Lely Welger: Operating Manual

LELY WELGER
RP 405 / 435 / 505 / 535
RP 435 MASTER
1755.99.03.03 10.08
Operating Manual
Send back to:
Lely International N.V.

TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbttel
Handover declaration 1
(Copy for the Manufacturer)
Complete and return this document within 4 weeks when the machine is delivered.
Possible guarantee requests cannot be handled before this document has not been sentback.
Date of delivery:
........................................................................
Machine type:
RP 405 / RP 435 / RP 505 / RP 535

........................................................................
Machine no. on the data plate (e. g. 1755.00.001):
........................................................................
I purchased / use this machine.

The operating manual including the EC conformity declaration (page next to the last in the operating manual) was delivered to me together
with the machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine.
Some components of the machine may have been removed for transportation.Do not use the machine unless these
components have been correctly installed again!
The following components must be reinstalled prior to first commissioning:
RP 405 / RP 435:
Wheels:
Maintenance platform:
Railing:
Guard hoods on pick-up:
Pick-up guide wheel:
Pick-up guard rail:
Support foot:
Ladder on support foot:
Drawbar head:
Branch deflector on machine roof:
Sensor support with sensor:
Chain tensioning blocks:
Bale ejector shock absorber:
Handles of side cover:
Hydraulic system control block:
see spare parts list pages A10, A20, A21

see spare parts list page K25 (items 0106, 0810, 1214)
see spare parts list page K25 (item 11)
see spare parts list page C25 (items 7, 8)
see spare parts list pages C30, C35
see spare parts list page B30
see spare parts list page K25 (items 15-20)
see spare parts list page J80 (item 45)
see spare parts list page J80 (items 25, 32)
see spare parts list page C10 (item 11)
see spare parts list pages K10, K11 (items 35)
see operating manual page 31
RP 505 / RP 535:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:

see spare parts list page K25 (items 15-20), page B35 (items 56)
Before first use: Unlock hydraulic of bottom door

(see chapter "7.4.2 Release bottom door")
..............................
.............................................................
Date
Customer's signature
Send back to:
Lely International N.V.

TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbttel
M
Complete and return this document within 4 weeks when the machine is delivered.
Possible guarantee requests cannot be handled before this document has not been sentback.
Customer
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
Marketing partner/Importer
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
..............................
Date
.............................................................
(Copy for the Customer)
Complete this document when the machine is delivered and keep it.
Date of delivery:
........................................................................
Machine type:
RP 405 / RP 435 / RP 505 / RP 535

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

RP 405 / RP 435:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:

RP 505 / RP 535:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:


..............................
.............................................................
Date
M
Customer
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
..............................
Date
.............................................................
(Copy for the Trader)
Date of delivery:
........................................................................
Machine type:
RP 405 / RP 435 / RP 505 / RP 535

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

RP 405 / RP 435:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:

RP 505 / RP 535:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:


..............................
.............................................................
Date
M
Customer
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
..............................
Date
.............................................................
(Copy for the Importer)
Date of delivery:
........................................................................
Machine type:
RP 405 / RP 435 / RP 505 / RP 535

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

RP 405 / RP 435:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:

RP 505 / RP 535:
Wheels:
Railing:
Pick-up guard rail:
Support foot:
Drawbar head:


..............................
.............................................................
Date
M
Customer
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
Name:
Street:
..................................................................................
...................................................................................
Postcode/Place:
Land/State:
..................................................................................
...................................................................................
Phone:
eMail:
..................................................................................
...................................................................................
..............................
Date
.............................................................
The serial number is shown on data plate on the right

machine side, as shown aside. Warranty claims and queries
cannot be dealt with unless the serial number is stated.
Please enter this number here immediately after delivery:
..............................................................................
Read and heed the operating instruction and safety instructions prior to commission the machine. In
this operating instruction all positions required for safety reasons are marked with a warning sign. Instruct
all other operators in safety instructions! The warning- and information signs located at the machine give
information for safe operation. Watch them for safety reasons!
Read and heed the separate operating instruction "E-LINK for RP 435 MASTER / RP 535 MASTER".
* Please watch, that the equipment marked with a [*] in this operating instruction, belong only to defined
types of the machine or that they are only deliverable for defined types as additional equipment.
Copy is not permitted - copyright and technical changes are reserved.
Illustrations are not binding on form and design.
2006 by Welger Maschinenfabrik GmbH, Wolfenbttel. Made in Germany.
Maschinenfabrik GmbH
Gebrder-Welger-Strae 3 D-38304 Wolfenbttel
Phone: (+49) 53 31 / 404-142 Fax: (+49) 53 31 / 404-143
eMail: wmf@welger.com
WELGER RP 405 RP 435 RP 505 RP 535
Table of Contents
1 VARIANTS ................................................................................................................................................... 6
2 SAFETY........................................................................................................................................................ 8
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
General safety instructions................................................................................................................. 8

Noise level........................................................................................................................................ 10
Instructions for fire protection........................................................................................................... 10
Tail gate safeguard........................................................................................................................... 11
Maintenance Platform and Ladder ................................................................................................... 11
Hydraulic System ............................................................................................................................. 12
Guard casings .................................................................................................................................. 13
WARNING SYMBOLS ..................................................................................................................... 14
Symbolised operating instructions ................................................................................................... 17
Proper use........................................................................................................................................ 21
Electromagnetic compatibility........................................................................................................... 21
To heed in the road traffic ................................................................................................................ 22
Environment/Disposal ...................................................................................................................... 26
3 ASSEMBLY GROUPS ............................................................................................................................... 27

4 START UP.................................................................................................................................................. 28
4.1
4.2
4.3
4.4
4.5
4.6
Coupling the baler ............................................................................................................................ 28

Drive shaft ........................................................................................................................................ 31
Hydraulic System ............................................................................................................................. 33
Electrical system .............................................................................................................................. 36
Compressed-air braking system ...................................................................................................... 37
Hydraulic braking system ................................................................................................................. 38
5 TWINE TYING*........................................................................................................................................... 39
5.1
5.2
5.3
5.4
5.5
Threading the twine.......................................................................................................................... 39

Adjusting the twine brake ................................................................................................................. 42
Setting the edge clearances............................................................................................................. 43
Adjusting the wrapping distance ...................................................................................................... 43
Edge wrapping adjustment............................................................................................................... 44
6 NET TYING* ............................................................................................................................................... 45

6.1
6.2
6.3
Inserting the net................................................................................................................................ 45

Tightening the net knife.................................................................................................................... 51
Adjusting the net length.................................................................................................................... 52
7 CUTTING DEVICE*.................................................................................................................................... 53
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Equipment ........................................................................................................................................ 53
Knife groups ..................................................................................................................................... 53
Moving in and out the cutting device................................................................................................ 56
Lock bottom door.............................................................................................................................. 71
Brittle crop material .......................................................................................................................... 72
Assembly and disassembly of the cutting device knives ................................................................. 72
Regrinding the cutting device knives................................................................................................ 73
8 FIELD USE ................................................................................................................................................ 74

8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
Locking the tail gate ......................................................................................................................... 75

Adjusting the bale diameter.............................................................................................................. 76
Setting the bale density.................................................................................................................... 77
Raising / lowering the pick-up .......................................................................................................... 78
Pick-up guide wheels ....................................................................................................................... 78
Windguard / Pick-up shield* ............................................................................................................. 79
Feed guide plate............................................................................................................................... 80
PTO speed ....................................................................................................................................... 80
Driving style...................................................................................................................................... 81
Safety clutch..................................................................................................................................... 83
9 OPERATION / TYING ................................................................................................................................ 84

9.1
9.2
9.3
9.4
BALERCONTROL E control box...................................................................................................... 84

E-LINK control box ........................................................................................................................... 87
Eject bales........................................................................................................................................ 91
Emergency operation ....................................................................................................................... 93
10 REMOVING A MATERIAL JAM ................................................................................................................ 98

10.1 Main drive reversing ......................................................................................................................... 98
10.2 Hydraulic bottom door*..................................................................................................................... 99
11 MAINTENANCE / SETTING .................................................................................................................... 102
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
General notes................................................................................................................................. 102

Grease knife lever .......................................................................................................................... 102
Tensioners...................................................................................................................................... 103
Maintenance of the net tying unit ................................................................................................... 103
Tensioning the roller chains ........................................................................................................... 104
Hydraulic layouts ............................................................................................................................ 105
Tire air pressure RP 405 / RP 435 ................................................................................................. 108
Tire air pressure RP 505 / RP 535 ................................................................................................. 108
Chain lubrication (oil lubrication) .................................................................................................... 109
Winter pause .................................................................................................................................. 111
Lubrication chart............................................................................................................................. 112
Lubrication points ........................................................................................................................... 114
12 TECHNICAL DATA.................................................................................................................................. 115
Variants
RP 405 SPECIAL
RP 435
RP 435 MASTER
2.00 m
2.25 m
NONCUT
Ring type rotor
PROFICUT
without cutting device
MASTERCUT
13-knife
XtraCut 17
17-knife
XtraCut 25
25-knife
firmly bolted
FLEXCONTROL
HYDROFLEXCONTROL
Net tying
Twine tying
BALERCONTROL E
with BCE control box
BALERCONTROL III
with E-LINK control box
Pick-up width
Rotor
Cutting device
Bottom
Tying
Control
z
}
=
=
=
series equipment
variant
not available
RP 505 SPECIAL
RP 535
RP 535 MASTER
2.00 m
2.25 m
NONCUT
Ring type rotor
PROFICUT
without cutting device
MASTERCUT
13-knife
XtraCut 17
17-knife
XtraCut 25
25-knife
firmly bolted
FLEXCONTROL
HYDROFLEXCONTROL
Net tying
Twine tying
BALERCONTROL E
with BCE control box
BALERCONTROL III
with E-LINKControl box
Pick-up width
Rotor
Cutting device
Bottom
Tying
Control
z
}
=
=
=
series equipment
variant
not available
Safety
2.1
General safety instructions
Attention!
Even if all instructions are observed the machine involves
residual dangers. Always handle the machine with care to avoid
danger to yourself and others!
x Before starting work perform a visual inspection of the
machine. Check whether any device has been changed or is
missing and pay attention to any unusual noise or leaks
which occur during operation.
x All protective devices, as for example casing sheets, rubber
skirts or distance brackets are for your safety! Never operate
the machine with defective or removed protective devices e.
x Keep all safety relevant parts always in correct function.
Before commissioning all guard casings must be mounted
and closed!
x Never perform maintenance- and repair works during
machine is in operation.
x In case of all work on movable parts or in the range of action
of movable parts: Switch off power take-off shaft, switch off
tractor engine, remove ignition key and disconnect drive
shaft from power take-off shaft end. Interrupt electrical
connection between tractor and machine.
x Bring no metal parts close to the machine, as long the
electric control is in operation (e.g. tools, safety boots with
metal caps). Reason: unintentional triggering of proximity
switches and thus unexpected machine moves.
x When carrying out work on the opened tail gate: insert tail
gate safeguard (chapter 2.4 Tail gate safeguard).
x Never remove any crop material from the machine while the
drive is running, or while the disconnected machine is still
moving. Always switch-off power take-off shaft and tractor
engine first.
x During work only the driver must be on the tractor. Riding on
the machine is prohibited!
x Never step onto the maintenance platform during machine is
in motion. Before stepping onto the maintenance platform:
stop machine, switch-off power take-off shaft and tractor
motor, take out ignition key and wait for standstill of the
machine.
x Do not step onto the drawbar or other parts of the machine,

when the machine is in operation. Keep sufficient distance to
baler (pick-up, running gear, bale unloading area).
x Before threading the tying material: stop machine, switch-off
power take-off shaft and tractor motor, take out ignition key
and wait for standstill of the machine. Make the control
powerless (disconnect electrical connection to the tractor).
x All protection devices must be mounted to the baler and
must be in correct state. Prior to opening the protection
devices switch-off power take-off shaft and tractor motor and
wait for standstill of the machine.
x Block the wheels of the baler with wheel chocks when
machine is parked. Carry the chocks on the machine when
transporting it or during field use.
x When opening the tail gate keep a minimum distance of 2 m
from electrical high-voltage lines.
x There is danger of cutting during works at the net knife or at
the knives of the cutting device of the baler. Wear protective
gloves.
x Works at the magnets of the knife holders: the function of
cardiac pacemakers can be interrupted by magnetic fields.
x Works at the magnets of the knife holders: Danger of injury
by splinters never hit the inserted knives from below with a
striking tool. Magnets could be damaged!
x Maintenance work may be carried out by trained persons
only. All maintenance- and repair works that are not part of
this operating instruction must be carried out by authorised
personnel only.
x Replace wearing parts of the braking system only at both
sides.
x Prior to disassembling the complete pick-up the machine
must be secured against backward tilt.
x In case of locations on a slope: place the round bales always
so that they cannot move automatically.
2.2
Noise level
The EC directive 86/188/EEC (or EC directive 2003/10/EC)

concerning noise at the workplace instructs employers and
employees to assess noise at the place of work and to control it.
The noise level during normal field work is subject to variations
which depend on the one hand on the noise level of the tractor
and on the other hand on the deployment conditions of the
baler.
The noise level generated by the WELGER balers, measured at
the head height of the driver with the tractor cabin window
open, is, under normal operating conditions, less than 70 dB
(A). The combined noise level of baler and tractor primarily
depends on the level of the noise from the tractor (radios are an
additional source of noise). We recommend that the tractor is
operated with closed windows.
2.3
Instructions for fire protection
The harvested crop can easily ignite! To prevent fire:

x remove crop remains and oil leaks.
x If any machine parts run hot: find and remove cause.
x Do not begin a journey with the machine attached unless the
manually operated brake has been completely released.
Otherwise there is danger of fire by brakes running hot (e. g.
in the field).
x Keep the electrical systems of tractor and baler and the
exhaust system of the tractor in proper condition.
Figure 1
x The existing wiring must not be used for any other

consumers than those installed in the factory or approved by
the manufacturer. Overloading the electrical lines leads to
excessive heating.
x Do not smoke in the vicinity of the machine.
x Keep fire extinguisher within reach.
10
2.4
Tail gate safeguard
If any short-time maintenance or assembly work is carried out

with the tail gate open, the tail gate must be hydraulically
secured against lowering: use shut-off valve (on the
maintenance platform). When the valve is shut off, the actuating
lever is at right angles to the flow direction (Figure 2).
In case of longer maintenance or assembly work with the tail
gate open, the tail gate must (in addition to the hydraulic
safeguard) be mechanically secured against lowering - using
suitable means.
Figure 2
After completion of any maintenance and/or assembly work

reset the valve to its initial position (along flow direction, Figure
3) and/or remove the mechanical safeguard.
Figure 3
2.5
Maintenance Platform and Ladder
Attention, danger of falling!

Never step on the maintenance platform [14] (Figure 4), while
the machine is in motion. Before stepping on the maintenance
platform: stop machine, switch-off power take-off shaft and
tractor motor and wait for standstill of the machine.
Climb and leave the maintenance platform exclusively via the
ladder [10]. Never step on the ladder when folded up always
fold down the ladder before using it.
Figure 4
(Figure 4) To climb the maintenance platform: fold down the
ladder [10].
(Figure 4) Before the machine can move on: fold up and lock
the ladder [10] again.

(Figure 4, Figure 5) For transportation the railing [15] is
removed from the maintenance platform in the factory and
enclosed with the machine. The railing must be mounted again
before commissioning of the machine:
Take the dismounted railing [15] out of the machine.
Mount the railing [15] to the maintenance platform using the
6 enclosed screws [16] (Figure 5).
Figure 5
11
2.6
Hydraulic System
Max. operating pressure of the hydraulic system:

x 210 bar
During assembly work on the hydraulic system, in particular if
accumulators are used (Figure 6):
x Depressurise the hydraulic system (control unit to "Lower")
x Secure hydraulically operated components (pick-up, tail
gate, cutting device, HYDROFLEXCONTROL bottom door)
mechanically against uncontrolled movement.
According to DIN 20066 hoses must not be older than six years,
including storage time.
Figure 6
12
2.7
Guard casings
To comply with the European safety regulations, since Jan. 1,

1995 manufacturers of machines have been obliged according
to EN 704 to design fixed, isolating guard casings in such a way
that they can only be opened by means of a tool, and will
automatically lock again without the need for a tool.
Figure 7
Open guard casings:

(Figure 7): Using a 13 mm spanner turn the hexagon head of
the locking mechanism slightly in counterclockwise direction
the casing engages in a safety catch.
(Figure 8): RP 405 / RP 435: Push safety catch up. The
casing opens fully.
(Figure 9): RP 505 / RP 535: Push safety catch down. The
casing opens fully.
To close the casing, press the panel against the machine so
that the locking mechanism can be heard to engage.
RP 405 / 435
Figure 8
Attention, danger of injury!

Never operate the machine with open guard casing!
Open guard casings only, when a free swivelling area is
available.
Never operate the machine with defective or removed protective
devices (e. g. guard casings and distance bracket). Before
opening the protections: Switch off p.t.o. shaft drive and tractor
engine, wait until machine has stopped, remove the ignition
key.
RP 505 / 535
Figure 9
13
2.8
WARNING SYMBOLS
2.8.1
Symbols in this manual
Instructions of particular importance in this manual are marked
by the following symbols and signal words:
Attention!
This symbol stands next to warnings: danger to life, danger of
injury, possible serious material damage.
Caution!
This symbol stands next to safety instructions: malfunctions and
impairments of correct operation, possible material damage.
Note!
This symbol stands next to useful information: special
information on how to use the machine most efficiently.
2.8.2
Symbols on the machine
Danger zones that cannot be secured by construction are
labelled with prohibition signs and yellow warning symbols.
Because they are without text in most cases the exact meaning
is described in the following.
The symbols must always be kept in recognisable state.

If any symbols on this machine are missing or have been
damaged, they must be replaced.
Prohibition signs
Meaning / Spare part No.

No smoking!
Spare part no.: 0388.37.00.00
Do not step on the area!
Spare part no.: 0386.11.00.00
14
Warning symbols

Read and heed the operating instruction and safety
instructions prior to commission the machine.
Spare part no.: 0388.11.00.00
Close guard casings prior to commissioning the machine!
Spare part no.: 0389.92.00.00
Never reach into the pick-up section when the tractor engine
is running and the power take-off shaft is coupled.
Spare part no.: 0389.94.00.00
Switch-off motor and take out the ignition key prior to

maintenance- and repair works.
Spare part no.: 0388.25.00.00
Switch-off motor and unplug the plug of the power supply prior
to maintenance- and repair works.
Spare part no.: 0388.13.00.00
Stay clear of tail gate swinging area while in operation.
Spare part no.: 0389.93.00.00
15
Riding on the machine, on treads or on the platform is

prohibited.
Spare part no.: 0391.06.00.00
Handle cutting unit blades only with gloves and suitable tool
Spare part no.: 0387.33.00.00
The accumulator is under gas and oil pressure. Depressurise

hydraulic system prior to disassembling or repair.
Spare part no.: 0387.37.00.00
Activate tail gate safeguard prior to enter the roll chamber.
Spare part no.: 0394.98.00.00
16
2.9 Symbolised operating instructions

The most important operating instructions are shown as symbols without text. The precise meaning is
described in the following.
Symbols
The two lift eyes at the upper traverse are indicated by this
symbol.
Other fastening points are not permitted for crane suspension.
Spare part no.: 0389.48.00.00
Note on crane loading

To ensure safe loading of the machine either a spreader must
be used, or the transport chain must have a minimum length
of 2.40 m.
Spare part no.: 0386.46.00.00
Tail gate locking device

If the lever is positioned at right angles to the flow direction,
the tail gate is secured against lowering.
Spare part no.: 0387.66.00.00
Maximum permissible hydraulic pressure

The machine may only be connected to a hydraulic system
providing a maximum oil pressure of 210 bar.
Spare part no.: 0387.36.00.00
Adjusting the variable load valve

For driving on the road, the variable load valve of the
compressed-air brake must be set to "full brake force"
.
Spare part no.: 0385.01.00.00
17
RP 405 / RP 435
Locking of the belt lever for maintenance purposes
Spare part no.: 0386.45.00.00
RP 505 / RP 535
Locking of the belt lever for maintenance purposes
Spare part no.: 0387.64.00.00
RP 405 / RP 435
Opening of the lateral guard casings
Using a 13 mm spanner turn the hexagon head of the
locking mechanism slightly in counterclockwise direction

Push safety catch up. The casing opens fully.
Ersatzteil-Nr.: 0386.43.00.00 (linke Schutzverkleidung)
Ersatzteil-Nr.: 0386.44.00.00 (rechte Schutzverkleidung)
RP 505 / RP 535
Opening of the lateral guard casings
Using a 13 mm spanner turn the hexagon head of the
locking mechanism slightly in counterclockwise direction

Push safety catch down. The casing opens fully.
Spare part no.: 0387.81.00.00 (l.h. side guard casings)
Spare part no.: 0387.80.00.00 (r.h. side guard casings)
18
Guard lever for cutting unit blade

To unlock the cutting unit blades the lever must be turned
down through about 90.
Spare part no.: 0387.31.00.00 and 0387.32.00.00
Setting of the bale density
Spare part no.: 0387.65.00.00
Adjustment of the bale density for emergency operation
Spare part no.: 0387.96.00.00
Lubrication! 1 x per day, check lubrication and relubricate if

necessary.
Spare part no.: 0387.63.00.00
Thread scheme for net tying
Spare part no.: 0389.40.00.00
Thread scheme for twine tying
Spare part no.: 0386.79.00.00
Spare part no.: 0386.96.00.00
19
Twine tying
Distance between the individual windings
Spare part no.: 0387.40.00.00 (on the right in travelling
direction)
Distance of the last winding from the bale edge

Spare part no.: 0387.41.00.00 (on the left in travelling
direction)
Note on crane loading

To ensure safe loading of the machine either a spreader must
be used, or the transport chain must have a minimum length
of 2.40 m.
Spare part no.: 0386.46.00.00
Screw couplings on the drawbar head. Observe the required

torques!
Spare part no.: 0386.55.00.00
Required PTO speed

Spare part no.: 0396.45.00.00
20
2.10
Proper use
x The machine is exclusively constructed for pressing bales

from agricultural straw material lying on the floor (proper
use). Using the machine for any other purposes does not
constitute proper use. The manufacturer cannot be held
liable for any damage resulting from such use; the risk of
improper use lies entirely with the user.
x Operating the machine within the limits of its proper use also
involves complying with the operating, maintenance and
servicing conditions prescribed by the manufacturer.
x The bale weight must not exceed 1.5 t. I. e. the maximum
bale size may not be available for silage bales (dependent
on the quantity of moisture the bales must be smaller). Bale
sizes: See chapter "Technical Data".
x The machine may only be used, serviced and repaired by
persons who are familiar with such work and instructed on
the dangers involved.
x Attachment of additional equipment other than at the
positions provided by the factory is prohibited. Only
additional equipment must be used that is allowed by the
manufacturer.
x The relevant accident prevention regulations and all other
generally accepted safety rules must be observed.
x Unauthorised modifications and installation of non-approved
parts and equipment on the machine preclude any liability of
the manufacturer for any damage resulting therefrom.
x Any changes to safety-relevant parts will invalidate the
conformity declaration and the CE marking.
2.11
Electromagnetic compatibility
The machine is equipped with electronic components and

modules; the function of these electronic components and
modules can be influenced by electromagnetic emissions of
other equipment. Such influences can cause risks to persons, if
the following safety instructions are not observed:
In case of subsequent installation of electrical and electronic
equipment and/or components into the machine, it is the user's
responsibility to check whether the installation impairs the
vehicle electronics or any other components.
Ensure above all that the electrical and electronic components
subsequently installed are in conformity with the EMC directive
89/336/EEC as amended, and that they are provided with the
CE.
21
2.12
To heed in the road traffic
Attention!
Prior to driving on the road ...
x ... the roll chamber must be completely emptied (acc. to road
traffic regulations).
x ... remove any crop material hanging loosely from the baler.
x ... connect the drive shaft to the tractor power take-off shaft;
x ... insert the spars of the bale ejector *.
x ... the ladder of the maintenance platform must be turned up
and locked.
x ... connect the lighting set of the machine to the tractor and
check function (also at daylight).
x ... insert and secure the pick-up guide wheels* in upper
position (pick-up width 2.25 m).
x ... fully release the manually operated brake. Otherwise
there is danger of fire by brakes running hot (e. g. in the
field).
Prior to operate the baler with connected machine (e.g. round
bale wrapper), obtain information from the manufacturer.
The wheel chocks (2 in number) which are part of the safety
equipment are to be carried on the baler at all times.
Permitted maximum speeds of individual assembly groups (e.g.
drawbar or axis) do not count for the allowed maximum speed
of the total machine. In this document only type relevant
maximum speeds are listed. Any deviating national regulations
must always be observed.
The following regulation applies in Germany:
Machine
22
Equipment
perm. maximum speed
RP 405
with pneumatic brake system
40 km/h
RP 435
brakeless
25 km/h
RP 505
40 km/h
RP 535

with 500/60-22.5 tire equipment
25 km/h
2.12.1 Pneumatic brake system*:

Do not begin a journey with the baler attached unless both
coupling heads (yellow and red) are connected to the tractor
and the pressure gauge in the tractor cabin shows the required
operating pressure.
Attention, danger of accident!

Prior to each journey pay attention to the lever position of the
variable load valve of the pneumatic brake system. Wrong
setting reduces the traffic safety (see chapter 4.5.1 Adjust
variable load valve*).
Start driving on the road with connected baler only when the
variable load valve is set to full load (see chapter 4.5.1 Adjust
variable load valve*).
2.12.2 Hydraulic brake system*:

Start driving on the road only when the according hydraulic tube
is connected to the tractor.
2.12.3 Germany (StVZO road traffic regulations):

Agricultural machines with permitted total weight of more than
3,000 kg need a type approval. (Technical changes such as
attaching a trailer coupling will invalidate the type approval)
Prior to changes at the machine it must be solved, if the
changes are permitted or if they can added to the documents by
an expert.
Further heed the national regulations of the country where the
machine is in use.
23
2.12.4
Data plate specifications
Figure 10
Item Meaning
1
Trade name of the machine
Ident no. individual machine number, please state in case of inquiries.
Machine type, machine version
Permissible total weight for operation on public roads.

The actual weight can be less according to the equipment.
Exception (only in field use):
The actual weight of the machine plus bale in the chamber can be higher.
Maximum support load of the machine, that acts at maximum load of tying material* to the hitch.
The open-type towing fixture of the tractor must be registered for this support load.
Permitted axle load for operation on public roads.
Year of construction of the machine
Internal batch number
Manufacturer's name and address
24
2.12.5
RP 405 / RP 435 only: Specifications on the data

plate of the drawbar head
Note!
RP 505 and RP 535 have no data plates on the drawbar heads.
Figure 11
Item Meaning
1
Drawbar type
official mark of conformity
Permitted maximum total weight of the machine
Permitted maximum support load
25
2.13
Environment/Disposal
2.13.1
Lubricants
Dispose of lubricants properly and do not pollute the

environment. Observe the safety data sheets of the lubricants
used. Dispose of biodegradable lubricants separately.
x 1 litre of oil pollutes 1 million litres of water.
x 1 litre of oil pollutes 10 million cubic meters of soil.
2.13.2 Consumables
Twines, nets, foils and machine parts thrown away pollute the
environment. They endanger in particular the animal world.
Therefore: dispose of twines, nets, foils and machine parts in a
professional manner.
26
Assembly groups
Figure 12
Item Assembly group
Item Assembly group
E-LINK control box*
Bale ejector
BALERCONTROL E control box*
Guide roller
ELS ("Easy-Load-System" for net rolls)
10
Catch
Net tying or twine tying
11
Bottom door*
Belt
12
Pick-up
Rocker arm
13
Cutting device*
Tail gate
27
Start Up

During handling in the area of the drawbar ensure that the
machine is secured against moving. Do not raise the support
foot before the baler has been safely coupled to the tractor.
Do not uncouple the baler, unless:
x the bottom for wheels and support foot is even and bearing.
x the baling chamber is empty and the tail gate closed.
x the wheels of the machine are blocked by means of wheel
chocks.
x the hydraulic tubes have been depressurised.
x the hitch is released.
Nobody must be between tractor and baler as long as the
vehicles are not secured against moving by manually operated
brake and/or wheel chocks!
Always keep children away from the machine!
4.1
Coupling the baler
Note!
Dependent on the equipment variant, a rotary or a rigid hitch
can be installed (observe national regulations!).
For trouble-free operation of the baler correct coupling of the
machine (with adjustment of the drive shaft) is of decisive
importance.
After coupling of the baler:
fully retract the support foot using the crank handle.
release the bolt.
push support foot fully in and lock it with the bolt.
28
4.1.1
Manually operated brake (according to version)
Attention, danger of burning!

Do not begin a journey with the machine attached unless the
manually operated brake [20] has been completely released.
Otherwise there is danger of fire by brakes running hot (e. g. in
the field).
After coupling the machine to the tractor: Release manually
operated brake [20] (turn crank to the left).

Figure 13

Machines not coupled to the tractor must be secured against
accidental rolling away by applying the manually operated
brake [20] and by means of wheel chocks.
Before uncoupling the machine from the tractor: Apply the
manually operated brake [20] (turn crank to the right).
31
1
2
3
4
250
7 5
115
100
120
1753-29
4.1.2
Drawbar positions
(all measures in [mm])
4 2
100
130
6
7
Figure 14
29
4.1.3
Adjusting the drawbar
Attention!
The height adjustment and thus the adjustment of the hitch may
be changed only by the manufacturer or an authorised special
workshop.
Place the baler on a horizontal ground.
Turn out the support foot so far that the machine stands
horizontally (axle plates horizontal, support foot vertical).

Measure the height of the drawbar on the tractor.
Measure the height of the hitch on the machine.
Using the dimensions stated in Figure 14 adjust the drawbar
Figure 15
to the pair of holes approximating the desired value most

closely. After each loosening of the safety nuts these must
be replaced.
After alignment of the triangular draw system, position the
hitch horizontally: loosen the fastening screws of the hitch
and correct the position of the hitch by means of the
threaded rod.
Firmly tighten all fastening screws and nuts:
4.1.4
Tow hitch version
In case of tractor's tow hitch coupling of the baler the
following dimensions must be observed, at all costs:

(see Table 1).
Attention!
Other tow hitches than showed in Figure 16 or Table 1 are not
permitted! Danger of breaking!
Figure 16
Category in
conformity
with
ISO 730-1
dimensions of the catch

opening
d
+1
catch
openingoutline
layout
B
min.
r1)
max.
c2)
min.
l
10
max.
permissible
vertical
support load
F
kg
60
70
70
80
220
250
400
500
1200
1500
-0
2
3
33
33
1) Provided the outer radius r is adhered to, different designs of tow hitch are permissible (see Figure 16).
2) To adhere to the dimension c, the upper part of the tow hitch can possibly be removed.
Dimensions in millimetres
Table 1: Dimensions, position and support load of the tow hitch
30
4.2
Drive shaft
4.2.1
Coupling the cam-type cut-out clutch*
Depending on the version, a drive shaft with automatic safety
clutch (cam-type cut-out clutch) is installed.
x Clean and grease the profile of the machine sided
connecting shaft prior to assembling.
x Loosen and turn out clamping cone [1].
x Open maintenance hole in the guard cone on the machine
side. Slide the clutch onto the connecting shaft so that the
location hole [2] points towards the maintenance hole.
Figure 17
x Position the location hole for the clamping cone above the
ring groove [3] of the connecting shaft.
x Turn clamping cone into location hole and tighten firmly
(approx. 70 Nm) while moving the hub slightly to and fro in
longitudinal direction.
x Check tight and firm seat of clutch hub by compression and
tensioning movements. During work, check clutch for correct
tightening at regular intervals.
Figure 18
4.2.2
Uncoupling of the cam-type cut-out clutch*
Loosen and remove clamping cone from clutch hub. If this
cannot be done by hand, drive out clamping cone from the
opposite side by means of a pin punch.
Figure 19
31
4.2.3
Adjusting the drive shaft
(Figure 20) Pay attention to maximum operating length Lmax
and minimum operating length Lmin! Aim at maximum
overlap possible.
x a)
Shortest operating length, i. e. complete overlap.
x b) During normal operation, the overlap of the sliding tubes

should be a least 2/3 of the profile overlap LU.
x c) For a short time, the drive shaft can be operated with
the length Lmax , i. e. the profile overlap is 1/3 LU.
Figure 20
If necessary: adjust length. Hold the drive shaft halves next
to each other in the shortest operating position and mark

them. Shorten inner and outer tubes by equal amounts so
that a sliding travel of 40 mm is retained in the shortest
operating position.
Secure the protective tubes of the drive shaft by retaining
chain against revolving.
Before the starting the drive shaft, check whether the locks
have properly engaged.
Figure 21
When driving through narrow bends ensure that the wide
angle joint (on the tractor side) is not bent more than
permitted by the manufacturer of the drive shaft.
Heed the operating instructions of the drive shaft's
manufacturer as well as national relevant signs with type
approval for drive shaft protection.
Only the drive shafts prescribed by the manufacturer may be
used!
Support drive shaft always with the drive shaft support when
machine is uncoupled (Figure 22). In case of bottom
coupling swivel up the support accordingly.
Figure 22

Protective tube and guard cone of the drive shaft, and the
power take-off shaft protection, must be fitted and be in proper
condition. Ensure before switching on the power take-off shaft
that the selected speed of the tractor is in conformity with the
permissible speed and direction of rotation of the machine (540
rpm).
Switch power take-off shaft only during idling!
32
4.3
Hydraulic System
4.3.1
Hydraulic connections for machines with E-LINK
Symbol on hydraulic tube
Function
Tail gate
open and close
Hydraulic switch with the

functions
x open and close
conveyor bottom
x raising and lowering the
pick-up
x move cutting device in
home- and in operating
position
Tractor connection
Colour of marking
single acting
yellow
double acting
with floating position
red
33
4.3.2
Hydraulic connections for machines with BALERCONTROL E
Symbol on hydraulic tube
34
Function
Tractor connection
Colour of marking
Tail gate
open and close
single acting
yellow
Pick-up
lift and lower
single acting
red
move bottom door in homeand in operating position

(for machines without
cutting device)
double acting
green
move cutting device in

home- and in operating
position
(for machines with fixed
bottom door)
double acting
green
Note!
For easier assignment of the correct oil connecting bushing in
case of future coupling of the baler, transfer the colour marks of
the hydraulic tubes to the connections of the tractor.
Clean the coupling parts of the hydraulic hoses with clean
cloth and plug them into the bushings at the tractor.
Caution!
Check hoses and tubing regularly for damage, ageing and
operating reliability. Defective parts must immediately be
replaced by original WELGER spare parts. Even in case of
permissible stress, tubes and hoses are subject to natural
ageing. They can therefore be used only for a limited period of
time.
The period of use for hydraulic tubing should not exceed six
years!
4.3.3
Prior to first commissioning: open hydraulic valve
RP 405 SPECIAL and RP 435
For transportation the bottom door is hydraulically blocked in
the factory, i. e. the bottom door valve on the hydraulic system
control block is closed. (See also: chapter 7.4 Lock bottom
door.)
Figure 23
Prior to first commissioning: open hydraulic valve.

Using appropriate tool: set the right ball valve 90
counterclockwise (Figure 23).
35
4.4
Electrical system
4.4.1
Lighting set
To connect the lighting system, insert the 7-pin plug
(ISO 1724) into the corresponding socket on the tractor.
Before travelling on the roads, check that the lighting system
functions correctly (also at daylight).
4.4.2
Control electronics
The machine will be delivered according to the version with
the following control:
x "Balercontrol E"
(with control box for "Balercontrol E" Figure 24)
x "Balercontrol III"
(with control box for "E-LINK" Figure 25)
Note!
Read and heed the separate
instruction "E-LINK for RP 435/535 MASTER".
Figure 24
Figure 25
operating
For attaching the corresponding control box a bracket is
delivered with, that must be mounted nearby the tractor

driver.
The respective control box is equipped with a magnetic plate
at the back and can be fixed onto a metallic surface into the
tractor's cabin.
Connecting the control box: To connect the control box to
the control system plug the small 7-pole plug (with screw
coupling) into the corresponding 7-pole socket on the
machine.
Connecting the power supply: A load socket according to
DIN 9680 is required on the tractor for connecting the control
electronics "Balercontrol". (Part of the delivery of the baler).
Fuse protection must amount to 30 A. (For balers without
twine tying a fuse protection of 16 A is sufficient.) Plug the 2or 3-pole plug of the machine into the load socket
(DIN 9680) of the tractor.
After connecting the plug supply voltage is available and a
short series of beeps can be heard from the control box
(only if the load socket of the tractor is permanently
connected or if the ignition of the tractor is actuated)..
To equip another tractor the plug socket with connecting cable
and fuse is available under the WELGER part no.
0972.20.40.00.
The correct polarity of the power supply of the tractor must not
be changed, otherwise the electronic control could be damaged
(Figure 26).
Figure 26
36
4.5
Compressed-air braking system
4.5.1
Adjust variable load valve*

Prior to each journey pay attention to the lever position of the
variable load valve (Figure 27). A wrong setting reduces the
traffic safety.
Symbol
Brake power
No brake power!
Not for road driving!
Not for field use!
Figure 27
Low brake power!

Restricted for field use!
Medium brake force!
Permitted for field use!
Full brake force!
Permitted for road driving!
Permitted for field use!
Table 2
Brake released (no brake power)

The machine has not sufficient braking power for driving on the road.
This lever position may only be used for moving the uncoupled
machine. This setting is not permitted for moving the machine with a
tractor.
Empty load (low brake power)
This lever position should not be used for field use of the machine.
When using this setting the tractor must have sufficient brake power.
For this heed the nature of the ground and of the site.
Half load (medium brake power)
This lever position can be used for field use of the machine. When
using this setting the tractor must have sufficient brake power. For this
heed the nature of the ground and of the site.
Full load (full brake power)
This lever position must be set for driving on public roads.
This lever position can be used for field use of the machine.
37
4.5.2
Connecting the pneumatic system (pneumatic

brake system)

Pneumatic braking system: Before any work is carried out on
the pneumatic system, the system must be depressurised.
Caution, danger of injury!

pressure gauge in the tractor cabin shows 5.0 bar. Otherwise
there is the risk of the brakes running hot.
Remove dirt, if any, from the sealing washers of the coupling
heads on the tractor and on the connecting tubes of the

machine.
Connect coupling heads for reservoir (red) and brake
(yellow) with the corresponding connections of the tractor.
Drain the compressed-air tank (left machine side) and check
for damage and tight seat daily.
To enable manoeuvring of the machine without connection to
the compressed air system:
lever of load apportioning regulator to:
machine manoeuvring.
Before the beginning of the next journey, or in order to brake
the machine again: Set lever of load apportioning regulator

according to demand
or
or
(see
chapter "Adjust variable load valve*").
4.6
Hydraulic braking system
4.6.1
Connect hydraulic system (hydraulic braking

system)

Hydraulic braking system: Before any work is carried out on the
hydraulic system, the system must be depressurised.
The machine can be equipped with a hydraulic brake according
to the legal regulations of the delivery country. The
corresponding hydraulic coupling is different from the other
hydraulic couplings in that the sleeve of the quick-action
coupling is fitted to the machine.
Please observe in this context the national regulations of the
country in which the machine is to be used.
38
Twine tying*
5.1
Threading the twine

Prior to inserting of new spools of twine and threading the
twine: stop machine, switch-off power take-off shaft and tractor
motor, take out ignition key and wait for standstill of the
machine. Make the control powerless (disconnect electrical
connection to the tractor).
Note!
Optimum results in production during use of our machines
depend of multiple factors. Therefore:
x The threaded twines must not contact each other or run
crosswise.
x Use high-grade twines (recommendation: plastic twines).
Place the twine spools upright side by side in the twine box.
If the spools are inserted the wrong way round, the twine will
tend to loop and break.
x Heed and follow the instructions given in the operating
instructions.
x For working in extreme ambient conditions: request to our
customer service. Heed the technical data at the end of this
operating instruction.
Twine A
(Shown by continuous line in Figure 28 and Figure 29.)
Twine B
(Shown by dotted - - - - - - line in Figure 28 and Figure 29.)
Twine A (Figure 28): Feed the beginning of the twine from
spool A1 upwards through the guide eye and then out of the
twine box. Knot end of twine of spool A1 with the beginning
of the twine of spool A2. Important: The knot must be very
small!
Twine B (Figure 28): Feed the beginning of the twine of
spool B1 upwards through the guide eye and then out of the
twine box. Knot end of twine of spool B1 with the beginning
of the twine of spool B2. Important: The knot must be very
small!
Thread the twines A and B each through the twine brake [1].
Wrap both twines around the guide rollers [2].
Thread in both twines upwards to the pair of eyes [3] on the
binding bar.
(Continued on the page after next.)
39
Thread scheme: from the twine box to the variable diameter disc
Figure 28
Thread scheme: from the variable diameter disc to the guide rollers
Figure 29
40
(Figure 29) Feed twines A and B through to the guide rollers
[8].
Loop twine A anticlockwise once around the variable
diameter disc [9].
Finally locate each twine at the entry to their respective
guide roller.
Turn the roller pair by hand until the thread has been
securely grasped.
Note!
The clamping and cutting devices [10] have been factory set so
that the driving twine (twine A) must be guided through the
guide rollers on the left-hand side, as seen from the direction of
travel.
After threading: tighten the two twine ropes towards the
twine spool.
41
5.2
Adjusting the twine brake
The twine brakes [1] (Figure 28) must hold the twines as taut as
possible for the twines to be tight around the bales.
(Figure 30) Adjust dimension "X" of the twine brake
according to the following table.
Basic setting
Length "X" of the spring

(Figure 30)
Twine A
39 mm
Twine B
37 mm
Note!
x The permitted thread tension is exceeded when the twine
breaks in the vicinity of the guide rollers [8] (Figure 30).
x The dimension "X" is measured between: washer bottom
edge and the bottom surface of the cranked plate.
Figure 30
42
5.3
Setting the edge clearances
For lateral limitation of the twine wrapping at the ends of the

bale:
adjust the left and right range spacer [1] (only the right
machine side is shown in Figure 31 and Figure 32).
With very dry and brittle crop materials select the retainers
in the middle of the baler.
Figure 31
Figure 32
5.4
Adjusting the wrapping distance
The distance between the wrappings is given by the diameter

used for the variable diameter disc [9] (Figure 29). The smaller
the effective diameter of the disc, the greater the distance
between the wrappings.
A lever [2] used to adjust the wrapping distance is located on
the far right-hand end (in travelling direction) of the binding bar
[2] (Figure 31 and Figure 33).
Swivelling the lever towards the machine centre will move
the two halves of the variable diameter disc apart, reduce

the effective diameter of the variable diameter disc and
result thus in a larger twine distance. Setting:
Figure 33
Position 1: maximum wrapping distance

Position 7: minimum wrapping distance
43
5.5
Edge wrapping adjustment
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.
A switching angle [3] (Figure 34) is installed in the right-hand
shuttle, which is attached by two screws in a unit with a set of
holes. Four different installation positions are available.
Figure 34
By displacing the angle towards the variable diameter disc, the

variable diameter disc is pressed closer together for the area of
the edge wrappings. The effective diameter increases and more
edge wrappings are applied to the edge of the bale. Setting:
Displace switching angle (3) towards the variable diameter
disk: more end windings on the edge of the bale.

Or:
Displace switching angle (3) towards the machine centre:
less end windings on the edge of the bale.
44
Net tying*
6.1
Inserting the net

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

There is danger of injury by cutting during work on the net knife
(Figure 48, item 10). Wear protective gloves.
Open left-hand side cover.
Attention, danger of injury by net knife turning down

automatically!
Only if the last wrapping process has not been completely
executed (e. g. because the net roll depleted during the
wrapping process): (Figure 35) Pull the handle of the knife
carrier hard to the front against the spring tension (the triangular
counting segment for the net length returns to its starting
position).
This prevents unexpected activation and automatic drop-down
of the net knife during threading of the net.
Figure 35
45
(Figure 36) Open safety chain [1].
Figure 36
(Figure 37) Pull out handle [5] of the crank handle. Crank
back the tensioning spindle [4] until the lock plate with the
crank handle.
5
4
Figure 37
Open upper hood.
(Figure 38) Slide net tightener [8] back and secure with
cotter pin.
Figure 38
46
(Figure 39) Depending on the diameter of the net rolls in use

the height of the net roll plate [10] must be set accordingly:
Net roll with net length 3,000 m: Mount net roll plate in lower
position (bottom thrill hole in Figure 40).
Net roll with net length 2,000 m: Mount net roll plate in
medium or upper position (centre or top thrill hole in Figure
40).
10
Figure 39
Figure 40
(Figure 41) Dependent on the width of the net rolls used an

extension tensioning spindle (16) can be mounted on the
original tensioning spindle (15):
Width of the net roll more than 1.23 m: extension tensioning
spindle not necessary.
Width of the net roll 1.23 m or smaller: Unscrew extension
tensioning spindle (16) and attach to the tensioning spindle
[15].
15
16
Figure 41
47
21
20
Figure 42
(Figure 42) Depending on the width of the net rolls in use the
complete net holder [21] must be moved horizontally and fasten
again:
Width of the net roll 1.23 m: move complete net holder [21]
in the slotted holes to the left until the lock plate and fasten
it.
Width of the net roll 1.30 m: move complete net holder [21]
in the slotted holes [20] to the right until the lock plate and
fasten it.
According to the width of the net rolls a position between the left
and the right lock plate can be selected for the net holder.
(Figure 43) Slide net roll until the lock plate into the tiltable
auxiliary net holder.
Note!
Watch wind-off direction of the net roll! The net must enter the
machine beneath the net roll (see Figure 48).
Figure 43
(Figure 44) Tilt net roll into the net holder.
Figure 44
Note!
(Figure 45) The tips of both tensioning spindles must point into
the sleeve of the net roll.
If the tips of the two tensioning spindles do not point into the
sleeve but onto the net material the height of the net roll plate
must be corrected accordingly (Figure 39 and Figure 40).
Figure 45
48
(Figure 46) Pull out handle of the crank handle. Crank
tensioning spindle with crank handle into the sleeve of the

net roll.
Figure 46
(Figure 47) Crank tensioning spindle so far until between the
bushing (25) and the crank handle (26) is only a gap of

approx. 2 mm left.
Fold back the crank handle again.
26
25
Note!
Before closing the side cover: Turn crank back into machine.
Fold back the crank handle.
The net roll must rotate free and easy. If not: Check and
Figure 47
repeat the setting described in this chapter "6.1 Inserting the

net", if necessary.
49
Figure 48
(Figure 48) Feed the net from the roll (11) around the upper
Figure 49
guide tube [4] and subsequently around the net tightener [3].
(Figure 48 and Figure 49) Feed the net across the
expanding device [5] and place its front end between rubber
roller [6] and steel roller [7].
(Figure 50) Turn the rubber roller [6] by hand until the net is
grasped. To prevent the net from getting into the roll
chamber too early during the baling process, the front end of
the net must not project more than approx. 10 cm beyond
the rubber roller.
(Figure 38) Remove cotter pin from the net tightener and
swivel net tightener to the front.
(Figure 43) Insert an auxiliary net roll into auxiliary net
holder.
(Figure 36) Close safety chain.
Figure 50
50
6.2
Tightening the net knife
Normal case: the net knife is tensioned automatically whenever

the tail gate is opened.
Special case: if, while the baling chamber is filled, new net tying
is necessary without opening of the tail gate (e. g. because of a
net roll change or a fault), the net knife can be tensioned by
hand:
(Figure 51) Pull the knife carrier against the spring tension to
the front. Triggering is effected as described in the chapter
"Operation / Tying".
Figure 51
51
6.3
Adjusting the net length
6.3.1
BALERCONTROL E
Using the scale (Figure 52) the net length (i.e. the number of
net wraps around the bale) can be adjusted continuously:
Slacken the wing nut.
Displace the wing nut in the slotted hole to adjust the desired
net length.
Retighten the wing nut.
Figure 52
Note!
First select a setting in the middle of the slotted hole. To save
net material change the setting step by step towards ( ) for
subsequent bales.
Do not use too little net material: The bale must still be held
together. For very smooth bales and high baling densities a
larger amount of net material must be adjusted.
Note!
If the bale diameter changes the net length must be adjusted
accordingly.
6.3.2
E-LINK
Via the E-LINK control system the net length can be adjusted in
increments of 0.5 from 1.5 to 5 net layers (net layers are the
number of net wraps around the bale).
Note!
In case of E-LINK machines the wing nut must be installed in
the separate square hole of the scale (Figure 52) (not in the
slotted hole).
Note!
Read and observe the separate operating
E-LINK for RP 435 MASTER / RP 535 MASTER.
52
manual:
Cutting device*
The cutting device (Figure 53) can be used for silage, hay and
straw. The knifes of the cutting device are swivelled in and out
hydraulically.

Prior to any work on the cutting device of the machine: Switch
off power take-off shaft, switch off tractor engine, remove
ignition key and disconnect drive shaft from power take-off shaft
end. Make the control powerless (disconnect electrical
connection to the tractor).
7.1
Equipment
The machines can be equipped as follows:

machine with
control box:
can be equipped with:
BALERCONTROL E
Figure 53
x without cutting device

x MasterCut
(13 knives)
x XtraCut 17
(17 knives)
Balercontrol E
E-LINK
x without cutting device
x MasterCut
(13 knives)
x XtraCut 17
(17 knives)
x XtraCut 25
(25 knives)
E-LINK
7.2
Knife groups
To change the cut length of the material to be pressed, knife

groups can be selected (that means, not all knives of the cutting
device are in use):
x The cutting device XtraCut 17 (17 knives) contains an 8knife group and a 9-knife group (8 + 9 = 17). Both knife
groups can be used in the following combinations:
0 knives 8 knives 9 knives 17 knives
x The cutting device XtraCut 25 (25 knives) contains a 12knife group and a 13-knife group (12 + 13 = 25). Both knife
groups can be used in the following combinations:
0 knives 12 knives 13 knives 25 knives
53
7.2.1
Select knife group (E-LINK)
Note!
Read and heed the separate operating instruction "E-LINK for
RP 435 MASTER / RP 535 MASTER".
Caution!
Before a knife group can be selected, all knives that can be in
cutting position must be totally moved into home position. see
chapter 7.3 Moving in and out the cutting device.
To move a knife group by means of the tractor's distribution
valve it must have been selected:
In the menu "MONITOR": Repeat pressing the centre key
until the symbol for the selected knife group appears in

the display (above the centre key).
For example: for a machine with 17-knife cutting device the
following selection is possible:
x
(8-knife group)
x
(9-knife group)
x
(8- and 9-knife group together)
The
selected
knives
can
be
moved
see chapter 7.3 Moving in and out the cutting device.
54
now:
7.2.2
Select knife group (Balercontrol E)
Caution!
Before a knife group can be selected, all knives that can be in
cutting position must be totally moved into home position. see
chapter 7.3 Moving in and out the cutting device.
To move a knife group by means of the tractor's distribution
valve it must have been selected by means of the hydraulic
valves [1] and [2] (Figure 54 and Figure 55). The hydraulic
valves are located on the left machine side, seen driving
direction.
Figure 54

The hydraulic valves are located in the range of action of the
pick-up and of the cutting device. Prior to operate the hydraulic
valves: Switch off the power take-off shaft, switch off the tractor
engine, remove the ignition key.
Desired knife group
no knives
1
Figure 55
Adjust hydraulic valves

(according to Figure 54)
Valve 1
Position 0
Valve 2
Position 0
8 Knife
Valve 1
Valve 2
Position "I"
Position 0
9 Knife
Valve 1
Valve 2
Position 0
Position "I"
17 Knife
Valve 1
Valve 2
Position "I"
Position "I"
Adjust hydraulic valves according to the table.

The knives can be moved, now: see chapter 7.3Moving in
and out the cutting device.
55
7.3
Moving in and out the cutting

device
7.3.1
General
On the following pages the conditions "Knives in cutting

position" and Knives in home position" are mentioned. Now, the
definition of the states:
x "Knives in cutting position" means:
The knives are totally moved out of the knife bottom plate
(Figure 56). Straw conveyed through the machine is cut by
the moved out knives.
x "Knives in home position" means:
The knives are totally inserted into the knife bottom plate
(Figure 57). Straw conveyed through the machine is not cut
by the inserted knives.
Figure 56
(Pictures from open bottom door)
Knives in cutting position
Figure 57
Knives in home position
7.3.2
Prior to first commissioning: open hydraulic valve
For transportation the bottom door is hydraulically blocked in
the factory, i. e. the bottom door valve on the hydraulic system
control block is closed. (See also: chapter 7.4 Lock bottom
door.)
Figure 58
56
Prior to first commissioning: open hydraulic valve.

Using appropriate tool: Set the right ball valve 90
counterclockwise (Figure 58).
7.3.3
E-LINK control box

13-knife cutting device
HYDROFLEXCONTROL bottom door
Note!
Read and heed the separate operating instruction "E-LINK for RP
405/435".
Caution!
Before a knife group can be moved into cutting position, all knives
that can be in cutting position must be totally moved into home
position.
Only those knife groups are displayed that can be moved in or out for
the actual moment, e.g.
(here: 8-knife group).
Move cutting device into cutting position

In the menu "MONITOR": Press centre key
so many times
until the symbol "Cutting device" (with the number of knives) is
.
displayed (above the centre key), e.g.
Set the tractor's distribution valve so long to "Lift" as it takes to
move the cutting device totally into cutting position (that means until
the knives are totally moved out of the knife bottom plate). If the
hydraulic bottom door was open (HYDROFLEXCONTROL) this,
too, swivels up.
That the hydraulic accumulators can be filled: After the knives have
reached the cutting position, the tractor's distribution valve must be
operated for another 5 sec.
Move cutting device into home position

so many times
until the symbol "Cutting device" (with the number of knives) is
.
displayed (above the centre key), e.g.
Set the tractor's distribution valve so long to "Lower" as it takes to
move the cutting device totally into home position (that means until
the knives are totally moved into the knife bottom plate).
That the hydraulic accumulators can be emptied: After the knives
have reached the home position, the tractor's distribution valve
must be operated for another 5 sec.
Note!
To prevent jamming the knife slots and to keep the knives movable:
Move in and out the cutting device multiple times a day.
57
Cutting device protection
Caution!
Special function for fault clearance. Not permissible for
production! Normal production only permitted with 40 bar.
To protect the cutting device against mechanical overload (e.g.
large stones or hard wood parts come into the cutting device),
the knives of the cutting device are protected via a hydraulic
circuit (cutting device protection). This hydraulic circuit limits the
hydraulic pressure available to the cutting device knives to a
standard pressure of 40 bar. Only this standard pressure is
available for swivelling the cutting device knives out to cutting
position.
If the knife slots are clogged, this standard pressure may not be
sufficient. A by-pass function is therefore available which
permits putting cutting device protection out of operation. This
means, the cutting device knives move out of the knife bottom
plate with the full hydraulic pressure of the tractor and can thus
better remove jams at the knife slots.

In the following the cutting device knives are moved without
cutting device protection.
so many
times until the symbol "Cutting device" (with the number of
knives) is displayed (above the centre key),

.
Important: Do not release the button!
(If the button was released: Press centre button so many
times that the symbol "Cutting device" is displayed again.
Important: Do not release the button!
At still pressed centre button: Set the tractor's distribution
valve so long to "Lower" as it takes to move the cutting
device totally into home position (that means until the knives
are totally moved into the knife bottom plate).
At still pressed centre button: Set the tractor's distribution
valve so long to "Lift" as it takes to move the cutting device
totally into cutting position (that means until the knives are
totally moved out of the knife bottom plate).
Repeat the two working steps above so long until the
jamming of the knife sots is removed and the knives move
free and easy.
58
Attention! The knives must finally moved in and out with

40 bar. Otherwise: Lost of guarantee possible when machine
was overload!
Important: Release centre key.
Move knives again into home position and then back to
cutting position by means of the tractor's distribution valve.

Just now the normal production can be continued.
59
7.3.4
Balercontrol E control box

fixed bottom plate (no bottom door)
Note!
For normal production the ball valve must point away from the
machine (see Figure 59 and Figure 60)!
Figure 59

Set the tractor's distribution valve so long to "Lift" as it takes
to move the cutting device totally into cutting position (that
means until the knives are totally moved out of the knife
bottom plate).
That the hydraulic accumulators can be filled: After the
knives have reached the cutting position, the tractor's
distribution valve must be operated for another 5 sec.

Set the tractor's distribution valve so long to "Lower" as it takes
to move the cutting device totally into home position (that
means until the knives are totally moved into the knife
bottom plate).
That the hydraulic accumulators can be emptied: After the
knives have reached the home position, the tractor's
Note! To prevent jamming the knife slots and to keep the

knives movable: Move in and out the cutting device multiple
times a day.
Caution!
Special function for fault clearance. Not permissible for production!
Normal production only permitted with 40 bar.
To protect the cutting device against mechanical overload (e.g. large
stones or hard wood parts come into the cutting device), the knives of
the cutting device are protected via a hydraulic circuit (cutting device
protection). This hydraulic circuit limits the hydraulic pressure
available to the cutting device knives to a standard pressure of 40
bar. Only this standard pressure is available for swivelling the cutting
device knives out to cutting position.
sufficient. A by-pass function is therefore available which permits
putting the pressure valve out of operation. This means, the cutting
device knives move out of the knife bottom plate with the full hydraulic
pressure of the tractor and can thus better remove jams at the knife
slots.
60

In the following the cutting device knives are moved without cutting
device protection.
Figure 60
Swivel ball valve (Figure 60) beneath the left side cover to the front:
180 bar (Figure 61).
Set the tractor's distribution valve so long to "Lower" as it takes to
move the cutting device totally into home position (that means until
the knives are totally moved into the knife bottom plate).
Set the tractor's distribution valve so long to "Lift" as it takes to
move the cutting device totally into cutting position (that means until
the knives are totally moved out of the knife bottom plate).
Repeat the two working steps above (tractor's distribution valve to
"Lift" and "Lower") so many times until the jamming of the knife
slots is removed and the knives move free and easy.
Turn the ball valve (Figure 60) again away from the machine: 40
bar (Figure 61).
Attention!
The knives must finally moved in and out with 40 bar. Otherwise: Lost
of guarantee possible when machine was overload!
Move knives again into home position and then back to cutting
position by means of the tractor's distribution valve. Just now the
normal production can be continued.
Figure 61
61
7.3.5

Note!
For normal production both ball valves must point away from
the machine (see Figure 62)!
Figure 62

Left machine side: Adjust ball valves of the hydraulic block
according to Figure 62.
Set the tractor's distribution valve so long to "Lower", until
the cutting device is moved completely to home position (i.e.
until the knives are moved completely into the knife bottom
plate) and until the bottom door is completely opened
(moved down).
Set the tractor's distribution valve so long to "Lift", until the
cutting device is moved completely to cutting position (i.e.
until the knives are moved completely out of the knife bottom
plate) and until the bottom door is completely closed (moved
up).

(moved down).
For working without cutting device:
according to Figure 63. Thus the cutting device is locked
hydraulically.
Set the tractor's distribution valve so long to "Lift" until the
bottom door is closed completely (moved up). The cutting
device rests completely in home position (the knives do not
move out of the knife bottom plate).
Figure 63
62
Note!
To prevent jamming the knife slots and to keep the knives
movable: Move in and out the cutting device multiple times a
day.
Caution!
position.
enables moving the knives of the cutting device out of the knife
bottom plate and into working position by means of the full
hydraulic pressure of the tractor. By this clogging of the knife
slots can be removed.

Left machine side: set left ball valve of the hydraulic block
Figure 64
according to Figure 64: 180 bar. set right ball valve of the
hydraulic block according to Figure 64: this releases the
knives.
Set the tractor's distribution valve so long to "Lower" as it
takes to move the cutting device totally into home position
(that means until the knives are totally moved into the knife
bottom plate).
bottom plate).
Repeat the two working steps above ("Lift" and "Lower") so
many times until the jamming of the knife slots is removed
and the knives move free and easy.
Set left ball valve (Figure 64) back to 40 bar.
Attention!
The knives must finally moved in and out with 40 bar.
Otherwise: Lost of guarantee possible when machine was
overload!
63

Special function: lock bottom door
The HYDROFLEXCONTROL bottom door (bottom door can be
opened and closed hydraulically) can be if desired locked
hydraulically. see chapter 7.4 Lock bottom door.
64
7.3.6

fixed bottom plate (no bottom door)
Note!
For normal production the ball valve must point away from the
machine (see Figure 65 and Figure 66)!
Figure 65
Caution!
Before a knife group can be moved into cutting position, all
knives that can be in cutting position must be totally moved
into home position.
Select 8-knife group or 9-knife group or all of the 17 knives
by means of the hydraulic valves (see 7.2.2Select knife
group (Balercontrol E).
to move the desired knife group totally into cutting position
(that means until the knives are totally moved out of the knife
bottom plate).

bottom plate).
Note!
day.
65
Caution!
position.
permits putting the pressure valve out of operation. This means,
the cutting device knives move out of the knife bottom plate
with the full hydraulic pressure of the tractor and can thus better
remove jams at the knife slots.

Figure 66
66

Swivel ball valve (Figure 66) beneath the left side cover to
the front: 180 bar (Figure 67).
bottom plate).
bottom plate).
Repeat the two working steps above (tractor's distribution
valve to "Lift" and "Lower") so many times until the jamming
of the knife slots is removed and the knives move free and
easy.
Swivel ball valve (Figure 66) back to the machine: 40 bar
(Figure 67).
Attention!
overload!

Figure 67
67
7.3.7

Note!
For normal production both ball valves must point away from
the machine (see Figure 68)!
Caution!
Before a knife group can be moved into cutting position, all
knives that can be in cutting position must be totally moved
into home position.
Figure 68

(moved down).
Set the tractor's distribution valve so long to "Lift", until the
plate) and until the bottom door is completely closed (moved
up).
Figure 69

(moved down).
For working without cutting device:
according to Figure 69. Thus the cutting device is locked
hydraulically.
Set the tractor's distribution valve so long to "Lift" until the
bottom door is closed completely (moved up). The cutting
device rests completely in home position (the knives do not
move out of the knife bottom plate).
68
Note!
day.
Caution!
position.
enables moving the knives of the cutting device out of the knife
bottom plate and into working position by means of the full
hydraulic pressure of the tractor. By this clogging of the knife
slots can be removed.

Left machine side: set left ball valve of the hydraulic block
Figure 70
according to Figure 70: 180 bar. set right ball valve of the
hydraulic block according to Figure 70: this releases the
knives.
bottom plate).
bottom plate).
Repeat the two working steps above ("Lift" and "Lower") so
many times until the jamming of the knife slots is removed
and the knives move free and easy.
Set left ball valve (Figure 70) back to 40 bar.
69
Attention!
overload!

Special function: lock bottom door
hydraulically. see chapter 7.4 Lock bottom door.
70
7.4
Lock bottom door

hydraulically. It acts then as a fixed bottom door, i.e. it cannot
be opened as long it is locked. Advantage: The knives can be
retracted and extended by means of the tractor distribution
valve WITHOUT the HYDROFLEXCONTROL bottom door
opening as well in each case.
7.4.1
Lock bottom door
Set lever to home position (according to Figure 71).
Figure 71
Remove lever from centre shaft and apply it to the right shaft
Figure 72
Set right lever to locking position (according to Figure 73).
The bottom door is locked now. I.e.: only the cutting device but
not the bottom door can be moved by means of the tractor's
distribution valve.
Figure 73
7.4.2
Release bottom door
Set the right ball valve according to Figure 74.
The bottom door is released. I.e.: the cutting device as well as
the bottom door can be moved by means of the tractor's
distribution valve.
Figure 74
71
7.5
Brittle crop material
While pressing brittle crop material it is recommended to move

the cutting device into home position short before wrapping
process. In this way the bale is finally wrapped with long
material and crop losses are minimised.
7.6
Assembly and disassembly of the

cutting device knives
Note!
By removing individual knives the cut length of the baling
material can be changed. (This counts mainly for the 13-knife
cutting device. At the 17-knife cutting device and the 25-knife
cutting device the same effect can be got by selecting knife
groups).
If no cutting function is desired for a longer period of time, all
knives can be removed.
Figure 75
25-knife cutting device: to optimise material flow in the

conveying elements and to stabilise the side faces of the bales
(in case of dry straw), the two outer knives of the cutting device
should be removed.

Wear protective gloves while working with the knives.
If any maintenance or assembly work is carried out with the tail
gate open, the tail gate must be hydraulically secured against
lowering for safety reasons:
For the following working steps:

see chapter 7.3 Moving in and out the cutting device.
Move cutting device to cutting position.
Swivel the bottom door* about half way down.
Open and secure tail gate (see chapter 9.3 Eject bales).
Figure 75: Swivel lever of the knife axle on the feeder
Figure 76
72
housing (on the right in driving direction) down through about

90 as far as the stop .
Using tongs withdraw the knives diagonally upwards from
the knife axle and remove them from the slot proceeding
from the roll chamber.
Note!
Removed blades should be replaced by blind blades* to prevent
soiling of the knife slots (part no. 1724.55.12.37)
Blind blades (Figure 76) and any blades removed can be
"parked and secured with a cotter pin behind the left casing
door (Figure 77).
Figure 77
7.7
Regrinding the cutting device

knives
To provide the best crop throughput it is recommended to

regrind the cutting device blades at least after cutting of 500
bales. Dependent on the working conditions sharpening may be
necessary earlier:
Note!
In case of cutting devices with knife groups (see chapter 7.2
Knife groups) the knife groups can be used one after the other
That means e. g. first 500 bales are produced with the 12-knife
group and subsequently another 500 bales are produced with
the 13-knife group. This duplicates the operation time of the
cutting device.
Attention, danger of injury when working on the

magnets of the knife holders!
the function of cardiac pacemakers can be interrupted by
magnetic fields.
Danger of injury by splinters: Never strike against the installed
knives from the bottom with a striking tool - this may damage
the magnets!
Remove knives, see chapter 7.6 Assembly and disassembly
of the cutting device knives.

Regrind knives from the smooth side. The temper of the
blades must not be drawn when grinding.
A grinder is available as special tool.
(Part no. 0980.70.14.00)
73
Field use
Attention!
The machine may only be operated by persons who are familiar
with the operating instructions and the safety instructions.
Never remove any malfunctions while the drive is running.
Never remove any harvested crop material from the machine
while the drive is running. Prior to work: Switch off power takeoff shaft, switch off tractor engine, remove ignition key and
disconnect drive shaft from power take-off shaft end.
During operation: do not climb the machine. Keep sufficient
distance to the range of action of the machine (pick-up, running
gear, tail gate, bale unloading area). As a matter of principle:
Riding on the machine is prohibited for the entire machine!
Keep children away from the machine!
Prior to first start: Make yourself with the control box and the
functions of this machine.
Nobody must stay between tractor and machine while the
tractor engine is running.
Never operate the machine with defective or removed protective
devices (e. g. casing sheets and distance brackets)! Before
opening the protections: Switch off power take-off shaft, switch
off tractor engine, remove ignition key and disconnect drive
shaft from power take-off shaft end.
Prior to enter the baling chamber: close tail gate locking device
(Figure 3).
Machines not coupled to the tractor must be secured against
accidental rolling away by applying the manually operated
brake (if available) and by means of wheel chocks.
manually operated brake has been completely released.
Otherwise there is a risk of fire due to brakes running hot.
74
8.1
Locking the tail gate
Before picking up of crop material is started and after every

ejection of a bale, the tail gate must be correctly locked:
Hold the tractor control valve for tail gate actuation in
"Lower" position. This will lock the tail gate automatically.
8.1.1

Extinguishing of the lamp [3] signals complete closing of the tail
gate.
Figure 78
8.1.2
RP 435 MASTER and RP 535 MASTER
Complete closing of the tail gate is signalled by:
x a single beep of the E-Link control box.
x (Figure 79) The tail gate is displayed closed on the display.
x (Figure 79) The swath on the display moves towards the
machine.
Figure 79
Note!
To avoid unnecessary load on the hydraulic pump of the tractor:
leave the control valve in "floating position" during the baling
process.
The upper lamp [3] should only light up when the tail gate is
unlocked. Should the lamp be on also during the baling
process, the sensor setting must be checked.
The lower lamp [4] should light up only for a short time, when
the bale rolls over the bale ejector. The tail gate must not be
closed as long as the lower lamp [4] is on.
75
8.2
Adjusting the bale diameter
Attention!
The bale diameter must be selected so that the bale weight
does not exceed 1.5 tons. So the bale diameter values must - of
necessary - be selected lower than specified in the following
table.
Crop
material
Machine
Bale diameter
Silage
0.90 m 1.55 m
Straw
0.90 m 1.60 m
RP 405 / RP 435
Silage
RP 505 / RP 535
Straw
1.10 m (max. 1.5 tons)

1.10 m 2.00 m
8.2.1

(Figure 80) Slacken the wing nut and adjust the desired bale
diameter with the pointer. The obtainable diameters are
between about 0.90 and 1.55 m for silage and 0.90 and 1.60
m for straw.
(Figure 84) Read the bale diameter currently reached on
display 2.
Figure 80
8.2.2
Actuate the right function key
repeatedly until the

symbol for "Bale diameter" appears in the display of the
control box (Figure 81).
Using the keys

Figure 81
and
set the desired bale diameter.
The obtainable diameters are between about 0.90 and
1.55 m for silage and 0.90 and 1.60 m for straw.
(Figure 82) The arrow in the bar graph shows the selected
diameter value.
Figure 82
76
8.3
Setting the bale density
Note!
Reduction of the bale density is recommended:
x for hey, if an airy bale core is desired.
x for extremely short and dry material, if material jams in the
feed area occur.
8.3.1
Figure 83

Basic setup:
Turn handwheel (Figure 83) clockwise up to the stop.
Turn handwheel a full rotation back.
Bale test bale and assess quality.
If required: readjust bale density.
The preset bale density (i. e. the baling pressure) is indicated
on the pressure gauge [1] (Figure 84):
Interrupt power supply to BALERCONTROL control box (pull
plug).
Open the tail gate. The tail gate now opens slowly and does
not reach its highest position.

Read preset bale density (i. e. the baling pressure) on the
pressure gauge [1].
Figure 84
8.3.2
RP 435 MASTER und RP 535 MASTER
Actuate the right function key

symbol for "Bale density" appears in the display of the
Using the keys
and
select the desired bale
density in 1-digit increments from 1 to 10.
Figure 85
77
8.4
Raising / lowering the pick-up
8.4.1

Raising and lowering of the pick-up are effected directly via
the connected tractor control valve.
8.4.2
Actuate the central function key

symbol for "Lift/lower pick-up" appears in the display of the
Actuate the connected tractor control valve. (The actuating
direction can be reversed by reversing the two connected
hydraulic tubes.)
Figure 86
8.5
Pick-up guide wheels
Tine distance from ground in field use: min. 2 cm

Lift the pick-up (see chapter 8.4 Raising / lowering the pickup ).
Draw out spring clip [1].
Hook the plate [2] into the required hole.
Secure the pick-up guide wheels again with the spring clips.
Select the same adjustment on both sides.
Figure 87
78
8.6
Windguard / Pick-up shield*
In case of all pick-up models (Figure 89 and Figure 90) the

windguard is mounted movably hanging above the pick-up.
Adjust the height of the windguard rake to the swath
thickness using the chain.
(Figure 88) To avoid that the pick-up grasps the chain the
upper end of the chain must always be fastened to the hook.
Figure 88
Caution!
On the pick-up with a pick-up width of: 2.25, both pick-up guide
wheels cover the circular path of the tines laterally and are
therefore also part of the safety equipment.
That is why both guide wheels must always be attached when
the baler is used.
Figure 89
Figure 90
79
8.7
Feed guide plate
The tear-shaped feed guide plate [1] is installed in the roll

chamber in the factory .
If a material jam occurs in case of an extraordinary crop
structure, the feed guide plate can be removed:
unscrew the right screw, seen in driving direction (arrow in
Figure 91) and remove profile from the roll chamber.
Figure 91
8.8
PTO speed
Operate baler at power take-off shaft nominal speed of 540

rpm.
Caution!
Only the drive shafts prescribed by the manufacturer may be
used! Protective tube and guard cone of the drive shaft, and the
power take-off shaft protection, must be fitted and be in proper
condition.
Always ensure that the drive shaft is installed and secured
correctly: Secure the drive shaft safeguard against revolving by
fitting the chain. Ensure before switching on the power take-off
shaft that nobody is within the range of danger of the device!
80
8.9
Driving style
8.9.1
Large swath
Drive speedily at nominal speed (hand throttle).
Let the swath centrally run into the pick-up.
If a small amount of baling material is in the baling chamber
and no pressure has built up yet (see pressure gauge), we
recommend to switch off the power take-off shaft during
empty runs (e.g. during turning round on the headland).
8.9.2
Small swath
Drive speedily at nominal speed (hand throttle).
The baling chamber must be evenly filled with material
across its entire width rapidly and without interruption.
At the beginning of each bale, change immediately
between left and right swath side and vice versa (Figure 92)
...
... until the set working pressure is reached (see pressure
gauge, Figure 93).
Figure 93
Figure 92
81
(Figure 94) Frequent visual checks through belt window.
Figure 94
(Figure 95) If the belts begin to leave their normal position
and drift apart, and/or if material escapes at such points

between the belts, the respective side of the baling chamber
is not sufficiently filled. In this case drive the machine
immediately across the swath with the side concerned.
Figure 95
(Figure 92) When the set working pressure is reached
(see pressure gaugeFigure 93): change regularly between

left and right swath side.
If a small amount of baling material is in the baling chamber
and no pressure has built up yet (see pressure gauge,
Figure 93), we recommend to switch off the power take-off
shaft during empty runs (e.g. during turning round on the
headland).
Operation at slopes
For baling at slopes we recommend to begin with the filling
of the higher side of the baling chamber. Then continue as
shown in Figure 92.
Visual check: after a bale has been ejected from the
machine, do not close the tail gate unless the belts run
again.
Dry, brittle, smooth crop material

If no material is taken up, the power take-off shaft should
always be switched off after 10 seconds at the latest.

Reconnect the power take-off shaftonly then, just before
material is picked up again.
82
8.10
Safety clutch

Causes of overload may only be removed after disconnection of
the control system from power supply (interrupt electric
connection to tractor), when the tractor motor has been stopped
and the ignition key removed!
8.10.1 Drive shaft with shear bolt yoke*

A shear bolt yoke is inserted at the machine side into the drive
shaft.
The bolt [1] shears off at overload and must be replaced by
a new one.
Do not restart the machine unless the source of the overload
is removed.
Use only original spare parts:
Figure 96
Shear bolt with nut ................................................ 0930.84.53.00
8.10.2 Drive shaft with cam-type cut-out clutch*

In the event of overload the cam-type cut-out clutch interrupts
the driving torque.
Switch off power take-off shaft and remove cause of
overload.
After switching on the power take-off shaft, the torque builds
up again so that the machine can be put into operation.
Figure 97
Avoid long and frequent overloads. Make sure, that only the
corresponding drive shaft is used.
83
Operation / Tying
9.1
BALERCONTROL E control box
9.1.1
The control box
The BALERCONTROL E control box has the following functions
and displays (Figure 98):
Item Part
Meaning
LED, green
Power supply correct
LED, red
Preset bale diameter reached or exceeded
LED, yellow
automatic net tying selected. (flashes

when net coupling is in operation)
LED, yellow
Automatic twine tying selected. (Flashes

when twine motor is in operation)
Button
Toggling between manual and automatic

tying (see chapter 9.1.2 Trigger tying
(BALERCONTROL E))
hold for 5 sec: resetting the bale counter
(TAZ)
Button
Manual activation of net tying
Button
Manual activation of twine tying
Display,
illuminated
Top line:
Cumulative counter cannot be deleted
Bottom line:
Day counter, can be deleted
acoustic buzzer
(back side)
Preset bale diameter reached
Figure 98
The following tying modes can be selected dependent on the

type and version of the machine:
x Manual net tying
x Automatic net tying
x manual twine tying
x automatic twine tying
84
9.1.2
Trigger tying (BALERCONTROL E)
(Figure 98) When the preset bale diameter is reached, this is
indicated to the tractor driver by the red LED [2] and the buzzer
[9].
According to the selected tying mode the tying process is
triggered either manually or automatically:
x manually, i.e. the operator presses the corresponding button
(button "Net" [6] or button "Twine" [7]).
x automatically, i.e. triggered by the control.
Figure 99
Manual net tying

Select manual net tying mode: press button [5] several times
until none of the yellow LED's is lighting.
When the preset bale diameter is reached, the red LED [2]
will first flash and then light continuously. A signal sounds.
Stop tractor and let pick-up run empty.
Press button Net [6] for approx. 2 sec. The yellow LED [3]
flashes simultaneously.
Let the tying process run at power take-off shaft standard
speed (540 min-1).
Check net run on the net roll. When the net knife drops down
(acoustic shock) and the net roll has stopped again, the
wrapping process is finished.
Open tail gate and eject bale (see 9.3 Eject bales).
Note!
Tying can also be triggered when the preselected bale diameter
has not yet been reached. Such a bale is not taken into account
by the vale counter.
Automatic net tying
Select automatic net tying: Press button [5] several times
until the left yellow LED [3] lights.
Approx. 2,5 s after the signal was triggered the net is
automatically inserted into the roll chamber. The yellow LED
[3] flashes simultaneously.
speed (540 min-1).
Check net run on the net roll. When the net knife drops down
(acoustic shock) and the net roll has stopped again, the
wrapping process is finished.
85
Figure 100
Manual twine tying

Select manual twine tying: Press button [5] for several times
until none of the yellow LED's is lighting.
During drive: Press button Twine [7] for a short time. The
yellow LED [4] flashes simultaneously.
Stop the tractor after about 5 sec. after pressing the Twine
button [7].
speed (540 min-1).
Check twine run at the twine guide rollers (Figure 100).
Tying is finished as soon as the guide rollers stop.
Automatic twine tying

Select automatic twine tying: Press button [5] several times
until the right yellow LED [4] lights.

will first flash and then light continuously.
The twine is inserted automatically in the roll chamber. The
yellow LED [4] flashes simultaneously.
A signal sounds approx. 2.5 sec. after automatic triggering
of twine tying. This is the time for stopping the tractor.
speed (540 min-1).
Check twine run at the twine guide rollers (Figure 100).
Tying is finished as soon as both guide rollers stop.
86
9.2
E-LINK control box
9.2.1
The control box
Note!
Read and heed the separate operating
instruction "E-LINK for RP 435 MASTER / RP 535 MASTER".
The following tying modes can be selected dependent on the
type and version of the machine:
x Manual net tying
x Automatic net tying
x manual twine tying
x automatic twine tying
Figure 101
87
9.2.2
Select tying mode
Actuate the left function key repeatedly until the symbol for
the desired tying mode appears in the display of the control
box:
Note!
Dependent on the SETUP setting one of the
tying modes is visible only in each case:
x "Net tying Automatic and "Net tying Manual
or
x "Twine tying Automatic" and "Twine tying Manual
x "Net tying Automatic (Figure 102) or
Figure 102
x "Net tying Manual (Figure 103) or
Figure 103
x "Twine tying Automatic" (Figure 104) or
Figure 104
x "Twine tying Manual" (Figure 105).
Figure 105
88
9.2.3
Figure 106
Trigger tying (E-LINK)
Manual net tying

Select tying mode: "Manual net tying" (see 9.2.2 Select tying
mode).
When the preselected bale diameter is reached, an acoustic
and an optical signal are output: The arrow in the bar graph
rises to the preset value (Figure 106).
Press START/STOP button for about 3 sec. The symbol for
"Tying in progress" appears in the display (Figure 107).
speed (540 min-1).
Should the net roll stop after release of the START/STOP
button: press START/STOP button once again for about 3
sec.
(Figure 108) Acoustic signal at the end of the tying process.
Subsequently: Open tail gate and eject bale (see 9.3 Eject
bales).
Figure 107
Note! When the power take-off shaft is running, tying can

always be started manually.
Figure 108
Automatic net tying

Select tying mode: "Automatic net tying" (see 9.2.2 Select
tying mode).
Tying is started when the preselected bale diameter is
reached, without the driver's action.
An interrupted signal tone taking 3 seconds requests the
driver to stop the tractor. (This signal begins optionally 0 or
2.5 or 5 sec. before net tying is started. The delay can be
entered in the Setup).
After tying has been triggered, the symbol for Tying in
progress appears in the display (Figure 107).
speed (540 min-1).
bales).
89
Figure 109
Manual twine tying

When the preselected bale diameter is reached, an acoustic
and an optical signal are output: The arrow in the bar graph
rises to the preset value (Figure 109).
Press START-STOP key shortly: the twine motor starts. The
symbol for "Tying in progress" appears in the display (Figure
110).
Stop the tractor after about 5 sec. after pressing the
START/STOP button .
speed (540 min-1).
bales).
Figure 110
Figure 111
Automatic twine tying

Tying is started when the preselected bale diameter is
reached, without the driver's action.

An acoustic signal requests the driver to stop the tractor.
(This signal begins optionally 0 or 2.5 or 5 sec. after tying is
started. The delay can be entered in the Setup).
After tying has been triggered, the symbol for Tying in
progress appears in the display (Figure 110).
speed (540 min-1).
Subsequently: Open tail gate and eject bale. (see 9.3Eject
bales).
90
9.3 Eject bales

Proceed with particular care when opening and closing the tail
gate. No persons may stay in the swivelling range of the tail
gate and in the bale unloading area.
When opening the tail gate keep a minimum distance of 2 m
from electrical high-voltage lines.
In case of locations on a slope: place the round bales always so
that they cannot move automatically.
Figure 112
Figure 113
9.3.1

After tying has been finished: open the tail gate hydraulically
by means of the tractor control valve so that the bale rolls
out. Hold tractor control valve in "Lift" position until tail gate
is fully open.
The upper white lamp [3] (Figure 113) (on the RP 505 SPECIAL
and RP 535 it is the left white lamp) will be on as long as the tail
gate is not locked.
The lower white lamp [4] (on the RP 505 SPECIAL and RP 535
it is the right white lamp) will light up only for a short time, when
the bale rolls over the bale ejector.
When the white lamp [4] has gone out (not earlier, because
the bale is still in the swivelling range of the tail gate): close
the tail gate hydraulically by means of the tractor control
valve. Hold tractor control valve in "Lower" position until the
tail gate is definitely locked.
As soon as the tail gate is closed, the white lamp [3] goes out
and crop pick-up for the next bale can be started.
Set tractor control valve to floating position after actuation
("Neutral" position).
91
Figure 114
9.3.2
After tying has been finished: open the tail gate hydraulically
by means of the tractor control valve so that the bale rolls
out. Hold tractor control valve in "Lift" position until tail gate
is fully open.
The request to close the tail gate appears in the display after
the bale has passed the bale ejector (Figure 114).
close the tail gate hydraulically by means of the tractor
control valve. Hold tractor control valve in "Lower" position
until the tail gate is definitely locked.
As soon as the tail gate is locked on both sides, the normal
display Bale (Figure 115) appears and crop pick-up for the
next bale can be started.
Set tractor control valve to floating position after actuation.
Figure 115
92
9.4
Emergency operation
Even in case of failure of the electronic control system the most

important machine functions can still be executed.
Note! Emergency operation must not be used for daily

production. It is intended only for finishing the work started.
9.4.1
Emergency operation: bale diameter reading
RP 405 SPECIAL / RP 435 / RP 435 MASTER
RP 505 SPECIAL / RP 535 / RP 535 MASTER
The current bale diameter can always be followed by observing
the bale diameter display [2] (Figure 116) on the machine front.
For triggering tying: see following chapters.
Figure 116
9.4.2
Emergency operation: Net tying
RP 405 SPECIAL / RP 435
Net tying can be triggered by means of the electric lighting
system. The plug connection [1] projecting from the cable
harness on the right side of the machine serves for this purpose
(Figure 117).
The black attachment plug [2] of the electric net coupling is
simply plugged into the empty white socket [1].

To trigger net tying, actuate the parking light of the tractor
until the bale has grasped the net.
Figure 117
Note! If the lighting system is permanently switched on

(e.g. for driving on the road), it is essential that the provisional
connection of the net tying unit is interrupted.
93
9.4.3
Emergency operation: Net tying
Net tying can be triggered by means of the electric lighting
system.
Interrupt electrical connection between tractor and machine.
(Figure 118) Move the net knife by hand to severing position:
pull the knife carrier slightly to the front against the spring
tension, so that the segment does not rest any longer on the
roller. Press the segment to the rear and place the knife
carrier slowly on the anvil.
Figure 118
(Figure 119) Move net position sensor as far as possible up
in the sensor support since otherwise the rod head will

damage the sensor. (see also point 6)
Figure 119
Remove connecting rod [1] (length 105 mm) from the square
hole of the control lever [2].
Figure 120
Remove connecting rod [1] (length 105 mm) from the cam
[3] of the rubber roller.
1
Figure 121
94
(Figure 122) Remove stop plate.
Figure 122
(Figure 123) Attach the longer connecting rod [1] (length 145
mm) included in the delivery to the slotted hole of the control

lever [2] and the cam [3] of the rubber roller.
Setting of the net layers (+/-): shift the wing nut of the
connecting rod [1] in the slotted hole.
1
3
Caution!
The control lever [2] must point downwards to prevent the
connecting rod [1] from dragging along the motor or the sensor
support.
2
Figure 123
(Figure 124) Action on the plug connection [11] (projecting from

the cable harness on the right side of the machine):
The black attachment plug [10] of the electric net coupling is
simply plugged into the empty white socket [11].
To trigger net tying, actuate the parking light of the tractor
until the bale has grasped the net.
10
11

Figure 124
95
Finishing emergency operation of net tying unit RP 435

MASTER and RP 535 MASTER:
Restore original state (install short connecting rod).
(Figure 119) Adjust the net position sensor shifted upwards
to a distance of 1-2 mm from the cam (rubber roller).
(Figure 122) Attach stop plate to angle bar and adjust a gap
of 2 mm to the knurled wheel.
In the "Diagnosis" menu: Check the net coupling / knife
triggering function and the function of the net run (net layer)
sensor. (See separate operating manual E-LINK for RP 435
MASTER.)
9.4.4
Emergency operation: TWINE TYING
No emergency operation possible.

This emergency operation requires an intact main power supply
between tractor and machine.
(Figure 125) Unplug the two plugs [5] and [6] from the
control unit [7] and fasten them so that they do not collide
with the running machine.
(Figure 117) Open the red plug connection. Then simply
plug the red attachment plug into the free white socket [1].
To trigger twine tying switch on the parking light (or the low
beam or the high beam) of the for a short time until the twine
is grasped by the bale.

Figure 125
96
9.4.5
Emergency operation: Bale density
A hydraulic block is located on the rear side of the machine
(Figure 126). Adjust the lever to vertical position
Turn the handwheel attached to the side of the machine
clockwise up to the stop. In this position maximum pressure
(maximum bale density) is set. If a lower bale density is
desired, the handwheel can be turned back in
counterclockwise direction.
The preset bale density (i. e. the baling pressure) is indicated
on the pressure gauge [1] (Figure 116).
Figure 126
97
10
Removing a material jam

Malfunctions on the draw-in elements (e. g. pick-up, draw-in
screws and tine rotor) may only be remedied after
disconnection of the control system from power supply (interrupt
electric connection to tractor), when the tractor motor has been
stopped and the ignition key removed!
On machines with cutting device* there is danger of injury by
knives when working in the feed channel. Wear always
protective gloves!
10.1
Main drive reversing
RP 405 SPECIAL / RP 435 without HYDROFLEXCONTROL*

RP 505 SPECIAL / RP 535 without HYDROFLEXCONTROL*
If the feed channel jams on machines without hydraulic bottom
door (without HYDROFLEXCONTROL) the main drive can be
reversed manually (Figure 127):
Switch off power take-off shaft.
Stop the tractor engine and take out the ignition key.
Attach turning handle (wrench size 46 mm) and reverse
machine until the feed channel can be emptied.
Figure 127
98

Prior to restart the machine: dismount turning handle and close
all guard casings!
10.2
Hydraulic bottom door*
The bottom door (HYDROFLEXCONTROL) can be opened

hydraulically. The empty space beneath the rotor is clearly
increased. In this way, jammed material is drawn through
easier, grasped by the bottom baling roller and conveyed into
the roll chamber.
Figure 128
10.2.1 Behaviour during material jam (E-LINK)

Stop driving and switch off power take-off shaft.
In the menu "MONITOR": Press centre key repeatedly until
the symbol "Bottom door" is displayed (above the centre
key).
Operate the tractor's distribution valve so long until the
bottom door is completely opened and until the knives are
moved completely to home position (i.e. until the knives are
moved completely into the knife bottom plate).
The window "Bottom door open" is displayed (with flashing

exclamation mark, Figure 129) when the bottom door is open.
The symbol "Cutting device" disappears when the knives are
inserted into the knife bottom plate (in Figure 129 still
displayed).
Switch on PTO shaft again.
Figure 129
After material jam has been removed by itself:

In the menu "MONITOR": Press centre key so many times
until the symbol "Cutting device" (with the desired number of

knives) is displayed (above the centre key).
Operate the tractor's distribution valve so long, until the
plate) and until the bottom door is completely closed
(window "Bottom door open" disappears).
That the hydraulic accumulators can be filled: Operate
tractor's distribution vale for another 5 sec.
99
10.2.2 Behaviour during material jam (BALERCONTROL E)

Actuate the connected tractor distribution valve until the
bottom door is completely opened and until the knives are
moved completely to home position (i.e. until the knives are
moved completely into the knife bottom plate).
Switch on PTO shaft again. The material jam is removed by
the running conveying devices.
After the material jam is removed:
Figure 130
Operate the tractor's distribution valve so long, until the

plate) and until the bottom door is completely closed.
distribution valve after moving the knives for another 5 sec.
100
10.2.3
Special case:
Behaviour in case of material jam
(BALERCONTROL E) in case of operation with
BLOCKED bottom door
See chapter 7.4 Lock bottom door.
Operate the connected the tractor's distribution valve so long
as it takes to move the knives totally into home position (that
means until the knives are totally moved into the knife
bottom plate).
Figure 131
If the material jam is removed:

Operate the connected the tractor's distribution valve so long
as it takes to move the knives into cutting position (that
means until the knives are moved out of the knife bottom
plate).
distribution valve after moving the knives for another 5 sec.
If the material jam is not removed:
Switch off power take-off shaft.
(Left machine side, Figure 132:) Turn right ball valve through
Figure 132
Figure 133
90 counterclockwise. The right ball valve of the hydraulic

block must point to the tail end of the machine. The left ball
valve of the hydraulic block must point away from the
machine.
Operate the connected tractor's distribution valve until the
bottom door is completely opened.
Close bottom door: Operate the tractor's distribution valve so
long, until the cutting device is moved completely to cutting
position (i.e. until the knives are moved completely out of the
knife bottom plate) and until the bottom door is completely
closed.
distribution valve after closing the bottom door for another
5 sec.
(Left machine side, Figure 133:) Turn right ball valve through
90 clockwise. The right ball valve of the hydraulic block
must point away from the machine again. The left ball valve
of the hydraulic block must point away from the machine.
Attention!
The knives move automatically into working position when
closing the bottom door. If it must be worked without knives the
knives must then be moved back to home position: see chapter
"7 Cutting device".
101
11
Maintenance / Setting

Never perform maintenance- and repair works during machine
is in operation. stop the tractor engine and take out the ignition
key, wait until the machine has stopped, switch off PTO shaft
and pull drive shaft from the PTO shaft before start working at
movable parts of the machine.
Never step onto the maintenance platform during machine is in
motion. Before stepping onto the maintenance platform: stop
machine, switch-off power take-off shaft and tractor motor and
wait for standstill of the machine.
If any maintenance or assembly work is carried out with the tail
gate open, the tail gate must be hydraulically secured against
lowering for safety reasons:
For this use the shut-off valve located at the maintenance
platform. When the valve is shut off, the actuating lever is at
right angles to the flow direction (Figure 2).
11.1
General notes
After the first 20 running hours: Retighten all fastening
screws, wheel nuts, drawbar screws and nuts also inside

the machine. Exception: Do not change adjusting screws,
e.g. on the twine guiding or the net brake.
11.2
Grease knife lever
Only machines with cutting device XtraCut 17 and XtraCut 25:

Nonrecurring 3 weeks after first commissioning: Grease the
knife levers [1] (grease nipple at the bottom side of each
knife lever).
Nonrecurring 3 weeks after first commissioning: Grease the
knife lever [2] (grease nipple at the bottom side of the knife
lever).
After set regrease once per season.
Figure 134
102
11.3
Tensioners
Caution!
(Figure 135) The gears [2] of the main drive shaft [1] are
mounted with tensioners to the shaft end. Working at the
tensioners [3] must only performed by instructed technical staff.
Figure 135
11.4
Figure 136
Maintenance of the net tying unit
11.4.1 Adjusting the disk brake of the net tying unit

(Figure 136 and Figure 137) To prevent coasting of the net
roll the disk brake must be adjusted in such a way that the
brake disk can no more be turned by hand when the lever [1]
points upwards.
Slacken screw [2] on the lever [1], tighten milled nut [3] so
far that the brake linings are fully attached to the brake disk.
Retighten screw [2].
When brake lining [4] is worn only one-sided slacken lock
nut [5] and slightly insert screw [6] until brake linings are
parallel again, lock screw [6] again.
Figure 137
103
11.4.2 Adjusting the shock absorbers

(Figure 138) On the left machine side, the movements of the net
tensioner [12] are braked by a shock absorber.
Two wing nuts (arrows in Figure 138) press the friction linings
against the net tensioner from both sides.
For adjustment first move the net tensioner to the top end
position and tighten the wing nut "hand-tight".
Proceed analogously in the bottom end position. The
adjustment is correct, if the net tensioner can just still be
moved to and fro between the two end positions by hand.
12
Figure 138
During net tying the net tensioner may move between the two
end positions only in such a way that the net always remains
properly tensioned.
Attention, danger of injury by cutting!

Do not reach into the area of the net knife! Wear protective
gloves.
11.5
Tensioning the roller chains
Chain tensioning has to be checked and/or retightened at
least after 500 bales.

On pick-up or cutting device drive*: loosen and readjust
chain tensioning blocks in the slotted holes. Subsequently

tighten the tensioning blocks properly.
The other drive chains are tensioned flexibly by springs
(arrow in Figure 139). Lock the nut again after adjustment. If
chain tensioning is no more possible, shorten the chain by
removing a chain link. If necessary insert a cranked chain
link.
12
Note! New chains elongate already after a short time of

operation. They can therefore be tensioned a little bit stronger.
Figure 139
104
11.6
Hydraulic layouts
11.6.1
Hydraulic layout
Machines
with E-LINK
with HYDROFLEXCONTROL bottom door
with 13-, 17- or 25-knife cutting device
Figure 140
Figure 141
105
11.6.2
Hydraulic layout BALERCONTROL E

Machines
with fixed bottom door
with cutting device
Figure 142
106
11.6.3
Hydraulic layout BALERCONTROL E

Machines
with HYDROFLEXCONTROL bottom door
with cutting device
Figure 143
107
11.7
Tire air pressure RP 405 / RP 435
Tire size
max. speed
Pressure
15.0/55-17 (NOT for RP 435 MASTER)
40 km/h
2.75bar
19.0/45-17
40 km/h
1.5 bar
380/55-17 (NOT for RP 435 MASTER)
40 km/h
2.0 bar
425/55-R17
40 km/h
2.0 bar
500/55-20
40 km/h
1.5 bar
2.0 bar
max. speed
Pressure
15.0/55-17 (NOT for RP 435 MASTER)
40 km/h
3,0 bar
19.0/45-17
40 km/h
2,0 bar
380/55-17 (NOT for RP 435 MASTER)
40 km/h
2,4 bar
425/55-R17
40 km/h
2,0 bar
480/45-17
40 km/h
2,0 bar
500/50R17
40 km/h
1,75 bar
500/55-20
40 km/h
1,5 bar
500/60-22.5
25 km/h
2,4 bar
2.0 bar
Tightening torque for wheel nuts: 460 Nm

170/60-8 (pick-up guide wheel)
11.8
Tire air pressure RP 505 / RP 535
Tire size
Tightening torque for wheel nuts: 460 Nm

170/60-8 (pick-up guide wheel)
108
11.9
Chain lubrication (oil lubrication)
(Figure 144) The mechanical chain lubrication system with oil

reservoir supplies the drive chains of the machine with
lubricating oil.
Caution!
Check oil level daily. Oil reservoir must never run completely
empty! Otherwise the lubricating pump and the roller chains
may be damaged.
Check oil level in oil reservoir daily (visual check). Never let
the oil reservoir run completely empty.
Figure 144
11.9.1 If nevertheless the oil reservoir runs empty:

Fill with oil
(see chapter 11.9.2 Fill with oil).
Deaerate the system
(see chapter 11.9.3 Deaerating the system).
11.9.2 Fill with oil

To prevent dirt from getting into the lubrication system
proceed as follows before opening the tank cover: Clean the

surroundings thoroughly. Unscrew tank cover.
Fill the oil reservoir with clean lubricating medium via the
filling filters!
Observe the lubricant specifications by the machine
manufacturer! Observe the safety data sheet by the lubricant
manufacturer! The viscosity range of the lubricant changes
with the operating temperature.
Check the oil level several times at equal intervals during the
first hours of operation.
If required refill clean lubricating medium.
Refill oil up to the max. mark.
Oil type: see chapter 11.11 Lubrication chart.
Caution!
To avoid damage to the lubricating pump and the roller chains
or to the machine: use exclusively clean and fresh oil.
Check tank screen in the oil reservoir for dirt or blockage
(visual check).
Screw cover down again.
109
11.9.3 Deaerating the system

Deaerate the system during first commissioning and whenever
the oil reservoir has been emptied completely ! Deaeration is
effected by unpressurized operation with all system outlets
opened.
Detach lubricating lines from the lubrication points.
Start and run the pump until the lubricating medium flows
from every lubricating line without air bubbles.
Collect lubricating medium at the end of the line in suitable
vessel (pollution control; safety at work).
Dispose of the collected lubricating medium properly.
Reconnect the lubricating lines to the lubrication points.
Perform visual inspection of the connections for tightness.
If required refill clean lubricating medium.
11.9.4
If required: clean screen
Unscrew tank cover.

Remove screen.
Clean the screen thoroughly using exclusively petroleum
benzine or petroleum.
Insert screen and screw cover on again.
Subsequently:
Check oil level in oil reservoir daily.
11.9.5 Once per year: clean complete lubricating pump

Detach the pump from the machine.
Disconnect all lubricating lines from the plug-type
connections.
Empty the pump completely.
Dispose of the lubricant residues properly!
Loosen cap nuts on the cover of the oil reservoir.
Remove cover and oil reservoir .
Wash pump thoroughly with benzene, petroleum or suitable
cleaning agent and rinse.
Wash oil reservoir thoroughly with benzene, petroleum or
suitable cleaning agent.
Reassemble the pump and attach it to the machine.
Fill oil (see chapter 11.9.2 Fill with oil).
Deaerate the system
(see chapter 11.9.3 Deaerating the system).
110
11.9.6
Regulating the flow rate:
Caution!
To avoid damage to the lubricating pump and the roller chains
or to the machine: The flow rate of the lubricating pump
correctly set in the factory must not be changed.
If certain cases require adjustment of the flow rate: such work
may be carried out only by trained and instructed service
personnel on the basis of the service information provided by
Welger.
11.10 Winter pause

Prior to a winter pause:
Place the machine on an even surface.
Unthread twine, unthread net.
Remove twine, net and straw remains from the machine.
Disconnect control box from the machine (pull plug).
Keep control box dry and at room temperature.
Remove, grind and reinstall cutting device knives.
Grease tying mechanism.
Thoroughly lubricate all bearings.
Slightly grease the surface of the baling chamber by means
of a lubricant degrading neither the environment nor the
fodder ( e.g. rape oil).
Check and if necessary adjust air pressure of tires (11.7
Tire air pressure RP 405 / RP 435 or 11.8 Tire air pressure
RP 505 / RP 535).
111
11.11 Lubrication chart

3 weeks after first commissioning
Item in
(Figure 145)
Machine part
14
Only machines with cutting device XtraCut 17

and XtraCut 25: grease knife lever (see
11.2Grease knife lever)
Lubricant (Table 3) Note

A
3 weeks after first commissioning,

then once per season
After each 500 bales (or daily)

Item in
(Figure 145)
Machine part
Lubricant metering device (roller lubrication)

A2)
Left machine side
After each 500 bales (or daily)

Item in
(Figure 145)
Machine part
Drive shaft
Autom. chain lubrication system
Hinge of tail gate
A1)
Locking hook
on both sides
Roller on locking device
on both sides
Cutting rotor
on both sides
Castors*
on both sides
Right machine side (Figure 144)

see 11.9 Chain lubrication (oil
lubrication)
1) Depending on version, already supplied by central metering device.

2) Supply metering device by means of 2 strokes from the manual grease gun - do not use compressed air grease gun.
112
Annually after the end of the season (in case of special operating conditions also weekly)
Item in
(Figure 145)
Machine part
Belleville springs of the locking hooks
Main gear unit
10
Movable parts of the net tying unit* or

movable parts of the twine tying unit*
provide for smooth motion
11
Hydraulic cylinder
on tail gate locking mechanism
on both sides
12
Star ratchet in pick-up drive
Left machine side
13
Twine eyes
grease chafe marks slightly
14
Only machines with cutting device XtraCut 17

and XtraCut 25: grease knife lever (see
11.2Grease knife lever)
3 weeks after first commissioning,

then once per season

E
C / 1.7 l
Dismantle, clean and grease;

Attention: do not change sensor
setting!
Oil change
Check filling level with dip stick or
overflow hole
Annually
Item in
(Figure 145)
Machine part
15
Brake

A
on both sides
113
11.12 Lubrication points
Figure 145
Lubricant
Trade name, e. g.
Multipurpose grease
Fuchs Renolit FEP 2

Bechem High-Lub LM 2 EP
BP Energrease LS-EP2
Elf Epexa 2
Esso Beacon EP 2
Chain lubrication
Lubricant according to ISO VG 68 ISO VG 220 (not thickening)
Gear oil
SAE 90 API GL - 5
Machine oil
---
Multipurpose grease
Gleitmo 810
Multipurpose grease
Multipurpose grease according to NLGI-class 2,

with high pressure additive, without solid parts
Table 3: Specification of the lubricants
114
12
Technical Data
Roll chamber ( x width) [m]

Net tying with high-grade round bale net
RP 405
RP 435
approx. 1.00 ... 1.55 x 1.23
approx. 1.00 ... 1.55 x 1.23
Length: 2,000 or 3,000 m / width: max: 1.30 m
Tying material stock (net)
1 roll in working position +

2 spare rolls

2 spare rolls
Pick-up*
Pick-up width [m]
2.00
2.00
2.25
Rake width [m] DIN 11220
1.60
1.60
1.86
Speed of tractor p.t.o. shaft [min-1]
540
540
Necessary connectors
Connection for lighting system
12 V (7-pole plug socket)
Connection for control system
(BALERCONTROL E or E-LINK)
12 V DIN 9680
Permissible total weight [kg]
s. data plate on the machine

1)
Design-conditioned permissible maximum speed
see chapter 2.12 To heed in the road traffic
Data are for approximate specifications and are not binding. Versions can vary.
1)
Observe deviating national road traffic law!
115
Roll chamber ( x width) [m]

Net tying with high-grade round bale net
RP 505
RP 535
approx. 1.00 ... 2.00 x 1.23
approx. 1.00 ... 2.00 x 1.23
Length: 2,000 or 3,000 m / width: max: 1.30 m
Tying material stock (net)

2 spare rolls

2 spare rolls
Pick-up*
Pick-up width [m]
2,00
2,00
2,25
Rake width [m] DIN 11220
1,60
1,60
1,86
Speed of tractor p.t.o. shaft [min-1]
540
540
Necessary connectors
Connection for lighting system
12 V (7-pole plug socket)
Connection for control system
(BALERCONTROL E or E-LINK)
12 V DIN 9680
Permissible total weight [kg]
s. data plate on the machine

1)
Design-conditioned permissible maximum speed
see chapter 2.12 To heed in the road traffic
RP 535
Data are for approximate specifications and are not binding. Versions can vary.
1)
Observe deviating national road traffic law!
116
EC Declaration of Conformity
according to Directive 98/37/EEC
We
Welger Maschinenfabrik GmbH
............................................................................................................................................................................................................
(Name of supplier)
Gebrder-Welger-Strae, D-38304 Wolfenbttel
............................................................................................................................................................................................................
(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 405 / RP 435 / RP 505 / RP 535
............................................................................................................................................................................................................
(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))
Wolfenbttel, Januar 2006
Englisch

Lely Welger: Operating Manual

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LELY WELGER

RP 405 / 435 / 505 / 535

Send back to:

Lely International N.V.

(Copy for the Manufacturer)

RP 405 / RP 435 / RP 505 / RP 535

Machine no. on the data plate (e. g. 1755.00.001):

I purchased / use this machine.

see spare parts list pages A10, A20, A21

see spare parts list pages A10, A20, A21

Before first use: Unlock hydraulic of bottom door

Send back to:

Lely International N.V.

(Copy for the Customer)

RP 405 / RP 435 / RP 505 / RP 535

Machine no. on the data plate (e. g. 1755.00.001):

I purchased / use this machine.

see spare parts list pages A10, A20, A21

see spare parts list pages A10, A20, A21

Before first use: Unlock hydraulic of bottom door

(Copy for the Trader)

RP 405 / RP 435 / RP 505 / RP 535

Machine no. on the data plate (e. g. 1755.00.001):

I purchased / use this machine.

see spare parts list pages A10, A20, A21

see spare parts list pages A10, A20, A21

Before first use: Unlock hydraulic of bottom door

(Copy for the Importer)

RP 405 / RP 435 / RP 505 / RP 535

Machine no. on the data plate (e. g. 1755.00.001):

I purchased / use this machine.

see spare parts list pages A10, A20, A21

see spare parts list pages A10, A20, A21

Before first use: Unlock hydraulic of bottom door

The serial number is shown on data plate on the right

WELGER RP 405 RP 435 RP 505 RP 535

General safety instructions................................................................................................................. 8

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

Coupling the baler ............................................................................................................................ 28

Threading the twine.......................................................................................................................... 39

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

Inserting the net................................................................................................................................ 45

WELGER RP 405 RP 435 RP 505 RP 535

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

Locking the tail gate ......................................................................................................................... 75

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

BALERCONTROL E control box...................................................................................................... 84

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

General notes................................................................................................................................. 102

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

WELGER RP 405 RP 435 RP 505 RP 535

Ring type rotor

without cutting device

WELGER RP 405 RP 435 RP 505 RP 535

Ring type rotor

without cutting device

WELGER RP 405 RP 435 RP 505 RP 535

General safety instructions

WELGER RP 405 RP 435 RP 505 RP 535

x Do not step onto the drawbar or other parts of the machine,

WELGER RP 405 RP 435 RP 505 RP 535

The EC directive 86/188/EEC (or EC directive 2003/10/EC)

Instructions for fire protection