-- --

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.

'128-10

Contents ,I

Technical Data 2 Knotter Beak Tension 15

Preparing for Werk 4 Twine Retainer Tension 16
Attaching
theBaler... .
Positioning Drawbar
.. ... 4
4
Adjusting the Twine Flicker
Twme Stop Spring
16
16
,1 PICK-U P BALERS
Fitting the Universal Drive Shaft. 5 Twine Guide Plots " 16
Cleaning Knotters 5 Twine Tensioner " 16
Inserting Twine Spools 5 Overloading Safety Devices 17
Securing the Knotter Trip. . . . . . .
Threading the Twine
6
6
Double Slip Clutch end Shear
Bolt in Main Drive AP 42, AP 53 . 17
AP3B
Setting the Twine Tensioner... .. 7 Single Slip Clutch Unit end Shear
Tripping the Knotter Mechanism. 7 Bolt in Main Drive AP 48
Slip and Overrunning Safety
17 AP42
Bringing Twine info Knotter 7
BaleCounter 7 Clutch of Pick-up Drive 17
Bale Density " 7 Safety Device for Packer end
Cross-feed AP 42 end AP 53 18
AP4B-AP4BD
Adjusting Pick-up Height 7
Packer with Mechanical Over-
Windguard Adjustment
Setting the Bale length
8
8 loading Safety (AP 48) 18 AP~53-AP53D
pro Speed 8 Safety of Tripping Mechanism ... 18
Windrowing 8 Pick-up Balance Spring.. 18
EvenBaling 8 Need le protection " 19 Twine Tying Wire Tying
Before Turning .." 8 lubrication Chart
Troubles end Remed:es
20
22
Safety Devices 8 i'
Useful Accessories 8 Faultytwine Knots 24 'I
Service end lubrication 10 Wire Tying - AP 48 D / AP 53 D ... 26 Domestic and Foreign Patents
Oil Change of Gear Box. . . . . .. 11 Inserting the Wi.re 26
lubricating the Knotter Unit 11 Pulling Wire info the Tiers. . . . .. 27
Adjustment of Ram 12 Service end lubrication 27 "

Setting of Frame Knife 12 Needle Adjustment , 28

Grinding Knives 12 Shear lever Adjustment 28
BalerTiming 12 Timing of Twister Hook 29 GEBRUDER 1IIIELGER
Timing Need!e to Ram 13 Needle to Ram Timing 29
GMBH & CO. KOMMANDITGESELLSCHAFT
Timing Top Feed to Ram 13 Mistying Wire 30
Packer Position Adjustment 14 General Accident Prevent-ive
Timing of Cross-feed Safety Rules 32 Address: D-3340 Wolfenbüttel, P. O. Box 1560
to Top Feed 14 After season Maintenance of 5331-404-0
Baler 32 Telephone:
NeedleSetting 15 95639 ~
Telex:
IMPORTANT NOTE Teletex: (17) 5331831
This operation manual covers the models AP 38, AP 42, AP 48 and AP 53. If not Telegrams: welger wolfenbüttel
-
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.
RePn>duetion prohibited - all rights reserved, including design alterations without
prior nollee, technieal details are not binding.
Copyright 1984 by GEBRODER WELGER, Wolfenbüttel -'- Printedin the Federal
Republie of Germany.
 --1

Technical Data
AP 38/42 AP 48/53
AP 38/42 AP 48/53
Required tractor power:
Dimension of baler depending on duty end terrain from 15 kW (20hp) 18 kW (25 hp)
(in mm)
, Overaillength: Number of ram strokes 100/min 100/min
a) transport
4400 4600 14650
4670 5000 1 5050
b) at werk with chute Capacity (hay):
1
a) haies depositedon the ground up to 12 t/h upto14
Overall width: depending on respectively 16 t/h
2410 2490 1 2560 b) withloading chute
a) with standard tyres loading personneil depending on
2490 2515 1 2585
b) with special tyres loading personnel
1445 1500 double twine double twine or
Height: Tying:
double wire
Weight of baler in Standard version (kg): Tying material:
1170/1180 1300/1380
a) twine tying 1320/1400 a) sisal baling twine 200 or 150 m/kg 200 or 150 m/kg
b) wire tyjng 300 or 225 ft./rlb. 300 or 225 ft./lb.
Bale si:z:e: consumption approx. 2) 1,8 kg/t 1,4 kg/t

