ Display lights up .......................................................................................................

• ........ The start-up message appears on the display.........................................................

• ........ Monitoring display appears.......................................................................................

• ........ Does the BALERCONTROL accept commands, e.g. density selection?.................

Step 2

⇒ Mode: Start SETUP

Check the settings:

• Dialog language.............................................................................................................

• Baler type.......................................................................................................................

• Delay 2.5 or 5 seconds .................................................................................................

Step 3

⇒ Mode: Start SYSTEMINFO

• View hardware and software and note as required......................................................

Step 4

⇒ Mode: Start DIAGNOSIS (alternatively: AUTO DIAGNOSIS)

• In

DIAGNOSIS / SENSOR, activate/deactivate each sensor, i.e. hold metal in front of

sensor and away from sensor; check for function, setting and correct position in the

display;...........................................................................................................................

• In

DIAGNOSIS / ANALOG, check the electrical values

Set values: a) unloaded: (0), approx.100 to 160, max. total of 305.............................

b) at maximum load: approx. 244 (10) 244.............................................

•

DIAGNOSIS / ACTUATOR, check all actuators for -/- and +/+.....................................

• In

DIAGNOSIS / VOLTAGE, check the operating voltage

− Voltage drop not greater than 1 - 2 Volts ..................................................

− Voltage under load not less than 11 volts ................................................

WELGER RP 202 • RP 220 • RP 302 • RP 320 77

12.10. Pin-outs of control unit RP 220 • RP 320 MASTER / PROFI

78 WELGER RP 202 • RP 220 • RP 302 • RP 320

12.11. Chain lubrication (oil lubrication)

The mechanical chain lubrication system supplies the drive chains of the machine with oil.

• Check the oil level in the lubrication oil tank daily (visual inspection). Never let the lubrication oil tank run completely empty.

Warning! Check oil level daily. Avoid complete emptying. Otherwise air may enter the distribution system and the pump may possibly reach its full capacity only after some time.

Oil type: see chapter „12.13. Lubrication chart“.

If required: refill oil:

• Unscrew tank lid.

• Refill oil up to the Max mark.

• Screw down tank lid again.

• Check sieve in the lubrication oil tank for soiling or

blockage (visual inspection).

If necessary: clean tank sieve:

• Unscrew tank lid.

• Remove tank sieve.

• Thoroughly clean the tank sieve using exclusively benzine

or paraffin oil.

• Insert tank sieve and screw tank lid down again.

Subsequently:

• Check oil level in oil tank.

Warning! Never use for cleaning: Tri, Per, Methanol, Acetone or other polar, organic solvents.

fig. 94

WELGER RP 202 • RP 220 • RP 302 • RP 320 79

12.12. Roller lubrication (grease lubrication)

The electrical roller lubrication system supplies the baling rollers of the machine with grease.

The electrical roller lubrication system runs continuously as long as the machine is connected to power supply. Therefore:

• When the machine is not in use (e. g. longer downtimes, ,

driving on the road, power supply must be interrupted (pull plug).

Please observe the separate operating instructions for the roller lubrication system (attached to the lubricant tank).

• Check filling level in the lubricant tank daily (visual

inspection). Do not allow the level to drop below the minimum mark.

Warning! Do not allow the level to drop below the minimum mark. Otherwise air may enter the distribution system, and deairing may become necessary.

Grease type: see chapter „12.13. Lubrication chart“.

If necessary: Refill grease:

• Clean filling nipple on lubricant tank.

• Fill lubricant tank via the filling nipple using a lever-type

grease gun.

fig. 95

80 WELGER RP 202 • RP 220 • RP 302 • RP 320

12.13. Lubrication chart

after every 500 bales (or daily)

Item

(fig. 96)

Baler component Lubricant

(Table 4)

Remark

1 Universal drive shaft A

2 Chain lubrication B Right side of baler

(fig. 94 and fig. 96)

3 Tailgate hinge1) A Both sides

4 Lubricating manifold*, left front

Lubricating manifold*, right front

not shown in fig. 96

5 Lubricating manifold*, left rear

Lubricating manifold*, right rear

not shown in fig. 96

Locking hook

A Both sides

7 Locking roller A Both sides

Cutting rotor*

A Both sides

9 Swivel wheels* A Both sides

10 Tailgate guide dome A On right side of baler: grease

11 Pick-up unit 2.00 m (SPECIAL):

• bearing of actuator (1x)

• bearing of rake shaft (2x)

• Sliding bearing of rake (2x)

A not shown in fig. 96

18 Roller lubrication F Right side of baler

(fig. 95 and fig. 96)

depending on the fitted equipment, already served by central lubricating manifold

Supply the lubricant distributor with 1 - 2 cautious strokes from a hand lever grease gun – do not use a

compressed air grease gun.

yearly after the end of season (weekly under extreme operating conditions)

Item

(fig. 96)

Baler component Lubricant Remark

12 Star ratchet in the pick-up unit drive A

For 1.50 m pick-up, only installed outside the EU

13 Main gear box

• RP 202 / RP 302

• RP 220 / RP 320

• RP 220 / RP 320 („V V“)

C / 1,65 l

C / 1,50 l

C / 2,00 l

Oil change

Check oil level with dipstick or overflow hole

14 Moveable parts of the net wrapping

system*

D Keep running smoothly

15 Moveable parts of the twine wrapping

system*

D Keep running smoothly

16 Locking hook disc spring E

Dismantle, clean and grease; Warning: do not change sensor settings!

