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Summary of Contents for KUHN RW1600
- Page 1 RW1600 O p e r a t i o n m a n u a l Issue 04/2009 Date of printing 6.2009 Language From machinenumber (PIN) VGEW000365 Serial number (PSN) 03EW01 Reference number ZNA012EN...
- Page 2 5667 KP Geldrop The Netherlands Phone +31 40 2893300 KUHN-GELDROP B.V., retains all copyrights and rights of usage. The contents of this operating manual are subject to change without notice. All rights reserved. The right to technical revision is reserved.
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Page 3: Table Of Contents
Table of contents Table of contents Preface ............. 5 Preparation at the field ........ 46 Target group of this operation manual Safety Symbols used Performing settings Prior to wrapping Safety instructions ......... 7 Placing into working position For your safety Safety decals at the machine Use at the field .......... - Page 4 Table of contents Optional equipment ........92 General Film roll holder Film roll magazine Wheel chock set Bale turner Hydraulic bale turner Bale stop arm Drop mat Drop plate Road lighting set Remote control Troubleshooting ........... 95 Safety Electronic control system Applicutter Pre-stretcher Hydraulics...
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Page 5: Preface
Preface Preface This operation manual is meant for those concerned with the control, T a r g e t g r o u p o f use and maintenance of the machine. It contains all data required for t h i s o p e r a t i o n a safe handling, use and maintenance of the machine. -
Page 6: Symbols Used
Preface In this operation manual the following symbols and terms are used: S y m b o l s u s e d • A bullet stands at enumerations > A triangle stands at steps, which you must do → An arrow shows cross-references at other text passages [+] The plus sign shows that it involves optional equipment, which does not belong to the standard model. -
Page 7: Safety Instructions
Safety instructions Safety instructions This chapter contains all general safety instructions. Subject-specific F o r y o u r s a f e t y safety instructions are located per chapter. Take care of the safety instructions • because of your own safety •... -
Page 8: Safety Decals At The Machine
Safety instructions The installed warning and advisory signs give important hints for a S a f e t y d e c a l s a t safe operation; adhering to serves your own safety. Keep safety t h e m a c h i n e decals and signs clean and legible at all times. - Page 9 Safety instructions M e a n i n g o f t h e s a f e t y d e c a l s Read the operation manual carefully Read the operation manual carefully before taking the machine into operation.
- Page 10 Safety instructions Pre-stretcher rotation 30 rpm The prescribed pre-stretcher rotation of maximum 30 rpm may not be exceeded. Use ear protection Use adequate ear protection during wrapping. Serious hearing injuries can occur. Never stay behind the machine while unloading Stay clear of the table area while unloading a bale. An outcoming, rolling bale has a heavy mass and a high speed.
- Page 11 Safety instructions Use the table safety bar Prior to any maintenance, repair and adjustment work on the tipped table, place the table safety bar. A non-secured table can cause serious or deadly injuries. Stay clear of the applicutter rollers Stay clear of the applicutter rollers. Hands can be squeezed between the rollers.