Height x width (mm): 310x410 360 x 480 b) plastic baling twine 400 or 320 m/kg 400 or 320 m/kg
Length (m): 0.5 - 1.0 0.5 - 1.2 600 or 385 ft.llb. 600 or 385 ft./lb.
Steplessly variable from consumption approx. 2) 0,9 kg/t 0,7 kg/t
c) wire Ungalvanized,
Bale weight (kg): annealed end oiled
according to length 8-20 10-35 tying wire of 1.8
end density or 2 mm gauge,
tensile strength
Pick-up width (mm): 1660/1730 1660/1730 35-49 kg/mm2
610ngation mini-
Tines per row: 20 20 mum of 12% at
25,4 cm length
Tine space (mm): 71 71 Dimension of wire
coil (mm):
Track width (mm): I a) euter coil
dia. 336 mm
a) standard tyres 2105 2200/2240 b) inner wil
2245 1
b) special tyres 2185 dia. 208 mm
c) coil width
Tyres: 152 mm
a) standard Irres left 7.00-12 Impl. 10.0175-15Impl. d) coil weight
approx. 45 kg
right 5.60-15 5.60-15/7.00-12Impl. consumption
approx. 3.6 kg/t 2)
b) special tyres left 10.0175-15Impl. 11.5/80-15Impl. ') Required:
right 7.00-12Impl. 8.00-12Impl. -
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
540/min 540/min circumstances usa 1080 r.p.m. PTOspeed.
Required tractor pro speed I): 'J ot medium bole weight

2 3

Preparing tor Work
Balersare thoroughlytested and carefull lubricated before leaving our werks and
are ready tor immediate service at fu,lr 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
22 mm 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 160 mm. 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.
4
1
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.
fig.4
Clearance between pro end and traetor draw-
bar hole (distance C in fig. 3) should be 330-
600 mm. 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 300 mm 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. fig. 5
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). fig. 6
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.
fig, 7
5
I-
 Observe fig. 10 closely when threading the
twine. Correctly threaded twine should not
touch end run freely.

Setting the Twine Tensioner

fig. 9 fig.8
For fight adju'Stmentof twine tensioner check
distanceU on page 16.
Attention! Securing the Knotter Trip ~,
If needles are in bole chamber turn flywheel in fight direction unHI needle end Tripping the Knotter Mechanism
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. Disengage trip (fig. 9). Turn metering wheel 2
by hand in direction of arrow until control
rod 3 trips.
Threading the Twine
Attention!Weit for standstill of baler before threading, secureknaller trip first as
describedabove. 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 fig. 12

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 fig. 13
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.10 fig.14

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
'4: 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 1.60 m 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 P 23.
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.
8
/
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-up Cover 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.
Trailer Hifch
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 ,is pushed ,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 1000 mm 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.
9
~
 ~

Pick-up Guide Wheel eil Change of Gear Box

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 Carry out first oil change after first 10 duty
:t~ can be adjusted :in heighrt as requested. Set pick-up so thai fines have a ground hours! Remove crank guard, take off oil filling
alearance of approx. 2 cm (fig. 14). Observe correot Irre pressure of 11.5bar. 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
Baler-Mounted Bale Thrower P 23 Oi,1SAE 90 (EP 90) info geer box until oil leve,1
is reached. Refit bolts 1 and 2 fighten. Change
is mounted to the end of the bale chamber. It loads the boles on to an allached oll again at the end of every season. Oll level
trailer with special body extension. Economical one man operation where baling hag to be checked regu,larly.
end loading is doneat the same time. The acreage covered is increased by up
to 40%. fig. 15

ASSEMBL
Y: 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.

Lubricating the Knotter Unit

Service and Lubrication

After every season apply a light coating of

To keep the value end long life of the machine, generous lubrication end careful "Lithium" grease to shafts of twine retainer 4
regular serv,icing wil.l keep your baler at peak performance and avoid prema- and knoller back 5 (fig. 16). Loosen lock nut 6
lure repairs. 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
General Hints: 'after the first 20 working hours, firmly fighten up all bolts and knocked out of pinion 13, then pull twine
nuts, inside and outside the machine. Timing boHs on knoller and rom sildes retainer and knotter back out of knoller frame
shou,ld not be changed. and apply "Lithi'um" grease onto shafts. Care- fig. 16
fuJ.lywipe off all surplus paste.
Usa lithium multi-purpose grease only for your grease gun. NeVer lubricate the
runni,ng machine! Clean grease nipples before applying the gun. Drive greas e
,