17 Twine guide eyes A Lightly grease chafe mark

Gearbox is labelled on the top side with the letters "V V"

WELGER RP 202 • RP 220 • RP 302 • RP 320 81

12.14. Schematic diagram of the lubricating positions

Lubricant Trade name, e. g.

A Multi-pupose grease Fuchs Renolit FEP 2

Bechem High-Lub LM 2 EP

BP Energrease LS-EP2

Elf Epexa 2

Esso Beacon EP 2

B Chain lubrication Oil according ISO VG 68 – ISO VG 220 (non thickening)

B Chain-adhesive oil Optimol Non Fluid 150

C Gear oil SAE 90

D Machine oil - - -

E Multi-pupose grease Gleitmo 810

F Multi-pupose grease Multi-pupose grease according NLGI-Class 2,

with high-pressure additive, without solids

Table 4: Specification of lubricants

fig. 96

82 WELGER RP 202 • RP 220 • RP 302 • RP 320

Never carry out adjustments and repairs, or maintenance and service work on the baler while it is running. Switch off engine and remove the ignition key Wait for the baler to stop. Switch off the pto shaft and disconnect the universal drive shaft from the pto shaft before working on the moving parts of the baler.

If maintenance or installation/assembly work is performed with the tailgate open, it is essential to secure the tailgate to prevent it from falling.

Use the cut-off valve on the right side of the baler for this purpose. When it is in a locked state, the operating lever is at right angles to the direction of flow (fig. 3).

The shut-off valve may only be actuated from the open right hand side guard door.

12.15. Setting the dividing plates

In order to prevent binding material from coming out of the roll chamber, two dividing plates [1] were built into the area near the front rollers (fig. 97). Upon loosening the fastening screws in the side walls, the dividing plate clearance to the rollers can be set. For correct setting, the longitudinal section of the operating rollers should just about gently strike the dividing plates. Finally tighten the screws once again.

1742-49

fig. 97

WELGER RP 202 • RP 220 • RP 302 • RP 320 83

12.16. Tensioning the roller chain

Proper chain tensioning reduces wearing of chains, chain wheels and bearings on rollers. The tension of the chain should be checked at the latest every 500 bales and re-adjusted as required.

Note: New chains will lengthen shortly after placing them into

operation. Therefore these can be tensioned a little more than usual.

Rotor drive chain

The double chain of the rotor drive must be tensioned so far that the distance between the two pulleys is about 70 mm (fig. 98).

Roller drive chains

The chains of the roller drives must be tensioned so far that the spring plates are approximately flush with the measuring angles (fig. 99 and fig. 100).

fig. 98

fig. 99

fig. 100

84 WELGER RP 202 • RP 220 • RP 302 • RP 320

Main drive chain

The main drive chain must be tensioned so far that the distance between the upper and the lower pulley is about 90 mm (fig.

101).

Worm and pick-up drive chain

Chain tensioning of the worm and pick-up drive chain is effected by a silentbloc chain tensioner and two tensioning blocks (fig.

102).

After loosening of the screw on the square block the silentbloc must be turned to the effect that the arrow reaches 15° on the scale. Then retighten the screw.

After loosening the screw connection, tension the tensioning blocks (one each on the left and on the right machine side) so far that the upper strand of the chain (above the tensioning block) can still be depressed by about 10 mm.

12.17. Winter break

Before a winter break:

• Remove all crop residues from the machine.

• Thoroughly lubricate all bearings.

• Remove, grind and reinstall cutter blades.

• Grease wrapping unit.

• Check and – if necessary – adjust air pressure.

fig. 101

fig. 102

WELGER RP 202 • RP 220 • RP 302 • RP 320 85

12.18. Tyre air pressure

Tyre size max.

speed.

