Page 1 LELY WELGER RPC 445 TORNADO RPC 445 TORNADO 4895.99.03.01 10.10 (Translation of the original manual) Operating Manual...
Page 3 Complete this form on delivery of the machine and return it within 4 weeks. Possible guarantee requests cannot be handled before this document has not been sent back. Date of delivery: ................ RPC 445 Tornado Machine type: ................ Machine no. on the data plate (e. g. 4895.00.001): ................
Page 4 Send back to: Lely International N.V. TSS (Technical Service Support) Postfach 1965 D-38289 Wolfenbüttel Complete this form on delivery of the machine and return it within 4 weeks. Possible guarantee requests cannot be handled before this document has not been sent back. Customer Name: Street:...
Page 5 Handover protocol 2 (Copy for the costumer) Complete this document when the machine is delivered and keep it. Date of delivery: ................ RPC 445 Tornado Machine type: ................ Machine no. on the data plate (e. g. 4895.00.001): ................ 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.
Page 6 Complete this document when the machine is delivered and keep it. Customer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ..................................Marketing partner/Importer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ....................................................Date Signature Customer Service...
Page 7 Handover protocol 3 (Copy for the trader) Complete this document when the machine is delivered and keep it. Date of delivery: ................ RPC 445 Tornado Machine type: ................ Machine no. on the data plate (e. g. 4895.00.001): ................ 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.
Page 8 Complete this document when the machine is delivered and keep it. Customer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ..................................Marketing partner/Importer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ....................................................Date Signature Customer Service...
Page 9 Handover protocol 4 (Copy for the Importer) Complete this document when the machine is delivered and keep it. Date of delivery: ................ RPC 445 Tornado Machine type: ................ Machine no. on the data plate (e. g. 4895.00.001): ................ 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.
Page 10 Complete this document when the machine is delivered and keep it. Customer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ..................................Marketing partner/Importer Name: Street: ..................................Postcode/place: Land/State: ..................................Phone: eMail: ....................................................Date Signature Customer Service...
Page 11 This manual must always be available wherever the machine is in use. Please read the separate operating manual "PRO-LINK for LELY WELGER RPC 445 Tornado" Observe all safety instructions! Attention, danger of injury! Prior to first commissioning the machine must be calibrated! See separate operating manual: "PRO-LINK for RPC 445", chapter "CALIBRATION".
Page 12 © 2010 by Welger Maschinenfabrik GmbH Wolfenbüttel Made in Germany. 4895.99.03.01 Rev 10.10 Print 10.10 Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143 eMail: wmf@welger.com LELY WELGER RPC 445 Tornado...
Page 13: Table Of Contents
Definition: Cutting Position and Home Position ..........................69 Working with the Desired Knife Group.............................. 70 Cutting Device Protection ................................. 71 Bale optimisation....................................74 Brittle Crop Material ..................................74 Removing the cutting device knives..............................75 Regrinding the Cutting Device Knives .............................. 78 LELY WELGER RPC 445 Tornado...
Page 14 Belt Guide Pulleys ..................................132 11.14 Film Knife Change ..................................133 11.15 Hydraulic System (Complete Machine) ............................134 11.16 Visual Inspection of Hydraulic System ............................134 11.17 Pin Assignment of the Control Electronics ............................. 134 LELY WELGER RPC 445 Tornado...
Page 15: Type Overview
Control box / control electronics Control box PRO-LINK Control electronics Balercontrol III Feed channel floor Feed channel floor (HYDROFLEXCONTROL, swivelling) (hydraulic opening and closing) Brakes Hydraulic brake Compressed air brake Mechanical manually operated brake Table 1 LELY WELGER RPC 445 Tornado...
Page 16: Warning Symbols
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. LELY WELGER RPC 445 Tornado...
Page 17: Symbols On The Machine
Keep all symbols in a recognisable state. If any symbols on this machine are missing or have been damaged, they must be replaced. 2.2.1 Prohibition signs No smoking! Spare part no.: 0388.37.00.00 Do not step on the area! Spare part no.: 0386.11.00.00 LELY WELGER RPC 445 Tornado...
Page 18 Spare part no.: 0388.25.00.00 Attention, danger of injury! Prior to any repair, maintenance and cleaning work: stop the engine and pull off the plug of the power supply. Spare part no.: 0388.13.00.00 LELY WELGER RPC 445 Tornado...
Page 19 Handle the cutting unit blade only when wearing protective gloves and using suitable tools. Spare part no.: 0387.33.00.00 Attention, danger of bruising! Keep out of the range of action of the support feet plates when lowering the support feet. Spare part no.: 0386.32.00.00 LELY WELGER RPC 445 Tornado...