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

,J
off old grease rims (dust protection I). IMPORTANT: The lubricant shou'ld never gel
on to retainer taper 4 end clamp
14.
Service of Gears

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

Re-fit twine retainer and beak at correct
Road Wheels position of clamp 14 and knaller cam 15. Fit
pins 12 in correct posiJion of pinlion 13. Mount
Check wheel nuts and Gaps and fixing bolts of wheel stub axles for light fit. knaller unit in reverse order. Adjust screws 7
Maintain correct Irre pressure, on AP 38/42 standard Irres on both sides 2.0 bar. end 8 at leaf spring 9 as detailed on page 17.
On AP 48/53 standard Irres for right side 7.00-12 also 2.0 bar, on left Irre 10.0/75- Fit balls 7 and 8 on tension spring as described fig.17
152.3 bar. Pressure for special Irres see page 8. on page 15 and 16.

10 11

Ii.
 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.
~ andtighten. Remove oll blockings.
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 10 Top Feed
should, if possible, be done in a dealer's
servi,ce station.
12
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 pi nion 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.22
(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
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 30 mm.
fig. 23
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).
13
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-I in 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 605 mm 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.
f 14
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
:t 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!
fig. 28
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) must be 108-115mm tor AP 48/53 end
90-110 mmtor AP38/42.If not,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 'lock nut 7.
fig. 29
Distance N between needle head end knoller
base plots (fig.30) mustbe 170mm on AP38/42
end 175 mm 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,1 has 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 11 accordingly.
fig. 30
fig.32 fig.31
 Twine Retainer Tension
Adjust twine tension spring to distance Q (fig.
32).The measuring 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 between nase 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.36 fig. 37
Overloading Safety Devices
Double Slip Clutch and ShearBolt in Main
Drive AP 42, AP 53
j 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. 38
(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,t at
the factory. Normally no adjustment is needed
hut if clutch plates end linings are warn they
should be replaced.
fig..39
IMPORTANT: 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.
17
 ""'I
~
r

Safety Device tor Packer end Cross Feed Needle protection

AP 42 end AP 53 The needles are protected against overload.
If the upward stroke of needles is obstructed,
holt 1 (fig. 41) will break. Trace the causa end
,

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

Cross feed end packer are fitted with an removing expanding pin 2 end pin 3. Take off
automatie safety release whi,ch causes the the te,lescop,ing tube end remove broken shear
packer fines to swing away. If the baler be- holt. Refit needle lift rod 4 with new holt 1
comes clogged or a foreign body has been (Order No. 0901.98.10.00)end fighten carefully.
drawn on to the feed fable the fines deflect,
as in fig. 40 a 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-
fig. 40 fig. 40 a 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- fig. 41
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 ti ne deflection increases wear of aH drive parts.

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.'
,

il~
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 11
share. I
I
I
I
Packer with Mechanical Overloading Safety (AP 38/48) I
i
The AP 38/48 has a mechaniwl overloading safety device instead of a deHecting I
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 11

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.
 '"

Lubrication Chart

Lubricants and Notes

Symbols I

;
None Lithium multipurpose greose
x Number of greasing .points
0 Only for twine tying
,0. Only for wire tying
Hypoid gear oil SAE90
[see poge 11)
« Thin flowing machine oil

Lubricate daily

1 Cross feed bearing 1x

10 ,0.Twisterframe 3~
2 Packer bearing 1x
3 1x 11 ,0. Bearing frame
Knotter drive geer
12 ,0.Crank guide 1x

Check regular, grease as

necessary

14 * Gear box 1x
Lubricate weekly 15,0.«Shear lever shaft 2x
4 0 Knotter shaft 1x 160 Twine grip end knotter
bearing see fig. 16 8x
4 ,0.Knotter shaft 2x
5 2x 17 « Bearing plates on
Guard tube bearing
deflecting packer end
6 Tractor universal shaft 2x cross feed AP 42/53 only 1x
7 Profile tube 1x
8 Needle lift rod 1x
9 Blocking lever 2x

20 21
 ... -.- - -. =-~= ~,~

Troubles and Rernedies

~ Trouble! Possiblec~1 Remedy Remarks
Slacken density seepage 7 '

. Working conditions vary so wide.ly that it is impossible to cover oll causes which I Crop is damp
control
I
"

