Inline baler help

Picked up a 2006 New Idea 7210 baler recently. I’ve been going though the baler part by part to do a full inspection and rebuild. The goal is to have everything back within factory spec before putting in the field come spring.

The baler has somewhere around 100k bales on it based on wear in the string guides by the needles. Prior owner has put some parts in the baler. Newer bill hooks and gears, new plunger safety stop rod, and possibly stuffer fork bushings as there is only enough movement in the forks to be able to tell it’s moving (less than an 1/8”).

I’m at the point I’m verifying timing. Book spec for stuffer to plunger is 1/4” minimum. With the plunger and grease fitting aligned as it should be (I didn’t have to move anything), then roll the plunger up till the forks are closest, this one measures 3”. No way that can be right. Looking at the motion of the stuffer, it can’t get any closer to the plunger. The forks are flat/parallel to the bottom of the plunger and at the pinnacle of its upward travel/arch with the 3” gap. It would literally be impossible for the plunger to ever hit the stuffer the way this is.

I’ve moved the timing a few links both directions to verify, the gap never changes. Another odd thing in the stuffer... the forks have at some point contacted the main frame on the front of the baler. Like the frontward travel was to much (reaching to far towards the pickup teeth). And, if the pick up is raised, the fork will contact the end of the rods on the wind guard.

Checked the needle timing and it’s way off to. Should be 1-1/2 to 2-1/4” from needle tip to plunger knife mount. This one is 5”. I haven’t adjusted that yet as I really want to get the plunger stuff figured out first.

I was told the baler was baling the day the dealer traded for it. But after getting into this thing, I doubt it was baling very well.

Any help is appreciated. Forgive the new guys long first post.

Inline baler help