Page 20 Spare part no.: 0387.86.00.00 Attention, danger of running-over! Use wheel chocks! Keep out of the travelling range of the wheels. Secure wheels by means of wheel chocks. Spare part no.: 0386.25.00.00 LELY WELGER RPC 445 Tornado...
Page 21 Spare part no.: 0387.35.00.00 Maximum permissible hydraulic pressure The machine may only be connected to hydraulic systems providing a maximum oil pressure of 210 bar. Spare part no.: 0387.36.00.00 LELY WELGER RPC 445 Tornado...
Page 22 (The scheme shows the top view of the two wrapping film stretching units on the wrapping arms.) Spare part no.: 0384.48.00.00 Torque 300 Nm Tighten screw couplings of the drawbar to the specified torque. Spare part no.: 0386.27.00.00 LELY WELGER RPC 445 Tornado...
Page 23 Spare part no.: 0387.65.00.00 Locking the belt rocker (for maintenance purposes only) Spare part no.: 0385.94.00.00 Information on crane suspension To ensure safe loading of the machine a spreader must be used. Spare part no.: 0386.47.00.00 LELY WELGER RPC 445 Tornado...
Page 24 Scale for adjusting the number of net wraps around the bale. Spare part no.: 0390.84.00.00 Direction of rotation of wrapping arms! The arrow indicates the direction of rotation of the wrapping ring (round bale wrapper). Spare part no.: 0386.83.00.00 LELY WELGER RPC 445 Tornado...
Page 25 HYDROFLEX HYDROFLEX Tailgate Tailgate cutting device cutting device Net knife Net knife Connection sizes – Size 3 Size 3 Size 5 Size 3 Size 3 Oil flow direction Decal 0384.31.00.00 0388.18.00.00 0388.18.00.00 0389.80.00.00 0388.26.00.00 0384.32.00.00 LELY WELGER RPC 445 Tornado...
Page 26: Safety
SAFETY SAFETY Proper use This "Straw Baler/Wrapper" LELY WELGER RPC 445 Tornado. serves exclusively producing wrapping bales compressed from agricultural straw material lying on the ground. 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;...
Page 27: Foreseeable Misuse
The type approval, declaration of conformity and the CE sign loose their validity by changes made to safety relevant parts (e.g. brake and drawbar). LELY WELGER RPC 445 Tornado...
Page 28: General Safety Instructions
During operation: Never climb the drawbar or any other parts of the machine. Keep sufficient distance to baler (pick-up, running gear, bale unloading area). Keep sufficient distance to the range of action of the round bale LELY WELGER RPC 445 Tornado...
Page 29 Carry the chocks on the machine when transporting it or during field use. Never operate parked machine. machine movements (e.g. tailgate, wrapping ring) may cause breaking of the support foot and tipping of the machine. LELY WELGER RPC 445 Tornado...
Page 30: Operator Positions On The Machine
Figure 2 (top view) 1: Wrapping wring rotation range 10: Operator position on the tractor 2: Bale unloading area 11: Operator position on the machine 3: Pick-up catch area (control panel) 4: Wheel rolling area LELY WELGER RPC 445 Tornado...
Page 31: Fire Protection
70 dB (A). The combined noise level of machine and tractor primarily depends on the level of the noise from the tractor (radios are an additional source of noise). We recommend: to operate the tractor with the windows closed. LELY WELGER RPC 445 Tornado...
Page 32: Guard Casings
The guard casings swivel automatically up away from the machine. (Figure 4 and Figure 5) Guard casing lock [1]. Figure 4 For closing press the guard casing against the machine until the locking of the catches can be heard. Figure 5 LELY WELGER RPC 445 Tornado...
Page 33: Emergency Stop
(Figure 7) Emergency stop palm button [1] on the control box (left machine side). (Figure 8) Emergency stop palm button [2] on the machine frame (right machine side). Emergency stop palm buttons Figure 6 Figure 7 Figure 8 LELY WELGER RPC 445 Tornado...
Page 34: Maintenance Platform And Ladder
After completion of maintenance and assembly work: Set the shut-off valve to its initial position (longitudinal to flow direction, Figure 11) and remove the mechanical safeguard. Figure 11 LELY WELGER RPC 445 Tornado...
Page 35: Net Knife Safeguard
(Figure 13) Cover the left and right film knives by a protection hood. Secure the protection hoods using split pins. After completion of maintenance and assembly work: remove the two protection hoods. Figure 13 LELY WELGER RPC 445 Tornado...
Page 36: Wrapping Ring Safeguard
(Figure 14) After driving on the road and before starting work: set the two shut-off valves to their initial position (longitudinal to flow direction). Figure 15 LELY WELGER RPC 445 Tornado...
Page 37: Driving On The Road
Before travelling on public roads the following requirements must be met: see chapter "Driving on the Road", page 81. The wheel chocks (2 in number) which are part of the safety equipment are to be carried on the machine at all times. LELY WELGER RPC 445 Tornado...