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Page 12: Who Is Allowed To Operate The Machine
Safety instructions Authorised people only W h o i s a l l o w e d t o The machine may only be used, maintained or repaired by authorised o p e r a t e t h e people who have been informed about the dangers when handling the machine. -
Page 13: Hitching The Machine
Safety instructions Increased danger of injury H i t c h i n g t h e While hitching the machine onto the tractor an increased danger of m a c h i n e injury occurs. Therefore: • prevent the tractor from rolling away, shut down the engine and remove the ignition key •... -
Page 14: Road Transport
Safety instructions Pay attention to a road-safe condition R o a d t r a n s p o r t When driving on the local roads, the machine must correspond to the current traffic prescriptions. To which e.g. belongs: •... -
Page 15: Working With The Machine
Safety instructions First use only after instruction W o r k i n g w i t h t h e The machine may at the first time of use only be brought into use by m a c h i n e employees of the dealer, factory representatives or employees of the manufacturer. -
Page 16: Unhitching The Machine
Safety instructions Increased danger of injury U n h i t c h i n g t h e While unhitching the machine from the tractor an increased danger of m a c h i n e injury occurs. Therefore: •... -
Page 17: Care And Maintenance
Safety instructions Observe the care and maintenance intervals C a r e a n d Observe the prescribed intervals and those stated in the operation m a i n t e n a n c e manual for recurring checks and inspections. In case of negligence of the intervals damages to the machine or accidents can be caused. -
Page 18: Further Prescriptions
Safety instructions Careful when cleaning with compressed air cleaner The machine can partly be cleaned with compressed air. Clean electric parts and the hydraulic valve block with low pressure only. Too high pressure can damage these parts. No aggressive wax additives When cleaning do not use aggressive wax additives. -
Page 19: Acquaintance With The Machine
Acquaintance with the machine This chapter contains general information about your machine and Acquaintance with the machine information about: • characteristics • technical specifications This machine is exclusively appropriate designed for film wrapping of D e s t i n a t i o n o f t h e round bales of ligneous plants, mainly grasses, taking into account all m a c h i n e prescriptions, procedures, etc. -
Page 20: Description Of The Components
Acquaintance with the machine D e s c r i p t i o n o f t h e c o m p o n e n t s Table Applicutter Loading arm Pre-stretcher Drawbar Film roll storage [+]... - Page 21 Acquaintance with the machine T e c h n i c a l s p e c i f i c a t i o n s D i m e n s i o n s / w e i g h t Weight Maximum weight (kg) 1,550...
- Page 22 Acquaintance with the machine B a l e r e q u i r e m e n t s Round bales Minimum diameter (cm) Maximum diameter (cm) Maximum width (cm) Maximum weight (kg) 1.200 Maximum 150 cm...
- Page 23 Acquaintance with the machine O p t i o n a l e q u i p m e n t Film roll holder Road lighting set Film roll magazine Film end kit (for manual control only) Drop mat Bale turner Additional counter weights Adapter for 500 mm film rolls Remote control...
- Page 24 Acquaintance with the machine T r a c t o r r e q u i r e m e n t s Tractor requirements Electronics 12 V (DC) coupling for control box (DIN 9680) 12 V (DC) coupling for road lighting (DIN ISO 1724) [+] Hydraulics 1 single acting control valve with pres-...
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Page 25: Delivery And Preparation
Delivery and preparation Delivery and preparation Wear safety shoes S a f e t y During all work at the machine never bring your feet under the machine and always wear safety shoes. Wearing safety shoes prevents or decreases the risk of serious injuries. Completely delivered C h e c k i n g t h e The machine is delivered completely. -
Page 26: Hitching The Machine
Hitching the machine Hitching the machine Increased danger of injury S a f e t y • Prevent the tractor from rolling away • Never stay between the tractor and the machine during hitching • Operate the three-point hitch slowly and carefully In case of negligence serious or deadly injuries can occur. -
Page 27: Hitching
Hitching the machine Remove tractor lower links H i t c h i n g Remove the tractor lower links to avoid them touching the drawbar. During turning, the lower links can touch the drawbar and the machine can tip over. Personal or machine damages can occur. The machine is ex works provided for hitching to the tractor towing hook. - Page 28 Hitching the machine M o v i n g t h e d r a w b a r Towing hook height (cm) Minimum Maximum > Secure the drawbar by placing it in a well suited hoist > Loosen the bolts and nuts Drawbar >...
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Page 29: Support Jack
Hitching the machine S u p p o r t j a c k > Fully retract the support jack using the handle Pin / Handle > Remove the spring clip spring clip > Remove the pin > Lift the support jack completely >... -
Page 30: Installation Cable Control
Hitching the machine Check correct lying of the cables I n s t a l l a t i o n c a b l e Cables may not get stretched or get trapped. Take care of sufficient c o n t r o l free space. -
Page 31: Installation Joystick Control
Hitching the machine Check correct lying of the cables I n s t a l l a t i o n Cables may not get stretched or get trapped. Take care of sufficient j o y s t i c k c o n t r o l free space. -
Page 32: Installation Control Box
Hitching the machine Correct connection of the electronic control system I n s t a l l a t i o n Never connect the cable to the cigarette lighter because of c o n t r o l b o x interference risk. -
Page 33: Connections
Hitching the machine C o n n e c t i o n s Hydraulic coupling only pressureless H y d r a u l i c Only couple the hydraulic hoses to the tractor when both tractor and c o n n e c t i o n s machine hydraulics are pressureless. - Page 34 Hitching the machine The machine is standardly adjusted for tractors with an open centre H y d r a u l i c b l o c k - hydraulic system. o p e n c e n t r e No adjustment of the hydraulic block is necessary.