.'l
i
may lead to operating troubles. Seil properties, thickness of windrows, condition I fig.13
111

of crap, inexperienced handling or negligent servicing of the machine may a,1I laboured working see page 12
be responsible. If the following chart does not help you to trace end eliminate 5 gradually getting BI'unt knivas fig.19
a fault, call on the expert advice of our appointed representatives, dealers end worse end 20
1.,-g"Od '0;1,
service engineers who are always af your disposal.
Baling chamber
stuck with squashed
Empty chamber, I

clean inside waJls

material
I

Trouble Possible causa Remedy Remarks

No. I I
I

I Shear bolt broken i

usa wide foreign matter Removeforeign I }

Curves taken tao Shutoff pto before bolt .
I
angle uni,- in crop
tight,ly 6 Ram stops body, fht new shear seepage 17
Universal shaft versal shaft
I

1 knacks end runs I making aturn Baler overloaded .J

out of balance
I Reducespeed,pick-
by very thick
I Attach baler I seefig. 2 windrows I up less material
- Incorrect C:UPli:9 .[ correctly land 3

I Drive more slowly I

Main dri,ve material

I pick up lass I
2
I dutch is slipping I BQleVO"ooded

Torque is to smaH I Adjust clutch

(300-450 Nm)
I see page 17
see page 14
Uneven .
compachon I .Re-setpackerad-
lustment brac ket
I Clear clogging, 7 Curved Bales
Clogged through
reduce speed,
overload, safety
pick up less
clutch operates
3 material
I Pick-up stops I I

-.-.

Pick-up drags on I seepage 7 .

ground, set to lew Continuous res- I Reduce speed by I

I Set pick-op high., I fig.14

I

1 ponse of deflecting same pto speed

Reduce speed,
I
I I packer I (540 rpm) I

Crop bunched
materi.al "
up between I Baler overloaded I pick up lass I
8 Mistying(twine) I see page 24
4 I I I

I pick-up end

I fe.edfable
I Windguard is bellt
I
I Straightenwind-
guard 9 f Mistyihg (wire) I r r see page 30

22 23
'-
 ('

No.! KnoHer fault (twine) I Possible cause Remedy ~

I Twine tensioner too loose. Tension spring on twine

Twine does not run over
nose of guide pfote a tensioner fig. 37

Knot weil forrned, !

1 but too fight, Twi.ne not held by twine
flicker end not led over I Correctly set twine
twine tom off
nose of guide plate a
I flicker fig. 34
Spring b jammed by point Clean spring b to restore
or dirt free action
I

So thaI twine Spring c

fig.42 2 Loop too short insufficiently tensioned,
too loosely held by
knotter beak d
Tighten bolt e, maintain
distance p fig. 31
Spring c much too slack,
3 Knot not lied knotter beak d holds
twine far too slack

Long twine end

4 I frayed, twine
left on twine fluff I Spnng
. f t 00 t aut
reta'iner
Slacken bolt g, maintain
distance Q fig. 32
Ends tom, approx.
5 I 5 cm weste drops I Spring f much too taut
away

Knot looks firm,

but under strain Knotter beak does not Tighten bolt e, check
", 6 correct distance p fig. 31,
one end 'slips dose properly
out again if necessary clean knotters

Only one twine Spring h too slack,

twine retainer k does Tighten bolt i, check
7 end knotted, loop
end too short not hold twine during correct distance R fig. 33
fig. 43 bole compaction
Faulty twine knots are shown in the adjoining Needle too far frorn
illustrations (No. 1-9). No. 10 is a correctly Simple kn?t lied,
lied knot, with oll specified distances main- 8 so thai twlne runs knotter frame, retainer Note fig. 30:
back to next bole k end knolfer beak d do 0 = 1 - 2 mm
tained end all springs properly tensioned. Figu- not seize twine
res 42 and 43 show the knotter assembly. The
fable on page 27 lists possible causes end Knotter beak d does not
remedies tor badly lied knots. Strictly observe Note fig. 22, 28 end 30:
the following instruction: seize twine raised by check distance L, M end N
Only one twine needle
When re-setting with bolts e - 9 - i, always Re-set twine flicker
9 end knotted, Material between rom
maintain specified Distances P Q- - R to fig.
loop end too long ' end top casing forces Remove ba,ling material
31,32 end 33. from between top of rom
twine away from knotter end knotter base pfote
I
beak d
24
All distances correctly
10 Correctly lied knot
I

set ',8'" springs properly

I I
tensloned

'J'\
1
f,

/-"

l'I

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.
PuM inner 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)1 in 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 aga in.
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.