Page 38 Further heed the national regulations of the country where the machine is in use. LELY WELGER RPC 445 Tornado...
Page 39: Data Plate Specifications
Maximum support load of the machine, that acts – at maximum load of tying material* – on the hitch. The open-type towing fixture of the tractor must be registered for this support load. Model year of the machine Year of construction of the machine Internal number Manufacturer's name and address LELY WELGER RPC 445 Tornado...
Page 40: Hydraulic System
Prior to any assembly work on the hydraulic plant, in particular if accumulators are used (Figure 16): depressurise the hydraulic system. secure hydraulically operated components against uncontrolled movement (pick-up, cutting device, tailgate, wrapping table, wrapping ring, film knife, bale transfer unit). Figure 16 LELY WELGER RPC 445 Tornado...
Page 41: Electromagnetic Compatibility (Emc)
Ensure above all that the electric and electronic components subsequently installed are in conformity with the EMC directive 2004/108/EC (formerly: 89/336/EEC) as amended and are provided with the CE marking. LELY WELGER RPC 445 Tornado...
Page 42: Technical Data
Width max. when driving on the road [mm] (without using the pick-up guide wheels) 2850 Height [mm] 3455 perm. total weight (with wrapping material, without bale) [kg] see data plate on the machine Design-conditioned permissible maximum speed 40 km/h = Observe deviating national road traffic law! Table 2 LELY WELGER RPC 445 Tornado...
Page 43: The Machine
Film clamping device and film knife Pick-up (hidden in the picture) Film stretching unit (stretch rollers and film roll) Support foot Wrapping ring with 2 film stretching units Ladder for maintenance platform Control box PRO-LINK (in the tractor cabin) LELY WELGER RPC 445 Tornado...
Page 44: Function
The two film knives clamp the two film web ends. The wrapping table swivels and unloads the bale via the rear of the machine (depending on the setting in the "MONITOR" menu, separate operating manual "PRO-LINK for RPC 445"). LELY WELGER RPC 445 Tornado...
Page 45 For maintenance work and fault clearance the following machine assemblies can be operated manually via the manual control box: tailgate bale transfer unit wrapping table film stretching unit wrapping ring (height) film clamping device film knife LELY WELGER RPC 445 Tornado...
Page 46: The Control Electronics
BALERCONTROL III. Provide for all-polo disconnection of the power supply to the machine (disconnect battery). Interrupt power supply between tractor and machine. Take strong heat generation at welding points into account. Dismount sensitive parts (cables, sensors, plastic parts) before welding. LELY WELGER RPC 445 Tornado...
Page 47: Serial Numbers Of The Control Electronics
HW version........Control electronics SG 2 Memory ......... Serial no........See separate operating manual: SW version ........"PRO-LINK for RPC 445", Chapter 9 "SYSTEMINFO". SW date......... HW version........Control electronics SG 3 Memory ......... LELY WELGER RPC 445 Tornado...
Page 48: Commissioning
(e.g. guard casings and distance bracket). Before opening any protective devices: Switch off the power take-off shaft, switch off the tractor engine, remove the ignition key. Disconnect control electronics from power supply (disconnect electrical connection to the tractor). LELY WELGER RPC 445 Tornado...
Page 49 Attention, danger of damage! The machine must never be used without the bale wrapper. If film wrapping is not desired: select pass-through mode (see separate operating manual "PRO-LINK for RPC 445", chapter "Wrap bale or pass bale through?"). LELY WELGER RPC 445 Tornado...
Page 50: Transport
Attention, danger of damage! Never lift the machine without spreader. Never lift the machine without shipping rod. (Figure 18) Use spreader! (Figure 19) Mount the shipping rod included in the delivery to reinforce the machine frame. Figure 19 LELY WELGER RPC 445 Tornado...
Page 51 Fasten lifting gear exclusively to the lift eyes and/or fastening points intended for this purpose (Figure 20): Lift eye [1] on the left machine side (Figure 21). Lift eye [2] on the right machine side. Hitch [3] of the machine. Figure 20 Figure 21 LELY WELGER RPC 445 Tornado...
Page 52: Connection Of Hydraulic System
Note! Hydraulic oil temperature: maximum 85 °C. Hydraulic oil flow rate: about 35 l/min (maximum 70 l/min). Max. operating pressure of the hydraulic system: 210 bar. Note! Hydraulic connections: see chapter "Hydraulic connections", page 17. LELY WELGER RPC 445 Tornado...
Page 53 Pressure: Pick-up Feed channel floor Cutting device Return flow: Wrapper white Tailgate double acting Net knife single-acting with Pressure: unpressurised return flow Wrapper yellow Tailgate Net knife Load sensing Load sensing connection blue LELY WELGER RPC 445 Tornado...
Page 54: Adjustment Of Hydraulic System / Load Sensing
Tractor with constant flow pump or closed hydraulic system (Load Sensing): (Figure 23) Loosen lock nut (knurled nut). Figure 22 Turn in adjusting screw (knurled screw) up to the stop. Tighten lock nut (knurled nut). Figure 23 LELY WELGER RPC 445 Tornado...
Page 55: Connecting The Pneumatic System (Compressed Air Braking System)
(yellow) with the corresponding connections of the tractor (Figure 24). Drain the compressed-air reservoir (left machine side, above the spare film rolls) daily and check for damage and proper tightening. Adjust variable load valve: see next chapter. LELY WELGER RPC 445 Tornado...
Page 56 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. LELY WELGER RPC 445 Tornado...
Page 57: Connecting The Hydraulic System (Hydraulic Braking System)
Turning the crank counterclockwise = releases the manually operated brake Before uncoupling the machine from the tractor: apply the manually operated brake. After coupling the machine to the tractor: release the manually operated brake LELY WELGER RPC 445 Tornado...
Page 58: Connection Of Electrical Equipment
On the outside or inside the tractor: Power supply: 2-pole On the outside of the tractor: Indicator/brake/parking light: 7-pole Into the tractor cabin Emergency stop: 4-pole Control box: 7-pole LELY WELGER RPC 445 Tornado...
Page 59 Power supply: connect the 2-pole plug of the cable harness to the corresponding socket on the tractor. Once the connection has been established, the supply voltage is present and a short sequence of beeps sounds from the PRO-LINK control box. LELY WELGER RPC 445 Tornado...
Page 60: Prior To First Commissioning
All covers and guard casings must be installed, properly fastened and closed. Check all visible sensors and actors for tight seat (must not be loose). Check oil level for automatic chain lubrication (note maximum and minimum marks). Check tires for proper condition. LELY WELGER RPC 445 Tornado...
Page 61: Coupling The Machine
Observe national regulations! (Figure 28) [1] Coupling variant: upper linkage (open-type towing fixture), with rigid hitch [2] Coupling variant: lower linkage (tow hitch), with rotating hitch [3] Coupling variant: Ball hitch 80 mm Figure 28 LELY WELGER RPC 445 Tornado...
Page 62 COMMISSIONING 7.11.1 Correct tilt of the machine Figure 29 Distance from ground to machine frame top edge: 1190 mm LELY WELGER RPC 445 Tornado...
Page 63 Figure 30 tractor are at the same height. Important: Replace safety nuts whenever they have been loosened! (Figure 30) Tighten fastening screws and nuts: 300 Nm. Figure 31 LELY WELGER RPC 445 Tornado...
Page 64: Drive Shaft
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. LELY WELGER RPC 445 Tornado...
Page 65 Ensure before switching on the power take-off shaft that the selected speed of the tractor is in conformity Figure 36 with the permissible speed and direction of rotation of the machine (540 1/min). Switch power take-off shaft only during idling! LELY WELGER RPC 445 Tornado...
Page 66: Inserting The Net
(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. LELY WELGER RPC 445 Tornado...
Page 67 (Figure 38) Open safety chain [1]. Figure 38 Turn back the tensioning spindle [4] to the stop using the crank handle [5]. Open upper hood. (Figure 39) Slide net tightener [8] back and secure with cotter pin. Figure 39 LELY WELGER RPC 445 Tornado...
Page 68 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: screw extension tensioning spindle (16) onto the tensioning spindle [15]. Figure 42 LELY WELGER RPC 445 Tornado...
Page 69 Note! Watch wind-off direction of the net roll! The net must enter the machine beneath the net roll (see Figure 48). Figure 44 (Figure 45) Tilt net roll into the net holder. Figure 45 LELY WELGER RPC 445 Tornado...
Page 70 (Figure 47) Using the crank handle turn the tensioning spindle into the sleeve of the net roll up to the stop The net roll must rotate free and easy. If not: Check and repeat the setting described in this chapter, if necessary. Figure 47 LELY WELGER RPC 445 Tornado...
Page 71 (Figure 39) Remove cotter pin from the net tightener and swivel net tightener to the front. (Figure 44) Insert an auxiliary net roll into auxiliary net holder. Figure 49 (Figure 38) Close safety chain. Figure 50 LELY WELGER RPC 445 Tornado...
Page 72: Tensioning The Net Knife
The number of net layers around the bale can be set from 1.5 to 4 by means of the PRO-LINK control box. Note! See separate operating manual: "PRO-LINK for RPC 445", chapter "Setting the net layers". LELY WELGER RPC 445 Tornado...
Page 73: Selection Of Film Prestretching Rate
Applies only to the gear wheel with 19 teeth: use stud. Install the two stretch rollers [2] and [3] in the frame [1]. Figure 53 Install the frame [1] with the two stretch rollers [2] and [3] in the stretcher unit. LELY WELGER RPC 445 Tornado...
Page 74: Inserting/Replacing Film Rolls
In case of films with glue: the glued side must lie on the bale. Figure 55, top view Attention, danger of bruising! Leave the turning range of the wrapping ring before switching on the tractor engine! LELY WELGER RPC 445 Tornado...
Page 75: Narrow Films - Wide Films
To achieve optimum production results the following target settings can be made. The number of film layers on the bale. The width of the film overlap. See separate operating manual: "PRO-LINK for RPC 445", chapter "Film layers and film overlap". LELY WELGER RPC 445 Tornado...
Page 76: Cutting Device
The cutting device XtraCut 25 (25 knives) contains a 12-knife 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 LELY WELGER RPC 445 Tornado...
Page 77: Definition: Cutting Position And Home Position
Straw conveyed through the machine is cut by the projecting knives. Figure 59 "Knives in home position" means: The knives have been fully moved into the feed channel floor. Straw conveyed through the machine is not cut by the inserted knives. Figure 60 LELY WELGER RPC 445 Tornado...
Page 78: Working With The Desired Knife Group
When the touch screen button CUTTING DEVICE is shown with a yellow background, the 13-knife group is active (i. e. the 13- knife group can be operated via the tractor control valve). Move 13-knife group fully to operating position via the tractor control valve. LELY WELGER RPC 445 Tornado...
Page 79: Cutting Device Protection
180 bar and thus can remove blockages at the knife slots. Touch screen button Meaning Cutting device protection active Cutting device protection deactivated LELY WELGER RPC 445 Tornado...
Page 80 Repeat the two working steps above so long until the jamming of the knife sots is removed and the knives move free and easy. Attention! cutting device protection must reactivated immediately after removal of the knife slot blockages to avoid damage to the cutting device. LELY WELGER RPC 445 Tornado...
Page 81 Finally the knives must be moved once again with 40 bar. Otherwise: Loss of guarantee possible in case of machine overload! Move 12-knife group fully to operating position via the tractor control valve (40 bar). Only now may daily production be continued. LELY WELGER RPC 445 Tornado...
Page 82: Bale Optimisation
(chapter "CUTTING DEVICE", page 68). In this way the bale is finally wrapped with long material and crop losses are largely avoided. LELY WELGER RPC 445 Tornado...
Page 83: Removing The Cutting Device Knives
Switch machine to "Manual" mode: See separate operating manual "PRO-LINK for RPC 445", chapter "MENU: MONITOR (MANUAL MODE)". Move bale transfer unit to home position (underneath the tailgate): See separate operating manual "PRO-LINK for RPC 445", chapter "Bale transfer". LELY WELGER RPC 445 Tornado...
Page 84 (Figure 63). Note! Removed blades should be replaced by blind blades to prevent soiling of the knife slots. Swivel lever of cutting device knife axle up through about 90° as far as the stop. Figure 63 LELY WELGER RPC 445 Tornado...
Page 85 See separate operating manual "PRO-LINK for RPC 445", chapter "Wrapping ring (up and down)". If now production is to be started switch the machine to "AUTOMATIC/STAND-BY" mode: See separate operating manual "PRO-LINK for RPC 445", chapter "MENU: MONITOR (AUTOMATIC)". LELY WELGER RPC 445 Tornado...
Page 86: Regrinding The Cutting Device Knives
The temper of the blades must not be drawn when grinding. Economic grinding without heating (tarnishing) of the blades will prolong the service life of the cutting device knives. A grinder is available as a special tool. (Part no. 0980.70.14.00) LELY WELGER RPC 445 Tornado...
Page 87: Field Deployment
Keep sufficient distance to the baler (pick-up, running gear, tailgate, bale unloading area). Keep sufficient distance to the range of action of the round bale wrapper (wrapping table, wrapping ring, film knife, bale transfer area, bale unloading area). LELY WELGER RPC 445 Tornado...
Page 88 Attention, danger of damage! The machine must never be used without the bale wrapper. If film wrapping is not desired: select pass-through mode (see separate operating manual "PRO-LINK for RPC 445", chapter "Wrap bale or pass bale through?"). LELY WELGER RPC 445 Tornado...
Page 89: Driving On The Road
Fold bale tipper up and lock it with the transport lock. See chapter "Bale Wrapper: Bale Tipper", page 83. Fold up and lock ladder of the maintenance platform. Connect drive shaft to tractor power take-off shaft. LELY WELGER RPC 445 Tornado...
Page 90 48. Start driving on the road with the towed machine only when the variable load valve is set to full load (see chapter "Compressed air brake only: adjusting the variable load valve", page 48). LELY WELGER RPC 445 Tornado...
Page 91: Bale Wrapper: Bale Tipper
Mounting the bale tipper: attach bale tipper to the wrapping table of the bale wrapper using 2 bolts [2]. Secure the two bolts. Figure 66 Dismounting the bale tipper: loosen the two bolts [2] and remove the bale tipper from the wrapping table. LELY WELGER RPC 445 Tornado...
Page 92 Fix the joint of the transport lock: (Figure 67) insert bolt [6] into transport lock [4]. Via manual control box: raise wrapping ring fully. Figure 67 Secure wrapping ring against accidental lowering: see chapter "Wrapping Ring Safeguard", page 28. Figure 68 LELY WELGER RPC 445 Tornado...
Page 93 (Figure 69 and Figure 70) Open hook [4a] and remove it Figure 70 from the wrapping frame. (Figure 69 and Figure 70) Remove hook [4b] from bale tipper. (Figure 71) Store transport lock behind the left guard casing. Figure 71 LELY WELGER RPC 445 Tornado...
Page 94: Laying Swaths
(Figure 72) Both pick-up guide wheels cover the circular path of the tines laterally and are therefore part of the safety equipment. When the machine is in operation, the two guide wheels must be mounted in the bottom position. Figure 72 LELY WELGER RPC 445 Tornado...
Page 95: Windguard
If a material jam occurs in case of an extraordinary crop structure, the feed guide plate can be removed: (Figure 74) Turn out screw (on the right in travelling direction). Remove feed guide plate [1] from the baling chamber. Figure 74 LELY WELGER RPC 445 Tornado...
Page 96: Pto Speed
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 action of the pto shaft! LELY WELGER RPC 445 Tornado...
Page 97: Driving Style
At the beginning of each bale, change immediately between left and right swath side and vice versa (Figure 75)..until the set working pressure is reached (see pressure gauge, Figure 76). Figure 76 Figure 75 LELY WELGER RPC 445 Tornado...
Page 98 If no material is taken up, the power take-off shaft should always be switched off after 10 seconds at the latest. Switch on the power take-off shaft again just before material is taken up again. LELY WELGER RPC 445 Tornado...
Page 99: Adjusting The Bale Diameter
1.00 m – 1.55 m (max. 1750 kg) Straw 0.90 m – 1.60 m The desired bale diameter setpoint is set and indicated on the PRO-LINK control box: see separate operating manual "PRO-LINK for RPC 445", chapter "Setting the bale diameter setpoint". LELY WELGER RPC 445 Tornado...
Page 100: Setting The Bale Density (Baling Pressure)
Figure 79 (Figure 80) The preset bale density (i. e. the baling pressure) is indicated on the pressure gauge [1]. After emergency operation: move lever on hydraulic block to horizontal position. Figure 80 Figure 81 LELY WELGER RPC 445 Tornado...
Page 101: Tailgate Locked
PRO-LINK control box: Short acoustic signal: 1 beep. (Figure 82) A closed tailgate is shown on the display. Animation: Tailgate closed Animation: Tailgate open Figure 83 Figure 82 LELY WELGER RPC 445 Tornado...
Page 102: Net Tying And Bale Unloading
Wait until the tailgate opens and the baler transfers the bale to the bale wrapper. beep: tail gate is fully closed Drive the tractor again. beep: film wrapping of the bale finished. Unload bale: see chapter "Unloading the bale", page 95. LELY WELGER RPC 445 Tornado...
Page 103 If Single Unloading or DOUBLE UNLOADING or SIGNAL- CONTROLLED UNLOADING has been selected: the bale is unloaded automatically. If MANUAL UNLOADING has been selected: press GO button. The bale is unloaded. If tractor has been stopped: start driving. LELY WELGER RPC 445 Tornado...
Page 104 AUTOMATIC. Only then will the bale transfer unit and the wrapping table take their bale transfer positions and the tailgate open automatically. Start AUTOMATIC mode: press touch screen button GO. Unload bale: see chapter "Unloading the bale", page 95. LELY WELGER RPC 445 Tornado...
Page 105 Start AUTOMATIC mode: Press touch screen button GO. Net tying is performed. Bale transfer unit and wrapping table swivel automatically to their bale transfer positions tailgate opens automatically. Unload bale: see chapter "Unloading the bale", page 95. LELY WELGER RPC 445 Tornado...
Page 106: Overload Protection
The cameras enable monitoring of the wrapping process on the bale wrapper. The cameras enable observation of the rear machine part (accident prevention). (Figure 86) The monitoring cameras are mounted on the left and right frame of the bale wrapper. Figure 86 LELY WELGER RPC 445 Tornado...
Page 107: Removing A Material Jam
(Figure 87). In this way, jammed material is drawn through easier, grasped by the bottom baling roller and conveyed into the baling chamber. Note! See separate operating manual "PRO-LINK for RPC 445", chapter "Bottom door". LELY WELGER RPC 445 Tornado...
Page 108 (Figure 89) When the knives have reached their operating position, the CUTTING DEVICE symbol appears. That the hydraulic accumulators can be filled: Operate tractor's distribution vale for another 5 sec. Figure 89 LELY WELGER RPC 445 Tornado...
Page 109: Maintenance Baler
When carrying out work on the opened tailgate: insert tail gate safeguard (chapter "Tailgate Safeguard", page 26). When carrying out work in the vicinity of the net knife: insert net knife safeguard (Kapitel "Net Knife Safeguard", page 27). LELY WELGER RPC 445 Tornado...
Page 110: Remarks
For maintenance work and fault clearance the following assemblies can be operated manually via the manual control box: Emergency stop: Press button [5]. Open tailgate: Press button [1] and button [9] simultaneously. Close tailgate: Press button [1] and button [10] simultaneously. LELY WELGER RPC 445 Tornado...
Page 111: Maintenance Platform
Tensioners Note! (Figure 91) 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 91 LELY WELGER RPC 445 Tornado...
Page 112: Wheels
1.8 bar – max. 3.6 bar Table 4 10.7.2 Pick-up guide wheel Adjust the recommended air pressure: Tire size max. speed Pressure no driving on the road 2.0 bar 6.50-8 4 PR Table 5 LELY WELGER RPC 445 Tornado...
Page 113: Compressed Air Brake Cylinder
If necessary: vent the hydraulic braking system (bleeder screw of the hydraulic cylinder). If necessary: replace or refill hydraulic fluid. Check hydraulic hoses and lines for leaks: no chafe marks, kinks or leaks must occur. LELY WELGER RPC 445 Tornado...
Page 114: Winter Pause
Check air pressure of tires and adjust – if necessary –. Disconnect PRO-LINK control box from the machine (pull off the plug) and store it at room temperature. Drain compressed air storage tank of compressed air braking system. (See also: chapter "Winter pause", page 127.) LELY WELGER RPC 445 Tornado...
Page 115: Lubricant Disposal
After cleaning: apply grease to the entire machine. Then perform a brief trial run so that the grease can spread into Figure 92 the bearings. LELY WELGER RPC 445 Tornado...
Page 116: Chain Lubrication System (Oil Lubrication)
(visual check). 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. LELY WELGER RPC 445 Tornado...
Page 117 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. LELY WELGER RPC 445 Tornado...
Page 118: Maintenance Of The Net Tying Unit
In case of single-side wear of the disk brake lining [4]: Figure 94: Loosen lock nut [5]. Turn screw [6] slightly in until the linings are again parallel. Lock the screw [6] again. Figure 94 Figure 95 LELY WELGER RPC 445 Tornado...
Page 119: Grease Knife Lever
[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 97 LELY WELGER RPC 445 Tornado...
Page 120: Lubrication Chart
1) Depending on version, possibly supplied by central lubricant metering device. 2) Supply lubricant metering device by means of a cautious stroke from the manual grease gun - do not use compressed air grease gun. LELY WELGER RPC 445 Tornado...
Page 121 1 grease nipple per knife lever (see "Grease knife lever", page 111) 3 weeks after first commissioning, then once per season Annually Item Machine part Lubricant Note (Table 6) (Figure 98) Brake lever on both sides LELY WELGER RPC 445 Tornado...
Page 122 Lubricating oil acc. to ISO VG68–VG220 (non-thickening) Gear oil SAE 90 Machine oil – Multipurpose grease Gleitmo 810 Multipurpose grease Multipurpose grease according to NLGI-class 2, with high pressure additive, without solid parts Table 6 LELY WELGER RPC 445 Tornado...
Page 123: Maintenance Of Hydraulic System
Openings must always be covered to prevent foreign matter from entering. Collect overflowing hydraulic oil in a suitable container together with the old filter element. Insert new filter element and tighten together with the filter housing. LELY WELGER RPC 445 Tornado...
Page 124: Hydraulic System (Complete Machine)
MAINTENANCE BALER 10.19 Hydraulic System (Complete Machine) Figure 100 LELY WELGER RPC 445 Tornado...
Page 125 MAINTENANCE BALER Figure 101 LELY WELGER RPC 445 Tornado...
Page 126: Maintenance Of Pneumatic System
Loosen and remove filter insert using hexagon socket key. If it is dirty: blow out the filter insert with compressed air. If it is damaged: replace filter insert. Figure 103 Refit filter insert. Figure 104 LELY WELGER RPC 445 Tornado...