RP 202

CLASSIC SPECIAL

RP 220

FARMER MASTER

PROFI

RP 302

CLASSIC SPECIAL

RP 320

FARMER MASTER

PROFI

25 km/h 2,3 bar



3,0 bar



11.5/80-15.3 Impl.8 PR

40 km/h



3,0 bar



3,0 bar

25 km/h 1,5 bar



1,8 bar



15.0/55-17 Impl. 10 PR

40 km/h



1,8 bar



2,1 bar

25 km/h 1,3 bar



1,5 bar



19.0/45-17 Impl. 10 PR

40 km/h



1,5 bar



1,7 bar

25 km/h

   

500/50 R17 146 D

40 km/h



3,4 bar



3,4 bar

25 km/h

   

500/55-20 Impl. 12 PR

40 km/h



1,5 bar



1,5 bar

25 km/h

   

500/60-22.5 Impl. 8 PR

40 km/h



1,5 bar



1,5 bar

16 È 6.50-8 4 PR

pick-up unit support wheels: 2,0 bar

86 WELGER RP 202 • RP 220 • RP 302 • RP 320

13. Technical Data

RP 202 RP 220

Roll chamber (∅ x width) [m]

approx. 1.25 x 1.23 approx. 1.25 x 1.23

Twine wrapping* with

a) Hemp twine

Running length: 200 or 330 m/kg

b) Plastic twine

Running length: 400 to 750 m/kg

Net wrapping* with

Quality roll bale net

Length: 2000 or 3000 m / width: max: 1.30 m

Binding material supply

Twine / Net

4 rolls / 2 rolls

4 rolls / 2 rolls1)

Pick up unit

Pick up unit width [m]

1.50 2.00 2.00 2.25

Rake width [m] DIN 11220

1.35 1.80 1.80 2.06

Rpm of tractor pto shaft [min

]

540 540

Required outlets Lighting outlet

12 V (7-pin plug)

 

Wrapping control outlet (BALERCONTROL) 12 V DIN 9680 A

 

Max. length [m] 4.21 4.50

Width, without pick-up unit support wheels [m] 2.30 – 2.56

Height [m] 2.44 – 2.54

Shipping weight, with binding materials at least [kg]

see data plate on the baler

Model-dependent permissible maximum speed limit

CLASSIC, SPECIAL

25 km/h

–

FARMER, MASTER, PROFI, without brakes

–

25 km/h

FARMER, MASTER, PROFI, with air brakes

–

40 km/h

WELGER RP 202 • RP 220 • RP 302 • RP 320 87

RP 302 RP 320

Roll chamber (∅ x width) [m]

approx. 1.50 x 1.23 approx. 1.50 x 1.23

Twine wrapping* with

a) Hemp twine

Running length: 200 or 330 m/kg

b) Plastic twine

Running length: 400 to 750 m/kg

Net wrapping* with

Quality roll bale net

Length: 2000 or 3000 m / width: max: 1.30 m

Binding material supply

Twine / Net

4 rolls / 2 rolls

4 rolls / 2 rolls1)

Pick up unit

Pick up unit width [m]

1.50 2.00 2.00 2.25

Rake width [m] DIN 11220

1.15 1.60 1.60 1.86

Rpm of tractor pto shaft [min

]

540 540

Required outlets Lighting outlet

12 V (7-pin plug)

 

Wrapping control outlet (BALERCONTROL) 12 V DIN 9680 A

 

Length [m] 4.48 4.78

Width, without pick-up unit support wheels [m] 2.30 – 2.56

Height [m] 2.57 – 2.61

Shipping weight, with binding materials at least [kg]

see data plate on the baler

Model-dependent permissible maximum speed limit

CLASSIC, SPECIAL

25 km/h

FARMER, MASTER, PROFI, without brakes

25 km/h

FARMER, MASTER, PROFI, with air brakes

40 km/h

Data is approximate only and not legally binding. Configurations may vary.

Only 1 net roll can be inserted if twine wrapping is installed

Pay attention to applicable national road traffic regulations that may differ!

* Optional or additional equipment

Englisch

EC Declaration of Conformity

according to Directive 98/37/EEC

We Welger Maschinenfabrik GmbH

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

(Name of supplier)

Gebrüder-Welger-Straße, D-38304 Wolfenbüttel

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

(full address of the manufacturer - authorized representative established in the Community must also give the business name and address of the manufacturer)

declare under our sole responsibility, that the product

WELGER RP 202 / RP 220 / RP 302 / RP 320

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

(Make, model)

to which this declaration relates corresponds to the relevant basic safety and health requirements of the Directives 98/37/EEC and 89/336/EEC,

(if applicable)

and to the requirements of the other relevant Directives:

– – –

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

(Title and/or number and date of issue of the other Directives)

(if applicable)

For the relevant implementation of the safety and health requirements mentioned in the Directives, the following standard(s) and/or technical specification(s) has (have) been respected:

EN 704, EN 1553

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

(Title and/or number and date of issue of standard(s) and/or technical specification(s))

Wolfenbüttel, February 2004

Welger RP 302 SPECIAL, RP 320 FARMER, RP 320 MASTER, RP 320 PROFI, RP 220 MASTER Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual