Welger AP 38 Operating instructions

Brand: Welger

Model: AP 38

Type: Operating instructions

This manual is also suitable for

Working Instructions

The serial number of Jour pick-up baler

is stamped into the machlne piste shown

by arrow on the adjolnlng photo. Please

enter the number in the space below

as soon as you take delivery of the

machine. Guarantee claims and querles

cannot be dealt wlth unless the number

Is quoted in full.

Contents

TechnicalData 2

Preparing for Werk 4

AttachingtheBaler... . .. ... 4

Positioning Drawbar 4

Fitting the Universal Drive Shaft. 5

Cleaning Knotters 5

Inserting Twine Spools 5

Securing the Knotter Trip. .. . . . . 6

Threading the Twine 6

Setting the Twine Tensioner... .. 7

Tripping the Knotter Mechanism. 7

Bringing Twine info Knotter 7

BaleCounter 7

Bale Density " 7

Adjusting Pick-up Height 7

Windguard Adjustment 8

Setting the Bale length 8

pro Speed 8

Windrowing 8

EvenBaling 8

Before Turning .." 8

Safety Devices 8

Useful Accessories 8

Service end lubrication 10

Oil Change of Gear Box. . . . . .. 11

lubricating the Knotter Unit 11

Adjustment of Ram 12

Setting of Frame Knife 12

Grinding Knives 12

BalerTiming 12

Timing Need!e to Ram 13

Timing Top Feed to Ram 13

Packer Position Adjustment 14

Timing of Cross-feed

to Top Feed 14

NeedleSetting 15

----

'128-10

Knotter Beak Tension 15

Twine Retainer Tension 16

Adjusting the Twine Flicker 16

Twme Stop Spring 16

Twine Guide Plots " 16

Twine Tensioner " 16

Overloading Safety Devices 17

Double Slip Clutch end Shear

Bolt in Main Drive AP 42, AP 53 . 17

Single Slip Clutch Unit end Shear

Bolt in Main Drive AP 48 17

Slip and Overrunning Safety

Clutch of Pick-up Drive 17

Safety Device for Packer end

Cross-feed AP 42 end AP 53 18

Packer with Mechanical Over-

loading Safety (AP 48) 18

Safety of Tripping Mechanism ... 18

Pick-up Balance Spring.. 18

Need le protection " 19

lubrication Chart 20

Troubles end Remed:es 22

Faultytwine Knots 24

Wire Tying - AP48 D / AP53D ... 26

Inserting the Wi.re 26

Pulling Wire info the Tiers. . . . .. 27

Service end lubrication 27

Needle Adjustment , 28

Shear lever Adjustment 28

Timing of Twister Hook 29

Needle to Ram Timing 29

Mistying Wire 30

General Accident Prevent-ive

Safety Rules 32

After season Maintenance of

Baler 32

IMPORTANT NOTE

This operation manual covers the models AP 38, AP 42, AP 48 and AP 53. If not

stated differently, text and figures refer to all tour models. Pages 28 - 33 refer only to

AP 48 D respeetively AP 53 D. The indication right, left, front and rear refer to

the baler operating direction.

prior nollee, technieal details are not binding.

Republie of Germany.

,1 PICK-U P BALERS

AP3B

AP42

AP4B-AP4BD

AP~53-AP53D

Twine Tying

Wire Tying

Domestic and Foreign Patents

GEBRUDER

1IIIELGER

GMBH & CO. KOMMANDITGESELLSCHAFT

Address:

Telephone:

Telex:

Teletex:

Telegrams:

D-3340 Wolfenbüttel, P.O. Box 1560

5331-404-0

95639

(17) 5331831

welger wolfenbüttel

--1

Technical Data

AP 38/42

AP 48/53

Dimension of baler

(in mm)

, Overaillength:

a) transport

b) at werk with chute

Overall width:

a) with standard tyres

b) with special tyres

Height:

Weight of baler inStandard version (kg):

a) twine tying

b) wire tyjng

Bale si:z:e:

Height x width (mm):

Length (m):

Steplessly variable from

Bale weight (kg):

according to length

end density

Pick-up width (mm):

Tines per row:

Tine space (mm):

Track width (mm):

a) standard tyres

b) special tyres

Tyres:

a) standard Irres

left

right

b) special tyres

left

right

Required tractor pro speed I):

4400

4670

4600 14650

5000 15050

2410

2490

1445

2490 12560

2515 12585

1500

1170/1180

1300/1380

1320/1400

310x410

0.5- 1.0

360x 480

0.5- 1.2

AP 38/42

AP 48/53

Required tractor power:

dependingon duty end terrain

from 15 kW (20hp)

Number of ram strokes

100/min

Capacity (hay):

a) haiesdepositedon theground

b) withloading chute

up to 12 t/h

depending on

loading personneil

Tying:

double twine

Tying material:

a) sisalbaling twine

200 or 150 m/kg

300 or 225 ft./rlb.

1,8 kg/t

400 or 320 m/kg

600 or 385 ft.llb.

0,9 kg/t

consumption approx. 2)

b) plastic baling twine

consumption approx. 2)

c) wire

18 kW (25 hp)

100/min

upto14

respectively 16 t/h

depending on

loading personnel

double twine or

double wire

200 or 150 m/kg

300 or 225 ft./lb.

1,4 kg/t

400 or 320m/kg

600 or 385ft./lb.

0,7 kg/t

Ungalvanized,

annealed end oiled

tying wire of 1.8

or 2 mm gauge,

tensile strength

35-49 kg/mm2

610ngation mini-

mum of 12% at

25,4 cm length

Dimension of wire

coil (mm):

a) euter coil

dia. 336 mm

b) inner wil

dia. 208 mm

c) coil width

152mm

d) coil weight

approx. 45 kg

consumption

approx. 3.6 kg/t 2)

') Required:

clutch-controlled standard PTO (DIN 9611

-pottern A); highly recommended: angina PTO; in-

dependent clutch; impermissible: usa of ground PTO, governed by engoged geer; under no

circumstances usa 1080

r.p.m. PTOspeed.

'J ot medium bole weight

8-20

10-35

1660/1730

2105

2200/2240

2185

2245

7.00-12Impl. 10.0175-15Impl.

5.60-15

5.60-15/7.00-12Impl.

10.0175-15Impl. 11.5/80-15Impl.

7.00-12Impl.

8.00-12Impl.

540/min 540/min

Preparing tor Work

Balersare thoroughlytested and carefull

lubricated before leaving our werks and

are ready tor immediate service at fu,l capacity when observing the following

instruetions.

Attaching the Baler

Connect to traetor possibly without play, usa

the same dia. hole in traetor drawbar and

baler drawbar are. Standard fitting on baler

22mm dia. drawbar eye (also available with

32 mm dia. hole).

Stabilize traetor hitch or drawbar. Set baler

info horizontal position by turning handle 2

(fig. 1) and conneet to tantra of traetor hitch

or drawbar. If necessary re-set hitch on baler

drawbar according to height, side displacement

can be made up to 160mm. Secure safety chain

of conneeting pin around front of drawbar.

Retraet jack till stop by turning handle 2 (fig. 1).

Positioning Drawbar

Release bell 3 (fig. 2) and lock (operation of

bell 3 is also possible with a puUing rope from

traetor seal). Swing baler info position A or B

and re-positi,on bell 3 again.

ATTENTION!

Usa drawbar jack when storing baler, mind pin-

thing po,ints on swivel drawbar.

Hydraul,ic operated drawbar shifting device is

ava,i:lable as specia,! equipment tor AP 53.

ShiUing device is opera ted through traetor

hydraul,ic. The traetor must be equipped with

double aeting hydraulic valve.

FiHingthe Universal Drive Shaft

Clean splines on traetor and baler pto from

proteeting grease. Press in slide pins and fit

joints on both stubs (fig. 3), slide pins must snap

info position. Secure safety chai,n on to draw-

bar. Fold joint prop 4 away to the rear as

shown in fig. 1, see arrow.

Clearance between pro end and traetor draw-

bar hole (distance C in fig. 3) should be 330-

600mm. Usa Ionger pro shaft (size h) if distance

is more thon 600 mm. If i.t is smaller thon

330 mm, fit a drawbar extension. Telescoping

length of PTO-shaft tubes (distance D in fig. 3)

should be at least 300mm when driving straight

ahead. If necessary, shorten shaft by cutting off

equallengths from euter and inner tubes.

Cleaning KnoHers

Carefully clean knotter beaks and twine re-

tainers (see arrows in fig. 4), so thaI the twine is

securely held and cannot wind round the twine

retainer shaft.

Inserting Twine Spools

Only usa baling twine of best quality, see

technical data page 3. Place tour spools of

twine (fig. 5) side-by-side in upright position

info the twine box (wrongly inserted spools may

lead to tangled twi.ne and breakage). Four

balls of twine can be stored in the additional

twine box (AP53).

Pull twine end from spool E out of paper cover

and join to twine start of spool F (conneet

spool G and H in the same manner).

Plastoietwine allows any normal knot, but a

special knot is recommended tor si,sal twine as

fellows :

Rough up and untwist both ends. Make a single

knot, spließ and roll open ends together as

per fig. 6. Now hold ends closed (fig. 7) and

fighten the knot slowly.

Give knot a final hard lug and roll proieeting

ends between hands. Properly made, this spe-

cial knot (fig. 8) is hardly thicker thon the twine

itself.

I-

fig.4

fig. 5

fig. 6

fig, 7

fig. 9

fig.8

Attention! Securing the Knotter Trip

If needles are in bole chamber turn flywheel in fight direction unHI needle end

knotter geer is in resting position. Turn lolch 1 (fig. 9) upwards, slide it outwards

through the sial info position "Aus" end turn it down again.

Threading the Twine

Attention!Weit for standstill of baler before threading, secureknaller trip first as

describedabove.

fig.10

Observe fig. 10 closely when threading the

twine. Correctly threaded twine should not

touch end run freely.

Setting the Twine Tensioner

For fight adju'Stmentof twine tensioner check

distanceU on page16.

Tripping the Knotter Mechanism

Disengage trip (fig. 9). Turn metering wheel 2

by hand in direction of arrow until control

rod 3 trips.

Bringing Twine info Knotter

Turn flywheel in direction of arrow (fig. 11)

until needles have risen end returned end have

threaded the twine info both twine retainers.

PulI loops off .both knotters, remove twine ends

from needle frame.

Bale Counter

To have a control of the number of boles

made, the bole counter has to be turned to

"zero" with the key supplied before storting

to bole (fig. 12).

Bale Density

Loosen tension spring 6 (fig. 13) on both sides

of the bole chamber before storting to boJe:

Tighten them only gradually to desired bole

denstity when the boler is at werk.

Adjusting Pick-up Height

Set pick-up with rope 23 (fig. 14) so thai fines

have a ground clearance of approx. 2 cm. Tie

the control rope to the tractor leaving a little

slack. A light short pull reises the pick-up. To

lower it, first give one strang pull, then a

second light end brief one.

The hydraulic pick-up lifting device (extra equip-

meßt) is operated through the tractor hydraul,ic

system (single acti,ng control valve is necessary).

Connect hydraulic coupling (ba'ler side) to the

hydraul,ic connecting of tractor, open block

valve. Adjustment of pick-up is now made

through tractor hydraulic control valve.

fig. 12

fig. 13

fig.14

'4:

Windguard Adjusfmenf

The windguard can be set info two different positions, freely movable between

two stops. Accordingly to different baling material, the windguard can be set

info a lower or higher position. T0 pick-up short material the windguard is fixed

intb ,tower hole po

sition of pick-up side guard. Normal baling material in higher

hole position of pick-up side guard.

, Seffing fhe Bale Lengfh

By turning adjusting nut 4 (page 6, fig. 9) in direction of arrow the bole is getting

Ionger, turning in opposi.te direction the bole is getting shorter.

pro Speed

To maintain the specified number of rem strokes of 100/min. your pro speed

must be 540 r.p.m. Check this against your watch from time to time. Fast running

may causa trouble end wear - slow running overloads drive components end

universal joint.

Windrowing

The machine's capacity can only be lJ.tilized to the full when the crop is carefully

raked info' windrows. The windrow should be about 1.60m wide.

EvenBaling

end close matching of tractor speed to windrow height are very important. Where

windrows are tigntly bunched, briefly stop the tractor end allow the baler to

clear itself.

Before Turning

Before turning sharp curves disengage pro to prevent damage to drive parts.

Safety Devices

Indicating end teil lights must be kept clean end. shou,ld not be covered by over-

hanging material. Check function of lighting system regular. Two chocks should

always be carried on the baler.

Useful Accessories

Deflecfor Chufe

throws the boles to the left or right for more clearance of tractor with baler

attached (part number 1115.81.91.01). Fit deflector chute underneath bole chute

end secure with hooks.

Special Tyres

Special Irres are availbale if needed for special purpose.

Order number 1121.02.10.00for AP 38/42 with ~yres 10.0/75-15Impl. 2.3 bar for the

left end 7.00-12 Impl. 2 bar for the ride side. Necessary for operation with P23.

Order number 1122.02.10.00for AP 48/53 comprising of one Irre 11.5/80-15 Impl.

2 bar for the-Ieft side end 8.00-12Impl. 1.5 bar for the right side.

Bale Wedges

narrow baling chamber cross section end so increase bole density. They should

only be fitted when handling dry crops, optional 2 or 4 pe. Order number

1115.03.90.00.

Drawbar Eye for 20 mm (/) Pin

Thi5 type of drawbar eye (order number 1105.05.90.00) with pin (part number

2101.05.07.00)has been designed to f.it the baler more easily to the drawbar of

small tractors.

Pick-upCover Sheef

Pick-up cover sheet i5 recommended for pic~ing up short-stalk crops. (Order

number 1705.42.92.00for AP 38/48, for AP 42/53 order number 1121.42.92.00).

Wide-Angle

Universal Shaft -

Tractor with attached baler becomes more manoeuvrable, as the wide-angle

joint can deflect up to 70 degrees end needs no disengaging when negotiating

curves (order number 0930.14.03.00).

Universal Drive Shaft wifh Overrunning Clufch

It is advisable to use drive shaft with overrunning clutch on tractor's with hydraulic

opemted pro. If fitted, overrunning dutch shou'ld be fitted on baler side. Drive

sllaft with overrunning clutch, order number 0930.10.13.00i wide angle drive

sIlan with overrunning clutch order number 0930.14.04.00.

TrailerHifch

Trailer hitch for AP 38/42 (order number 1121.81.01.00)end for AP 48/53 (order

number 1122.89.01.00) adjustable for length is -necessary when working with

loading chute or the baler mounted bole thrower P 23.

Fit support pipe underneath

of ba,le chamber. Insert trailer h,itch ,info support

pipe in required position end secure with pin end spr,ing clip.

Mounti.ng: AP 38/42 the trai,ler hitch ,ispushed ,info the pipe which is welded under

fhe boJe chamber end i5 locked info required position with pin end spning clip.

Attention! It is not allowed to have more thon 1000mm overhang behind teil

lights villen trave,lIing on open roads.

Deflecfor Chufe

throws the boles to the left or right for more clearance of tractor with baler

attached (part number 1105.81.90.00).

Assembly: by shaft, safety spring end chain at the chamber outtet.

Loading Chute

Loading chute (order number for AP 38/42: 1104.81.06.00 end for AP 48/53:

1105.81.06.00)fitted with trailer hitch,pushes the boles on to an attached trailer.

Attenfion: Bale chute mu~t be laken off the baler for road transport.

Foldable Loading Chufe

A foldable loading chute is also available for AP 48/53 (order number

1122.80.00.00).The chute remains on the baler during transport, it is only folded

to the front. For AP 38/42 order number 1121.80.00.00.

:t~

Pick-up Guide Wheel

The baler can be equipped with a adjustable piä-up guide wheel to have optimum

matching of pick-up to ground condi,tion even on uneven fields end to guarantee

clea,n picking up of baling materi.ail.Order number 1121.42.93.00.The gU'idewheel

can be adjusted :in heighrt as requested. Set pick-up so thai fines have a ground

alearance of approx. 2 cm (fig. 14).Observe correot Irre pressure of 11.5bar.

Baler-Mounted Bale Thrower P 23

is mounted to the end of the bale chamber. It loads the boles on to an allached

trailer with special body extension. Economical one man operation where baling

end loading is doneat the same time. The acreage covered is increased by up

to 40%.

ASSEMBLY: at the factory when the baler is ordered with thrower allached, or

by your loGoidealer, if ordered at a leier stage.

Normal Irres of AP 38/42 should be changed against speoiallIrres, see page 8.

Service

and Lubrication

To keep the value end long life of the machine, generous lubrication end careful

regular serv,icing wil.l keep your baler at peak performance and avoid prema-

lure repairs.

General Hints: 'after the first 20 working hours, firmly fighten up all bolts and

nuts, inside and outside the machine. Timing boHs on knoller and rom sildes

shou,ld not be changed.

Usa lithium multi-purpose grease only for your grease gun. NeVer lubricate the

runni,n

g machine! Clean grease nipples before applying the gun. Drive greas

in until the old packing emerges from the sides of the bearings. Do not wipe

off old grease rims (dust protection I).

Service of Gears

Teeth of all spur end beye! gears should be cleaned as necessary.

Road Wheels

Check wheel nuts and Gaps and fixing bolts of wheel stub axles for light fit.

Maintain correct Irre pressure, on AP 38/42 standard Irres on both sides 2.0 bar.

On AP 48/53 standard Irres for right side 7.00-12 also 2.0 bar, on left Irre 10.0/75-

152.3 bar. Pressure for special Irres see page 8.

eil Change of Gear Box

Carry out first oil change after first 10 duty

hours! Remove crank guard, take off oil filling

bolt 1 with breather, oil drain bolt 2 end oil

level bolt 3 (fig. 15). Clean drain bolt, replace

and fighten. Fi.11about 1 liter of Hypoid Gear

Oi,1SAE 90 (EP90) info geer box until oil leve,1

is reached. Refit bolts 1 and 2 fighten. Change

oll again at the end of every season. Oll level

hag to be checked regu,larly.

Lubricating the Knotter Unit

After every season apply a light coating of

"Lithium" grease to shafts of twine retainer 4

and knoller back 5 (fig. 16). Loosen lock nut 6

and bolts 7 and 8, remoye leaf spring 9. Un-

screw bolt 10 (fig. 17) end balls 11, then re-

moye knoller unit. Expanding pins 12 are

knocked out of pinion 13, then pull twine

retainer and knotter back out of knoller frame

and apply "Lithi'um"grease onto shafts. Care-

fuJ.lywipe off all surplus paste.

IMPORTANT: The lubricant shou'ld never gel

on to retainer taper 4 end clamp

14.

Re-fit twine retainer and beak at correct

position of clamp 14 and knaller cam 15. Fit

pins 12 in correct posiJion of pinlion 13. Mount

knaller unit in reverse order. Adjust screws 7

end 8 at leaf spring 9 as detailed on page 17.

Fit balls 7 and 8 on tension spring as described

on page 15 and 16.

Ii.

fig. 15

fig. 16

fig.17

Adjuslmenl of Ram

Ram 1 (fig. 18) is guided in the bole chamber

by rollers. Its position on forward end back-

ward stroke is assured by two stee,1 angle

guides, one situated on bollom of knife side,

the second one on top of opposite side in bole

chamber. It has 10 be checked regulari,ly if rom

is running free of pier, if not guide angle 2

has to be adjusted accordingly:

Remove gu'ide plate from feed fable.

Loosen fixing bolls 3 (5 pe.) fig. 18, adjust angle

guide 2 with bolts 4 up against rom roller,

repeat until parallelism of guide angles is as-

sured. Fix bolts 3 end lock adjusting bolt 4.

IMPORTANT: After rom adjustment

Setting of Frame Knife

After rom guide adjustment end after the rom

knife is set against the bollom guide angle, the

distance between rom knife end side of bole

chamber must be even on top end bollom.

Frame kni,fe 5 (fig. 19) is set as fol,lows: Loosen

knife bolts, adjust knife 5 with shims to a dis-

tance between 0.1- 0.8 mm, then firmly fighten

knife bolts.

Grinding Knives

Blunt end serrated knives should be regrinded.

Culling angle end leading edges should be

grinded, 100 (fig. 19 and 20). Grind rom knife 6

to a cutting angle of 30 degrees end the low

lead on frame knife, too (fig. 20).

Baler Timing

The following baler timings

Needle 10 Ram

Top Feed 10 Ram end

Cross Feed 10Top Feed

should, if possible, be done in

servi,ce station.

a dealer's

fig. 20

Timing Needle 10 Ram

If new needles have been fitted they shou,ld

be adjusted first (see setting of needles on

page 15).

Disengage knotter (see fig. 9), open side cover 5

(fig. 25), remove locking bracket 7 from pinion

8 (fig. 21). Loosen olamping washer on pinion 8

end move pinion 8 sideways in direction of

arrow until it is disengaged out off knotter

drive geer 9. Turn knotter drive geer in direction

of arrow until point of needles 10 (fig. 22) is

flush with top edge of bollom bar in bole

chamber.

Block knoller drive geer 9. Turn flywheel in

direction of arrow until point of rom 12 has

post the point of needle by 15- 20 mm on its

working stroke. Engage pinion 8 back info

knotter drive geer 9. If it is not possible to

engage pinion 8 info the above mentioned

position, then remove guard out of Iwine box,

move circlip .13 (fig. 23) on hex. shaft about

300 mm to the left. Block top feed end fly-

wheel. Shift hex. shaft 14 out of bevel geer 15

(fig. 24) eHer loosening oIamping disk 18 unti,1

pinion 8 (fig. 21) can be pul.led away from hex.

shaft end be turned '/6 of a turn end be pushed

back on to hex. shaft. If pinion ,is sti,111not

ma,tching repeat ,this operation un~il pinion 8

is matching knoller dnive geer perfectly.

Push hex. shaft 14 back info bevel geer 15,

fighten clamping disk 18 replace locking

bracket 7 end clamping washer aga,inst pinion 8

andtighten. Remove oll blockings.

Now check Dislance L (fig. 22) with rom located

in this position:

Clearance between needle tip 10 end rom

tip 12 must now be 20- 30mm.

Timing Top Feed 10 Ram

When the intake hole is dear of the retracting

rom, the packer feeds the crop info the bole

chamber. This very speedy procedure requires

a perfecttiming.

Lift crank guard end remove guard out of

twi.ne box, take circlip 17 (fig. 23) away from

hex. shaff 14 end loosen clamping washer

on pinion 8 (fig. 21).

fig.22

fig. 23

fig.24

Pushhex. shaft 14 out of cross lead drive

pinion 16 (fig.23). Removecirclip 13 and also

push hex. shaft out of top feed drive pinion.

Align crank 1 (fig. 25) para-liel to top edge of

packer box 2 and block it there. Move con-rod

3 by turning the flywhee-Iin indicated di,rection

to distance J = 605 mm (fig. 26) from con-rod

head to front edge of bole chamber. Push hex.

shaft 14 (fig. 23) in this position info top feed

drive pinion. If the hex. shaft does not fit, con-

rod head must be turned so offen by lIywheel

to the distance of 605mm until hex. shaft 14

fils perfectly info top lead drive pinion. Remove

blockings of top feed. Check distance J again

which must now be between 600 end 620 mm.

Packer Position Adjustment

A good shaped bole depends upon even filling

of the bole chamber by the top feed. To reach

optimum bole shops when baling different

crops, pin 6 (fig. 25) can be changed info diffe-

rent holes of adjusting bracket to obtain the

best fi,lIing of the bole chamber. By moving

pin 10 info the bollom holes of adjusting bracket

more material is moved info the opposite side

of the frame knife in bole chamber, by moving

pin 10 info the ,top holes of adjusting bracket

more material is packed on the knife side

of the bole chamber. Secure pin 10 with spring

clip in adjusting bracket.

Packer position adjustment can a.lso be made

on AP 38/48. Through adjusting pack fingers

on top end cross lead the feeding effect can

also be changed.

Timing Cross Feed to Top Feed

Align cross lead crank 4 (fig. 27) parallel to top

edge of packer box 2 end block it there. Turn

flywheel in indicated direction until packer

crank 1 (hg. 27) is in vertiwl position (crank

hanging downwards). Now push hex. shaft 14

info cross feed drive pinion 16 (fig. 23). If the

hex. shaft doesn't fit turn packer crank 1 (fig.27)

by flywheel so offen info the vertical downward

position until you canpush the hex. shaft 14

info the cross feed drive pinion.

Re-fit circlips 13 end 17 (fig. 23), tighten clamp-

ing washer on pinion 8 (fig. 21) end re-fit oll

guards.

IMPORTANT: Any repairs on cross end top

feed shou-Id be clone in a dealer's service

station. Plots springs of the deflecling packers

on AP 42/53 are spring loaded, dismant,le care-

fu'lly!

Needle Setting

Trip knollers according to 'illustration 9. Turn

flywheel in direction of arrow until needles

have reached their highest posi,tion.

Distance M betweenleaf spJing end needle tip

(fig.28) mustbe 108-115mmtor AP 48/53end

90-110mmtor AP38/42.Ifnot,slackenlocknut7

(fig.29) end remove expanding pin out of pin 9.

Turn lork 10 in or out until measure M is

reached. Rep,lace fork 10 end pin 9 info

position, secure with expanding pin 8 end

fighten 'locknut 7.

Distance N between needle head end knoller

base plots (fig.30)mustbe 170mmon AP38/42

end 175mm on AP 48/53. Otherwise reshape

needle.

Distance 0 between needle end plots spring

(fig. 30) must be between 1-2 mm.

When operating slationary oll dirt end short

baling materia,1has to be removed from under-

neath the needle.

Knotter Beak Tension

Spring tension (fig. 31) should be adjusted to

di,stance P of 23-28 mm tor proper functioning,

if not adjust screw 11accordingly.

fig.32

fig. 28

fig. 29

fig. 30

fig.31

fig.36

Twine Retainer Tension

Adjust twine tension spring to distance Q (fig.

32).Themeasuring gauge along side the spring

gi,ves the correct measure. Adjust discrepan-

eies with holt 12.

Distance R is set as fellows end shown in fig.33:

glocken lock nut 1 by tour full turns. Slacken

holt 2 until leGt spring 3 is unloaded. Run down

holt 2, first till it contacts leGt spring 3, then by

exactly 3'/2 turns. This gives spring 3 a pre-

loading of 5 mm. Finally fighten lock nut 1

again.

Adjusting the Twine Flicker

Trip knotters (see fig. 9), turn flywheel in

direction of arrow until flicker 4 (fig. 34) stops

in forward position. Distance S must now be

1-2 mm. If not, glocken lock nuts 5 end turn set

screw 6 as required end secure again.

Twine Stop Spring

Spring 7 (fig. 35) must rest under tension against

nase 8 of twine guide plate. If necessary, bend

spring 7 as required.

Twine Guide fiale

After replacing twine guide plate 9 (fig. 36)

check

DistanceT,clearance betweennase 8 end

knotter heck 10 should be 1.5-2.5mm. If not,

fit shims to adjust twine guide plate 9.

Twine Tensioner

Tighten both wing nuts of twine tensioner 11

end 12 until spring length is 26 mm Distance U.

fig. 37

Overloading Safety Devices

Double Slip Clutch and ShearBolt in Main

Drive AP42,AP53

The mein drive

is protected against overload

by d double automatically reacting slip clutch.

. One overrun slip clutch in front of flywheel

(fig. 38) end one behind ihe flywheel situated

cone slip clutch with additional shear holt 1

(fig. 39) M7x50 DIN 931-8.8. The shear holt musr

.be fitted light with hex. nut M 7 DIN 934-8 end

spring washer A 7 DIN 127.

For the safety of the baler it is important thaI

the double acting slip eluIeh is operating

trouble-free. The torque of 500-650 Nm is se,tat

the factory. Normally no adjustment is needed

hut if clutch plates end linings are warn they

should be replaced.

IMPORTANT:

fig. 38

fig..39

Before the sepsen starts, remove clutch plates 2 of the front. over-

run clutch (fig. 38) end clean any fUgt from clutch surface with

emery paper. Clean the linings of the cone eluIeh if the safety holt 1

(fig. 39) shears tao offen. T0 remove clutch plates 2 (fig. 38) glocken

the 8 halts of triangular pfote spring 3 (fig. 38) until the spring is

without load. Do not remove the spring completely. To chonge

the above mentioned torque of 500,...650Nm, shim washers are

placed behind or in front of plate spring 3.

Single Slip Clutch Unit and Shear Bolt in Main Drive AP 38/48

A single slip alutch unit with shear holt M7x50 DIN 931-8.8is fitted on AP 38/48

instead of double slip clutch unit.

Slip and Overrunning Safety Clutch of Pick-up Drive

The Pick-up drive is operated through abevel geer with subsequently added over-

load slip oIutch. Bevel geer end eluIeh are combined in one drive unit which is

fitted underneath the ba,le chamber. The effect of the clutch is to prevent any

damage to be düne to pick-up end geer box. The torque of the eluIeh is set at

300-450 Nm. The built in overrunning cluleh pIlaws easy, backwardturning of

pick-up drum when baler runs out or für clearing of deflecting packers.

Safety Device tor Packer end Cross Feed

AP42 end AP53

fig. 40

Cross feed end packer are fitted with an

automatie safety release whi,ch causes the

packer fines to swing away. If the baler be-

comes clogged or a foreign body has been

drawn on to the feed fable the fines deflect,

as in fig. 40a end then automatically swing

back info working position (fig. 40). In that

war, the clogged baler will freeitself.

Briefly reducing PTO speed increases the'

deflection resistance in the packer linkage.

The ti,ght bunch of material is pushed info

the chamber end the machine resumes un-

obstructed working. The torque of the

deflecting cross-feed is set between 600 end

850 Nm end on top-feed between 750 end

850 Nm. The connecting rod must be fitted in 2nd. hole tram bottom of the ad-

justing bracket. If the fines swing away repeatedly, this indicates thaI the machine

is work,ing at the limit of its capa city. Engage the next lower tractor geer, as

frequent tine deflection increases wear of aH drive parts.

fig. 40a

IMPORTANT: If fines of c;:rossfeed end packers deflect five or six limes running

end the

trouble stil,1 pe

rsists, the obstruction 'is

too great to be cleared by the

automatie system. In that case, shut off the pto end clear the feed fable by hand.'

On no account, attempt to remove the obstruction by reversing the PTO dri,ve,

as this is Jiikely to band the leaf spring of the automatie clearing system out of

share.

Packer with Mechanical Overloading Safety (AP 38/48)

The AP 38/48 has a mechaniwl overloading safety device instead of a deHecting

safety device in the packer system. One hex. bo.It each M6x35 DIN 933-10.9 with

two hex. nuts M 6 DIN 934-10 are acting as shear olutch safety.

Safety of Tripping Mechanism

Unintentional tripping of knotter mechanism can be prevented if safety latch

is in position "Aus". Even if baler is running the needles will s'tay in resting

position. Operation of safety latch see page 6 end 7.

Pick-up Balance Spring

T0 avoid damage to the pick-up by travelling on uneven ground the pick-up is

equipped with a torsion spring. In working posi.tion the pick-up is ba,ianced by

the torsion sproing end will be released of its own weight to fellow the contours

of the ground.

""'I

Needle protection

The needles are protected against overload.

If the upward stro

ke of needles is obstructed,

holt 1 (fig. 41) will break. Trace the causa end

remove it. Pul,! needle lift rod tram crank after

removing expanding pin 2 end pin 3. Take off

the te,lescop,ing tube end remove broken shear

holt. Refit needle lift rod 4 with new holt 1

(Order No. 0901.98.10.00)end fighten carefully.

fig. 41

il~

Lubrication Chart

SymbolsI

;

None

Lubricants and Notes

Lithium multipurpose greose

Number of greasing .points

Only for twine tying

Only for wire tying

,0.

Hypoid gear oil SAE90

[see poge 11)

Thin flowing machine oil

10 ,0.Twisterframe

11 ,0.Bearing frame

12 ,0.Crank guide

Check regular, grease as

necessary

14 * Gear box

15,0.«Shear lever shaft

160 Twine grip end knotter

bearing see fig. 16

« Bearing plates on

deflecting packer end

cross feed AP42/53 only1x

Lubricate daily

Cross feed bearing

1 x

Packer bearing

1 x

Knotter drive geer

1 x

Lubricate weekly

4 0 Knotter shaft 1x

4 ,0.Knotter shaft

Guard tube bearing

6 Tractor universal shaft 2x

7 Profile tube 1 x

Needle lift rod

1 x

Blockinglever

Troubles and Rernedies

.Working conditions vary so wide.ly that it is impossible to cover oll causes which

may lead to operating troubles. Seil properties, thickness of windrows, condition

of crap, inexperienced handling or negligent servicing of the machine may a,1I

be responsible. If the following chart does not help you to trace end eliminate

a fault, call on the expert advice of our appointed representatives, dealers end

service engineers who are always af your disposal.

...

-.- -

-. =-~= ~,~

~ Trouble! Possiblec~1 Remedy Remarks

111

}

8 I Mistying(twine)

9 f Mistyihg (wire)

Continuous res- I Reduce speed by

ponse of deflecting

same pto speed

Ipacker (540rpm)

I I

I r

I seepage 24

r see page 30

No. I

Trouble Possible causa

Remedy

Remarks

Curves taken tao

I Shutoff pto before

usawide

angle uni,-

Universal shaft

tight,ly

I making aturn

versal shaft

knacks end runs

out of balance

I Attach baler

I seefig. 2

Incorrect C:UPli:9 .[ correctly

land 3

I BQleVO"ooded

I Drive more slowly

I pick up lass I

Main dri,ve

material

I dutch is slipping

I Adjustclutch

Torque is to smaH

I see page 17

(300-450 Nm)

Clogged through

I Clear clogging,

overload, safety

reduce speed,

clutch operates

pick up less

I Pick-up stops

material

Pick-up drags on

I Set pick-op high.,

I seepage7

ground, set to lew

I fig.14

Reduce speed,

Crop bunched

I Baler overloaded

I pick up lass

up between

materi.al

I pick-up end

I fe.edfable

IWindguard isbellt I Straightenwind-

I guard

I Crop isdamp

Slacken density I seepage7

control

I fig.13

laboured working

1.,-g"Od '0;1,

see page 12

gradually getting

BI'unt knivas

fig.19

worse

end 20

Baling chamber

Empty chamber,

stuck with squashed

material

clean inside waJls

I Shearbolt broken

Removeforeign I

foreign matter

body, fhtnewshear I seepage17

Ram stops

in crop

bolt .

Baler overloaded

I Reducespeed,pick-

by very thick

windrows

I up less material

. I Re-setpackerad-

see page 14

Uneven compachon

. b k

lustment rac et

Curved Bales

-.-.

fig.42

fig. 43

Faulty twine knots are shown in the adjoining

illustrations (No. 1-9). No. 10 is a correctly

lied knot, with oll specified distances main-

tained end all springs properly tensioned. Figu-

res 42 and 43 show the knotter assembly. The

fable on page 27 lists possible causes end

remedies tor badly lied knots. Strictly observe

the following instruction:

When re-setting with bolts e - 9 - i, always

maintain specified Distances P - Q - R to fig.

31,32 end 33.

Remedy

No.! KnoHer fault (twine) I Possible cause

I Twine tensioner too loose.