Page 127: Tensioning The Roller Chains
70 mm. 70 mm 10.21.2 Main drive chain The main drive chain must be tensioned to the extent that the two threaded rods project by 65 mm each. 65 mm LELY WELGER RPC 445 Tornado...
Page 128 10 mm. If required: insert a cranked chain link. Note! New, unused chains elongate already after a short time of operation. They can therefore be tensioned a little bit stronger. LELY WELGER RPC 445 Tornado...
Page 129: Locking The Belt Rocker
Remove mechanical safety device against lowering of the tailgate. Switch off hydraulic safety device against lowering of the tailgate. Release the wire from the hook by hand. Open tailgate fully. Close tailgate fully. LELY WELGER RPC 445 Tornado...
Page 130: Pin Assignment Of The Control Electronics
MAINTENANCE BALER 10.23 Pin Assignment of the Control Electronics "CON A" = connector A "CON B" = connector B 10.23.1 Control electronics SG 1 LELY WELGER RPC 445 Tornado...
Page 131 MAINTENANCE BALER 10.23.2 Control electronics SG 2 LELY WELGER RPC 445 Tornado...
Page 132 MAINTENANCE BALER 10.23.3 Control electronics SG 3 LELY WELGER RPC 445 Tornado...
Page 133: Maintenance Of Round Bale Wrapper
(chapter "Film Knife Cut Protection", page 27). 11.2 Remarks To ensure that your machine maintains its value as long as possible and that it works efficiently without the need for premature repairs, provide for correct adjustment, regular maintenance and thorough care. LELY WELGER RPC 445 Tornado...
Page 134: Manual Control Box
Open: press button [7] and button [9] simultaneously. Close: press button [7] and button [10] simultaneously. Open and close film knife: Open: press button [8] and button [9] simultaneously. Close: press button [8] and button [10] simultaneously. LELY WELGER RPC 445 Tornado...
Page 135: Screw Check
Remove film rolls. Lubricate film knife, bale transfer unit and wrapping table. Disconnect PRO-LINK control box from the machine (pull off the plug) and store it at room temperature. (See also: chapter "Winter pause", page 106.) LELY WELGER RPC 445 Tornado...
Page 136: Lubricant Disposal
After cleaning: apply grease to the entire machine. Then perform a brief trial run so that the grease can spread into Figure 105 the bearings. LELY WELGER RPC 445 Tornado...
Page 137: Lubrication Chart
2 grease nipples (for swivelling forward and back) r.h. side, 1 l.h. side) Wrapping ring brake 2 grease nipples r.h. side, 1 l.h. side) Wrapping frame bearing 2 grease nipples r.h. side, 1 l.h. side) LELY WELGER RPC 445 Tornado...
Page 138 Lubricating oil acc. to ISO VG68–VG220 (non-thickening) Gear oil SAE 90 Machine oil – Multipurpose grease Gleitmo 810 Multipurpose grease Multipurpose grease according to NLGI-class 2, with high pressure additive, without solid parts Table 7 LELY WELGER RPC 445 Tornado...
Page 139: Film Stretching Unit
11.11 Wrapping Ring Brake Annually and as required: Check and if necessary readjust spring tension of the wrapping ring brake. The threaded rod must project by 65 mm. 65 mm LELY WELGER RPC 445 Tornado...
Page 140: Chains Of Wrapping Table Rollers
Never reach into the running belt. Weekly: check belt guide pulleys on wrapping table for smooth running. If the belt guide pulleys block up: slightly loosen the screws above the belt guide pulleys. Otherwise: replace belt guide pulleys. LELY WELGER RPC 445 Tornado...
Page 141: Film Knife Change
(chapter "Film Knife Cut Protection", page 27). As required (if the films are not correctly cut): replace film knife. Turn out 8 screws per film knife. LELY WELGER RPC 445 Tornado...
Page 142: Hydraulic System (Complete Machine)
Note! In the event of heavy oil loss: consult a workshop. 11.17 Pin Assignment of the Control Electronics (See chapter "Pin Assignment of the Control Electronics", page 122.) LELY WELGER RPC 445 Tornado...
Page 143 Welger Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 D-38304 Wolfenbüttel declare that the product Round Baler/Wrapper Combination LELY WELGER RPC 445 Tornado. Serial number from 4895.50.101 is in conformity with the basic safety and health requirements of the following directives: EC Directive 2006/42/EC...

LELY WELGER RPC 445 TORNADO Operating Manual

1 Type Overview

2 Warning Symbols

3 Safety

4 Technical Data

5 The Machine

6 The Control Electronics

7 Commissioning

8 Cutting Device

9 Field Deployment

10 Maintenance Baler

11 Maintenance of Round Bale Wrapper

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