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Page 35: Road Lighting [+]
Hitching the machine The machine is standardly adjusted for tractors with an open centre H y d r a u l i c b l o c k - l o a d hydraulic system. s e n s i n g No adjustment of the hydraulic block is necessary. -
Page 36: Preparation For Use
Preparation for use Preparation for use Obey safety instructions S a f e t y Obey the safety instructions at the execution of all work. Ignoring the safety instructions can lead to serious or deadly injuries. Guarantee correct hydraulic coupling Check before using if all hydraulic couplings are coupled correct to the single and double acting valves. -
Page 37: Table Roller Adjustment
Preparation for use To ensure good stability of the bale during wrapping, the table roller T a b l e r o l l e r must be adjusted for small or large bales. a d j u s t m e n t Front position Rear position Recommended setting, depending on the bale diameter:... -
Page 38: Support Roller
Preparation for use To ensure a good stability of the bale during wrapping, the support S u p p o r t r o l l e r rollers can be adjusted for small or large bales. The support roller must be adjusted so, that the bale is in the middle S u p p o r t r o l l e r of the table. -
Page 39: Loading Arm Width
Preparation for use The width of the loading arm can be adjusted depending on the L o a d i n g a r m w i d t h diameter of the bales to be wrapped. The loading arm must be adjusted so, that the bale is in the middle of L o a d i n g a r m the loading arm. -
Page 40: Pre-Stretcher
Preparation for use Wear safety shoes P r e - s t r e t c h e r During all work at the machine never bring your feet under the machine and always wear safety shoes. Wearing safety shoes prevents or decreases the risk of serious injuries. -
Page 41: Film Installation
Preparation for use Before installing the film: F i l m i n s t a l l a t i o n > switch off the tractor engine > remove the ignition key Stay clear of pre-stretcher rollers Stay clear of the pre-stretcher rollers. Hands can be squeezed between the rollers. -
Page 42: Film Overlap
Preparation for use The film overloap is determined by the rotation speed of the table F i l m o v e r l a p belts. The speed of the table belts can be varied by mounting a Chain Chain tensioner different sprocket. -
Page 43: Check At Beginning Of The Season
Preparation for use The following items have to be checked before using the machine at C h e c k a t the beginning of the season: • b e g i n n i n g o f t h e Check the electric connections →... -
Page 44: Road Transport
Road transport Road transport Before road transport will take place, please read the following safety S a f e t y instructions. The compliance is prescribed and helps you to avoid accidents. Close valves Before road transport close all valves. With open valves and false operation the lifting cylinder can be lowered. -
Page 45: Road Transport
Road transport Check the machine before road transport by means of the checklist: C h e c k i n g t h e m a c h i n e • Tractor hydraulic is switched off? • All valves are closed? •... -
Page 46: Preparation At The Field
Preparation at the field Preparation at the field Obey the safety instructions S a f e t y Obey the safety instructions at the execution of all work. Ignoring the safety information can lead to serious or deadly injuries. Secure tractor and machine •... -
Page 47: Placing Into Working Position
Preparation at the field The machine must be used in working position. To bring the machine P l a c i n g i n t o into working position, the following steps are necessary: • w o r k i n g p o s i t i o n the loading arm lock must be removed The loading arm must be placed into working position. -
Page 48: Use At The Field
Use at the field Use at the field Driving along at the machine prohibited S a f e t y It is never allowed that people or objects drive along at the machine. Driving along at the machine is perilous and prohibited. No persons in the turning area Take care of no people be in the turning and working area of the machine. -
Page 49: Film Wrap Recommendations
Use at the field The number of table laps decides how many film layers the bale is F i l m w r a p wrapped with. It is recommended that a minimum 6 layers of film are r e c o m m e n d a t i o n s applied to the bale. -
Page 50: Start Position Mode
Use at the field The loading arm and the table must be put into start position before S t a r t p o s i t i o n wrapping can get started. m o d e The start position is reached when: •... - Page 51 Use at the field Automatic mode J o y s t i c k c o n t r o l > Drive to the bale Joystick > Push the joystick left to lift the bale using the loading arm onto the table >...