Twine does not run over

nose of guide pfote a

Knot weil forrned,

but too fight,

twine tom off

Tension spring on twine

tensioner fig. 37

Loop too short

I Correctly set twine

I flicker fig. 34

Spring b jammed by point

Clean spring b to restore

or dirt free action

Twi.ne not held by twine

flicker end not led over

nose of guide plate a

So thaI twine Spring c

insufficiently tensioned,

too loosely held by

knotter beak d

Spring c much too slack,

knotter beak d holds

twine far too slack

Knot not lied

Knotter beak does not

dose properly

Spring h too slack,

twine retainer k does

not hold twine during

bole compaction

Needle too far frorn

knotter frame, retainer

k end knolfer beak d do

not seize twine

Knotter beak d does not

seize twine raised by

needle

Material between rom

' end top casing forces

twine awayfrom knotter

beakd

I All distances correctly

10 Correctly lied knot

set ',8'"springs properly

tensloned

Knot looks firm,

but under strain

one end 'slips

out again

Only one twine

end knotted, loop

end too short

Simple kn?t lied,

so thai twlne runs

back to next bole

Only one twine

end knotted,

loop end too long

Tighten bolt e, maintain

distance p fig. 31

Slacken bolt g, maintain

distance Q fig. 32

Tighten bolt e, check

correct distance p fig. 31,

if necessary clean knotters

Tighten bolt i, check

correct distance Rfig. 33

Note fig. 30:

0 = 1- 2 mm

Note fig. 22, 28 end 30:

check distance L, M end N

Re-settwine flicker

Remove ba,ling material

from between top of rom

end knotter base pfote

'J'\

Long twine end

4 I frayed, twine fluff IS . f t t t

left on twine pnng 00 au

reta'iner

Ends tom, approx.

5 I 5 cm weste drops ISpring f much too taut

away

AP 48 D / AP 53 D - Wire Tying

Inserting the Wire

Use only top qua:lity (trade-mark) wire{ note techniwl detai,ls on palge 2, when

ordering. WirB coils shou,ld be neatly end evenly wound. Before fitti,ng coils{

immerse them in eil to compilete saturation. Switch off prof weit until oll moving

parts have come to a complete stop. The wirB box takes two cous as shown

in fig. 44{ !wo spare coih can be placed in the com-

partment behind the packer box. Fit coils wh,ile stil<!

closed by straps{ turns running clock-wise. Do not

tangle the winding turns when cutting the straps.

PuMinner wirB ends out through holes in box. Avoid

kings end loops{ or mistying may result. Fix rree

euter wirB end to box edge.

Thread wirB as indicated in fig. 45{ which shows the

run as seen from below:

/-"

Carefully tie end of wirB "A" end "B" to cross bracket.

Pulling Wire info the Tiers

Trip tie unit as shown in fig. 9. Turn flywheE)1in direction of arrow fig. 11until

needles have moved up end down end the tiers have laken up the wirB. Pull wirB

ends "A" end "B" tram cross bracket 5.

Service and Lubrication

Treat wirB coils with care end immerse them

in eil before storing them tor any length of

time. Regu.larly check thai oll wirB guide rollers

move easi.ly{ grease as required.

Thoroughly lubri,cate twister drive chain 11

(fig. 46) at frequent intervals. Chain tension is

operated automatically through tension spring

12 end tension roller 13. If chain 11 is removed

the following points have to be observed.

IMPORTANT: Before re-fi.tting the chain 11{

re-set twister hock to fig. 51.

Inspect edges of shear plate 14 end shear

bar 15 (fig. 47) tor bluntness or wear. Both

are double-edged end can be turned around

once before needing are-grind: '

Remove protE!cta,r cop out of deflector bar 16.

Slacken nut 17and bolt 18. Take off bar 15{

slacken ball 19{ fit shear bar 15 with deflector

bar the ether war round{ run down ball again.

Slacken balls 20{turn around shear pIlote 14 end

re-assemble. Fina.I,ly{ fit shear level 15 with

deflector bar 16 again end secure i1'.

IMPORTANT: Note positionand sequence of

shims 21 end re-fit them in origi-

nal arrangement.

Safety Device for Needles see page 19

Wire B:

Through wirB guide tube 1{ around guide roller 2{ between track

rollers 3{ over needle head 4 to cross bracket 5.

Through wirB guide tube 6 around guide roller end around guide

roller 7{ between t~ack rollers 8{ over needle head 9 to cross

bracket 5.

Check Distance A-D (page 28 end 29) regu-

larily end adjust{if necessary.

fig.47

'"-

-!~"2'

Needle Adjustment

Pulloff wi,re,trip tying mechanism (see fig. 7).

Turn flywheel to raise needles to topmost po-

sition.

Timing of TwisterHook

Ali.gn marking holes (see arrows in fig. 52) on

both chain wheels end the marking bores under-

neath, then lock chain wheels with 4 mm cf) pin

slid through the bores. Now fit chain ovar

correctly located wheels.

IMPORTANT: Never turn flywheel in reverse

with tying mechanism tripped.

Distance A between needle end twister hock

shaft shourldbe 0-2 mm (fig. 48).

Needle to Ram Timing

If new needles have been fitted they should be

adjusted first (see setting of needles).

Note: Re-shape needles only i,f no more thon

slightly bent end take cera to restore original

shape.

Distance B between needle roller end shear

lever should be between 3-8 mm (fig. 48). If

Distance B is less: Slacken bolts 1 (fig. 49) turn

out holt 2 end run down holt 3 to set needle

height. Secure holt 2 end fighten bolts 1 again.

Disengage knotter (see fig. 9), open side cover

5 (fig. 25). Remove locking bracket 9 from pinion

10 (fig. 53). Loosen clamping washer on pinion

10 end move pinion 10 sideways in direction

of arrow until it is disengaged out of knotter

drive geer 11. Turn knotter drive geer in di-

rection of arrow until point of needles 12

(fig. 54) are flush with top edge of bottom bar

in bole chamber 13. Block knotter drive geer 11.