Through wirB guide tube 1{ around guide roller 2{ between track Safety Device for Needles see page 19
rollers 3{ over needle head 4 to cross bracket 5.
Wire B: Through wirB guide tube 6 around guide roller end around guide
roller 7{ between t~ack rollers 8{ over needle head 9 to cross Check Distance A-D (page 28 end 29) regu-
bracket 5. larily end adjust{ if necessary. fig.47

26 27

Needle Adjustment
Pull off wi,re,trip
tying mechanism (see fig. 7).
Turn flywheel to raise needles to topmost po-
sition.
IMPORTANT: Never turn flywheel in reverse
with tying mechanism tripped.
Distance A between needle end twister hock
shaft shourld be 0-2 mm (fig. 48).
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.
If clearance B is exceeded: Slacl<en bolts 1, set
needle height by turning out holt 3 end running
down holt 2. Then secure holt 3 end fighten
borlts 1 again.
Distance C tram needle head to twister hock
shaft should be between 80-11 0 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).
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).
28
'"- - !~"2'
~
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.
Needle to Ram Timing
If new needles have been fitted they should be
adjusted first (see setting of needles).
lig. 52
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 300 mm to the left. Block lead end
flywheel. Shift hex. shaft 14 out of bevel geer 15
(fig. 24) after loosening olamping disk 18 until
lig.53
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.
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.
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.
fig.54
29
 Function Fault Cause Remarks
No. LFaulty Wire Twist~ock I I Remedy I

Windings jammed when See page 26

coil was fitted fig.45
I Cut off faulty ends re-thread wire I

lmmerse coils in oi,l, allways store

Wire rusty or not oiled them weil oiled
,

'$; I I

No twist; one wire end Wire run obstrueted Clean end lubricate wire guide tubes See page 26
1 cut straight, the other Wire tom before end rollers - replace if necessary fig.45
I I
pinched, then tom twisting
off Slacken dens:ity controll or set See pages 6-7
Crop very damp
I
shorter bole length I
figs. 9 end 13
Wire jumped out of See page 26
guide rollers I Re-fit wire or re-thread completely I
fig.45
Weste wire ,ends not Pull wa'ste ends off hooks under
removed after threading I
ba,ling chamber I

Needle bent sideways See page 28

I Bale comes out Checkspecified clearanceA fig.48
2 Needle does not I I

wi,thout wire strap

on one or both si des piece wire on tiers Track rollers shifted See page 26
I
I Une up roJ.lersto needles I
fig.45
Needile too low See page 28
Wires wind round fig.48
Wire not seized end I Set clearance B I

3
1

I twister shaft :- bole

c,?mes ::,ut 'Nlithout not cut by shearl.ever See page 28
Needle bent sideways
I
wlre tymg I Set clearance A I fig.48
1

Wires not twisted - Volume per rom stroke

one end cut off Crop pushes wire
4 ! away from twister too big because of slow
straight, the other hook rom speed
bent end cut
I
I,"""",am ,p"cl 10taO/rn;". I

Wires not twisted-one

I
end cut off strai,ght, Clamping at shear bar Re-set bar tor positive clamping See page 28
5 the other pinched but Wire not held by too weck action
shear lever fig.51
puHed straight end
scraped bright I

Wire rusty or unoiled r Free twister hook; immerse coils

Twisting lock too short
6 in olil, store them weil oi,led
end tom open I

See page 29
Twister hook wrongly set
I Free twister hook end re-set fig.52
Wire broken during
7 One wire tom close Free twister hook, clean end
, twisting or when
I to twisting length pu.I.led off twister Wire run obstructed grease guide tubes end rollers;
I I
hook replace if necessary

Guide roller spindie Free twister hook, take out roller

8 Both wi res tom close
to twisting length jammed or worn spindies, clean end grease -
replace if necessary

30 31

-- ~- -
 After Season Maintenance of Baler

A General Accident Preventive Safety Rules Clean baler thoroughly.

, Always stop baler before doing repairs or maintenance werk to the machine. Cover oll knotler parts with grease.
'4:
I1 Tighten oll halts and nuts on baler.
, Disconnecf and remove pro shaft working on moving parts.
I

Check oll movable parts for easy moving.

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

Replace oll damaged and lost parts.

I
Only one operator is allowed on tractor.
1
I Touch up point if necessary.
" Do not step on to barer frame when machine is running, keep away from running
I1
pick-up and cross-feed. Store baler in dry place.
i

l
>(
Stop barer before threading needles, move safety lolch on tripping mechanism
l to position ."Aus".
I'
[

11 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
w
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.

32

"-- -- - - -, -