- Page 52 Use at the field The required number of film wraps must have been set E l e c t r o n i c c o n t r o l → CYC, page 71 > Drive to the bale Automatic mode >...
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Page 53: Loading A Second Bale During Wrapping
Use at the field During wrapping, a second bale can be transported onto the loading L o a d i n g a s e c o n d arm. b a l e d u r i n g w r a p p i n g >... -
Page 54: Emergency Stop
Use at the field In case of emergency, wrapping can be stopped immediately. E m e r g e n c y s t o p > Push the joystick in any direction J o y s t i c k c o n t r o l >... -
Page 55: Wrap And Bale Counter
Wrap and bale counter Wrap and bale counter If the machine is equipped with a cable or an joystick control, the wrap G e n e r a l and bale counter can be mounted. This counter controls and monitors the wrapping of the bale. -
Page 56: Parameter Change
Wrap and bale counter The parameters can be changed upon desire. P a r a m e t e r c h a n g e > Push to enter the desired display > Push until the desired digit flashes >... -
Page 57: Parameter Settings
Wrap and bale counter Via the parameter settings, the entire wrapping process is prescribed. P a r a m e t e r s e t t i n g s The current number of table laps can be set. The pre-set number of C Y K table laps can be shown in the display. - Page 58 Wrap and bale counter The total number of bales wrapped. B A L + Number 0 - 99999 The total number of bales wrapped can not be reset The stop position of the table can be set. Which gives the possibility to leave the lever or joystick until the pre-set number of film wraps is reached.
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Page 59: Joystick Control
Joystick control Joystick control The machine can be equipped with the joystick control. This control G e n e r a l system controls and monitors the wrapping and clearing out of the bale. The joystick control enables supervision of the total bale wrapping J o y s t i c k c o n t r o l procedure from the tractor cab. - Page 60 Joystick control F1 button B u t t o n s • Short push: selection of manual or automatic control • Long push: parameter selection F2 button • Display selection button F3 button • Counter reset • In manual mode: table to unloading position •...
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Page 61: Control Mode
Joystick control The joystick control can be used in the following control modes: C o n t r o l m o d e • manual mode • semi-automatic mode The set of parameters determines working in semi-automatic mode. In manual mode, the wrapping cycle is manually controlled by the F M a n u a l m o d e buttons and the joystick. -
Page 62: Parameter Settings
Joystick control Via the parameter settings, the entire wrapping process is prescribed. P a r a m e t e r s e t t i n g s The current number of table laps can be set. The pre-set number of C Y K table laps can be shown in the display. - Page 63 Joystick control The total number of bales wrapped. B A L + Number 0 - 99999 The total number of bales wrapped can not be reset The total time the FJ button must be held during the start-up wraps at H O L D low table speed, before wrapping continues at normal speed.
- Page 64 Joystick control The time the table tips downwards. T I P D O W N Number Recommended number 0,0 - 5,0 > Push F2 to enter the display TIP DOWN > Push and hold F1 until the current time flashes >...
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Page 65: Electronic Control System
Electronic control system Electronic control system The machine can be equipped with an electronic control system. This G e n e r a l control system controls and monitors the wrapping and clearing out of the bale. Furthermore the system also provides error indicating functions. - Page 66 Electronic control system Auto button B u t t o n s • Selection of automatic control Stop button • To stop, interrupt a procedure. Rotation of the table is interrupted. Programme mode button • Programming functions • Counter reset To neutral position The loading arm is moved to its neutral position, in front of its sensor.
- Page 67 Electronic control system Joystick Pushing up: • lowering the loading arm Pushing down: • raising the loading arm Pushing to the left: • parameter selection • table rotation at normal speed Pushing to the right: • parameter selection • table rotation at low speed Upper toggle switch Pushing up: •...
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Page 68: Control Mode
Electronic control system The electronic control system can be used in the following control C o n t r o l m o d e modes: • manual mode • semi-automatic mode • automatic mode The set of parameters determines working in semi-automatic or automatic mode. - Page 69 Electronic control system In automatic mode, the entire wrapping cycle is automatic. A u t o m a t i c m o d e > Push to select automatic mode > Push to start wrapping The machine starts in a programmed cycle. In case of a failure or correction during wrapping >...