Turn flywheeL in direction of arrow until point

of rom 14 has post the point of needle 12 by

about 25 mm on its working stroke. Engage

pinion 10 back info knotter drive geer 11. If it

is not possible to engage pinion in the

above mentioned position, remove guard out

of twine box, moye circlip 13 (fig. 23) on hex.

shaft about 300mm to the left. Block lead end

flywheel. Shift hex. shaft 14 out of bevel geer 15

(fig. 24) after loosening olamping disk 18 until

pinion 10 (fig. 53) can be pulried out of hex.

shaft end can be moved '/6 of a turn end be

pushed barck on to hex. shaft. If pinionis still

not matching repeat this operation until pinien

10 is matching knotter drive geer 11 perfectly.

If clearance Bis exceeded: Slacl<en bolts 1, set

needle height by turning out holt 3 end running

down holt 2. Then secure holt 3 end fighten

borlts1 again.

Distance C tram needle head to twister hock

shaft should be between 80-110 mm (fig. 50). If

any difference, adjust needle lift rod as shown

in (~ig.29).

When operating stationary all dirt end short

baling material has to be cleaned away from

underneath the needle.

Shear Lever Adjustment

Note that shear lever 4 clamps down the wirB

alternaterly on left end right (fig. 51).

Push hex. shaft 14 back info bevel geer 15, (fig.

(24), tirghten clamping disk 18 replace .Iocking

bracket 9 end clamping washer against pinion

10 end tighten (fig. 53). Remove a,1Iblockings.

If wirB is to weakly clamped down, watch baler

at werk to see on which lever side the wirB is

pulled away. Let machine run on unHI needle

has once again placed wirB on that side of

lever 4 where it is not held firmly. Now stop

machine end glocken lock nut 5 (or 6), run down

set screw 7 (or 8) by '/2 to 1 JulI-turn until wirB

is firmly held, then secure again with nut 5 or 6

(fig.51).

Now check Distance D (iiig. 54)with rom located

in this position:

Clearance between needle tip 12 and rom

tip 14 must now be 25-40 mm.

lig. 52

lig.53

fig.54

'$;

-- ~- -

No. LFaulty Wire Twist~ock I

Function Fault

Cause Remarks

No twist; one wire end

cut straight, the other

pinched, then tom

off

I Bale comes out

wi,thout wire strap

on one or both sides

Wires wind round

3 twister shaft :- bole

c,?mes ::,ut 'Nlithout

wlre tymg

Wires not twisted -

one end cut off

straight, the other

bent end cut

Wires not twisted-one

end cut off strai,ght,

5 the other pinched but

puHed straight end

scraped bright

Twisting lock too short

end tom open

One wire tom close

to twisting length

Both wi res tom close

to twisting length

Windings jammed when

coil was fitted

Wire rusty or not oiled

Wire tom before

twisting

Wire run obstrueted

Crop very damp

Wire jumped out of

guide rollers

Weste wire ,endsnot

removed after threading

Needle bent sideways

Needle does not

piece wire on tiers

Track rollers shifted

Wire not seized end

not cut by shearl.ever

Needile too low

Needle bent sideways

Crop pushes wire

away from twister

hook

Volume per rom stroke

too big because of slow

rom speed

I Remedy I

I Cut off faulty ends re-thread wire I

lmmerse

coils in oi,l, allways store

them weil oiled

Clean end lubricate wire guide tubes

end rollers - replace if necessary

Slacken dens:ity controll or set

shorter bole length

I Re-fit wire or re-thread completely I

Pull wa'ste ends off hooks under

ba,ling chamber

I CheckspecifiedclearanceA I

I Une up roJ.lersto needles I

I Set clearance B I

I Set clearance A I

I,"""",am ,p"cl 10taO/rn;". I

See page 26

fig.45

See page 26

fig.45

See pages 6-7

figs. 9 end 13

See page 26

fig.45

See page 28

fig.48

See page 26

fig.45

See page 28

fig.48

See page 28

fig.48

Clamping at shear bar

too weck

Wire not held by

shear lever

Wire rusty or unoiled

Twister hook wrongly set

Wire broken during

, twisting or when

pu.I.led off twister

hook

Wire run obstructed

Guide roller spindie

jammed or worn

Re-setbar tor positive clamping

action

r Freetwister hook; immerse coils

I in olil, store them weil oi,led

I Free twister hook end re-set

Free twister hook, clean end

grease guide tubes end rollers;

replace if necessary

Free twister hook, take out roller

spindies, clean end grease -

replace if necessary

See page 28

fig.51

See page 29

fig.52

[

"--

A General Accident Preventive Safety Rules

After Season Maintenance of Baler

Clean baler thoroughly.

, Always stop baler before doing repairs or maintenance werk to the machine.

'4:

Cover oll knotler parts with grease.

, Disconnecf and remove pro shaft working on moving parts.

Tighten oll halts and nuts on baler.

Never remove hay or straw tram running pick-up, disengage pro first.

Check oll movable parts for easy moving.

Only one operator is allowed on tractor.

Replace oll damaged and lost parts.

Do not step on to barer frame when machine is running, keep away from running

pick-up and cross-feed.

Touch up point if necessary.

Store baler in dry place.

Stop barer before threading needles, move safety lolch on tripping mechanism

to position ."Aus".

All guards most be fitted in place and be in good condition.

Block road wheels with two chocks when barer is parked on the slope. Always

have two chocks on baler.

The pick-up barer may be employed only for its approved usage, otherwise no

liability for resulting damage can be accepted. Approved usage includes strict

adherence to the manufacturers' operating and maintenance instructions, as weil

as the exclusive fitting of Original Spare Parts.

The pick-up barer may be operated, serviced and repaired only by persons trained

in these duties and instructed on the possible hazards. The ruling accident pre-

vention code,as weil os generally recognized rules on occupational safety and

health and the local roadtraffic code should be observed at oll times.

-- - - -, -

Welger AP 38 Operating instructions

Brand: Welger

Model: AP 38

Type: Operating instructions

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Welger AP 38 Operating instructions

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Welger AP 38 Operating instructions

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