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Page 70: Parameter Change
Electronic control system The parameters can be changed upon desire. P a r a m e t e r c h a n g e > Push > Push joystick left or right to select the desired parameter > Push to change the parameter value >... -
Page 71: Parameter Settings
Electronic control system Via the parameter settings, the entire wrapping process is prescribed. P a r a m e t e r s e t t i n g s The number of table laps can be set. C Y C Number Recommended number 0 - 99 no recommendation... - Page 72 Electronic control system A buzzer can be switched on or off for A . o n / A . o f f • a sound after the last sensor by-pass • when an error occurs Setting Buzzer • • • •...
- Page 73 Electronic control system The bale unloading can be included in the wrapping procedure. A 3 : 1 / A 3 : 0 Setting Recommended setting • 1 = yes • 0 = no If ‘0’ is chosen, a new loading and wrapping cycle can be started >...
- Page 74 Electronic control system Start of the flashing light before the automatic wrapping cycle starts. It is recommended to mount a flashing light when a remote control is mounted. Beacon Setting Recommended setting • • • mounted 0.0 - 9.9 • •...
- Page 75 Electronic control system The time the table turns at half speed before stopping, after the last sensor by-pass t6 has taken place. Setting Recommended setting 0.0 - 9.9 1.5 - 2.5 The time the table is standing still before turning at half speed to the bale unloading position, after the table has stopped.
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Page 76: Cleaning And Caring
Cleaning and caring Cleaning and caring For all cleaning and caring activities applies: S a f e t y Do not penetrate bearings and hydraulic parts Be careful when cleaning with a high-pressure cleaner. Bearings, sealings and bolted joints are not waterproof. To avoid machine damages never penetrate bearings, sealings and bolted joints with water. -
Page 77: Storing The Machine
Storing the machine Storing the machine Obey the safety instructions S a f e t y Obey the safety instructions at the execution of all work. Ignoring the safety information can lead to serious or deadly injuries. Machine is no toy Store the machine in an area away from human activity. -
Page 78: Maintenance
Maintenance Maintenance For all maintenance work applies: S a f e t y Take care of the safety instructions Definitely take care of the safety instructions during all work. In case of negligence of the safety instructions serious or deadly accidents can occur. - Page 79 Maintenance Additives in oil and lubricants can have, under circumstances, harmful P r o t e c t i o n m e a s u r e s effects to health. Because an indication according to the danger order i n c o n t a c t w i t h o i l o r is not necessary, therefore in principle please pay attention to: l u b r i c a n t s...
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Page 80: General
Maintenance This information is related to all maintenance work. At all maintenance G e n e r a l work the machine must be secured in working position. In case the transport position is necessary for maintenance, you will find suitable tips to the maintenance work. -
Page 81: Attaching Elements
Maintenance Before doing any maintenance, the following must be obtained: M a i n t e n a n c e • Clean the machine before doing any repair work i n t e r v a l s • Never work on the machine while it is running •... - Page 82 Maintenance A t t a c h i n g e l e m e n t s All bolts and nuts must be checked and screwed tighter: S c r e w i n g b o l t s •...
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Page 83: Tightening Torques
Maintenance All screwed joints on this machine must be torqued in accordance with T i g h t e n i n g the values given in this table below unless indicated otherwise. t o r q u e s On this machine, 8.8 is both standard and minimum quality used. -
Page 84: Pre-Stretcher
Maintenance P r e - s t r e t c h e r The pre-stretcher must be checked • after the first 50 working hours • after every 500 working hours > Check that the bolts of the gear rollers are tightened correctly C h e c k i n g t h e p r e - >... -
Page 85: Wheels/Tyres
Maintenance Do not drive with worn-out or damaged tyres W h e e l s / t y r e s Exchange worn-out or damaged tyres immediately. Especially during road transport with such tyres an increased risk of accidents exists. Correct repairwork only Repairwork on wheels and tyres must only be carried out •... -
Page 86: Hydraulics
Maintenance Take care at welding work H y d r a u l i c s Do not carry out welding work near to hydraulic hoses. Hydraulic oil can ignite very easily. Hydraulic device pressureless Before replacing the hydraulic hoses, the hydraulic device must be pressureless. -
Page 87: Table
Maintenance T a b l e The table roller drive chain is under the cover, at the side of the table. D r i v e c h a i n t e n s i o n The chain should have a slight slack. Chain tensioner >... -
Page 88: Applicutter
Maintenance A p p l i c u t t e r Untighten the spring K n i f e r e p l a c e m e n t The knife is spring loaded. Always untighten the spring before handling the knife. -
Page 89: Lubrication
Maintenance All grease nipples must be greased after every cleaning with a high- L u b r i c a t i o n pressure cleaner. M o t o r g e a r > Grease the motor gear every 10 working hours Motor gear G e a r r i n g... - Page 90 Maintenance T a b l e s p r o c k e t > Grease the grease nipple every 50 working hours Grease nipple T i p p i n g f r a m e h i n g e s >...
- Page 91 Maintenance Untighten the spring A p p l i c u t t e r The knife is spring loaded. Always untighten the spring before Roller Pawl bar handling the applicutter. Serious injuries can be caused. > Grease the pawl bar every 50 working hours >...
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Page 92: Optional Equipment
Optional equipment Optional equipment Where parts are to be changed, only use genuine original spare parts. G e n e r a l When ordering, quote the machine identification numbers. Trained people only must carry out the use, maintenance and repair of the machine. -
Page 93: Wheel Chock Set
Optional equipment W h e e l c h o c k s e t To prevent wrapped bales from rolling away, the bale turner is used to B a l e t u r n e r place the wrapped bales on their flat side. Bale turner set H y d r a u l i c b a l e t u r n e r... -
Page 94: Drop Mat
Optional equipment The drop mat is used to prevent punctures on the bale from stiff D r o p m a t stubble when unloading the bale on the ground. Drop mat The drop plate can be used for a smooth bale unloading on the D r o p p l a t e ground. -
Page 95: Troubleshooting
Troubleshooting Troubleshooting Switch off engine S a f e t y Before any resolving of troubles: > switch off the engine and remove the ignition key Troubles can mostly be easily and quickly be remedied. Before you make an appeal to the service department, please check with help of the table, if you can remedy the trouble by yourself. -
Page 96: Applicutter
Troubleshooting Problem Cause Solution Page • Err 8 The magnet or the sensor for > Adjust the magnet/sensor the loading arm is defect or so, that the sensor is activat- wrongly positioned ed when the loading arm is in correct position •... - Page 97 Troubleshooting Problem Cause Solution Page • The film is not retained Too less pressure on the roll- > Check the distance, 4-5 mm > Check whether there is play between guide rollers A and catch rod L • The roller is dirty >...
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Page 98: Pre-Stretcher
Troubleshooting P r e - s t r e t c h e r Problem Cause Solution Page Holes in the stretched film The pre-stretcher rollers are > Clean the pre-stretcher roll- dirty The film tears at the lower edge The pre-stretchers are set too >... -
Page 99: Film
Troubleshooting F i l m Problem Cause Solution Page The film slips along the tilted The film is too little or not tacky Change to a film with more surface of the bale tackiness B a l e Problem Cause Solution Page Difficulties when bale loading... -
Page 100: Disposal Of The Machine
Disposal of the machine When the real life of the machine has finished, its separate parts must Disposal of the machine be properly disposed. Please observe the local current and valid waste disposal regulations. Metal parts All metal parts have to be delivered to a metal recycling company. The hydraulic oil must be disposed at a used-oil recycling company. -
Page 101: Ec Declaration Of Conformity
Nuenenseweg 165 5667 KP Geldrop The Netherlands declare under our sole responsibility that the product RW1600 and accessories to which this declaration relates, conforms to the relevant basic safety Identification plate and health requirements of EU Directive 98/37/EC. For the relevant implementation of the safety and health requirements... -
Page 102: Index
Index Index Aquaintance with the machine Characteristics of the machine Description of the components Destination of the machine Technical specifications Cleaning, caring and storing the machine Winter storage Disposal of the machine Drawbar adjustment Moving the drawbar EC Declaration of conformity Maintenance General Safety...
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