LELY WELGER AP 530 User manual

LELY WELGER
AP 530 / 630 / 730 / 830 - P23
AP 730
1132.99.03.03 07.14 (Original manual)
Operator Manual

2 LELY WELGER AP 530 AP 630 AP 730 AP 830

Send back to:
Lely International N.V.
TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbüttel
Delivery Note 1 (Copy for the Manufacturer)
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: ………………………………. ………………………………
Machine type: AP…………………………… P23
(Fz)-Ident-No. on the data plate: ………………………………. ………………………………
I purchased / use this machine. The operating manual including the EC conformity declaration was delivered to me together with the
machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
..................................... ...........................................................................
Date Customer's signature
Customer
Name:
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Postcode/Place:
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Phone:
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Street:
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Land/State:
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Email:
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Marketing partner / Importer
Name:
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Phone:
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Street:
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Land/State:
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Email:
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Date Signature Customer Service

Delivery Note 2 (Copy for the Customer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ………………………………. ………………………………
Machine type: AP…………………………… P23
(Fz)-Ident-No. on the data plate: ………………………………. ………………………………
I purchased / use this machine. The operating manual including the EC conformity declaration was delivered to me together with the
machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
..................................... ...........................................................................
Date Customer's signature
Customer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
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Land/State:
..................................................................................
Email:
..................................................................................
Marketing partner / Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
..................................................................................
Land/State:
..................................................................................
Email:
..................................................................................
.............................. .............................................................
Date Signature Customer Service

Delivery Note 3 (Copy for the Trader)
Complete this document when the machine is delivered and keep it.
Date of delivery: ………………………………. ………………………………
Machine type: AP…………………………… P23
(Fz)-Ident-No. on the data plate: ………………………………. ………………………………
I purchased / use this machine. The operating manual including the EC conformity declaration was delivered to me together with the
machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
..................................... ...........................................................................
Date Customer's signature
Customer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
..................................................................................
Land/State:
..................................................................................
Email:
..................................................................................
Marketing partner / Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
..................................................................................
Land/State:
..................................................................................
Email:
..................................................................................
.............................. .............................................................
Date Signature Customer Service

Delivery Note 4 (Copy for the Importer)
Complete this document when the machine is delivered and keep it.
Date of delivery: ………………………………. ………………………………
Machine type: AP…………………………… P23
(Fz)-Ident-No. on the data plate: ………………………………. ………………………………
I purchased / use this machine. The operating manual including the EC conformity declaration was delivered to me together with the
machine. I was clearly instructed in the safety, operating, and maintenance instructions of the machine.
Some components of the machine may have been removed for transportation.
Do not use the machine unless these components have been correctly installed again!
..................................... ...........................................................................
Date Customer's signature
Customer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
..................................................................................
Land/State:
..................................................................................
Email:
..................................................................................
Marketing partner / Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
..................................................................................
Land/State:
..................................................................................
Email:
..................................................................................
.............................. .............................................................
Date Signature Customer Service

LELY WELGER AP 530 AP 630 AP 730 AP 830 3
Table of Contents
1Introduction.....................................................................................................................................................5
1.1The Lely Welger AP baler .................................................................................................................................... 6
1.2Trademarks, Copyright and Disclaimer (2010-12) .............................................................................................. 7
1.3Warranty Restriction........................................................................................................................................... 8
1.4Applicability ........................................................................................................................................................ 9
1.5Registration....................................................................................................................................................... 10
1.6How to read this operating manual!................................................................................................................. 11
1.7Proper use......................................................................................................................................................... 12
1.8Foreseeable misuse........................................................................................................................................... 13
1.9End of life .......................................................................................................................................................... 13
2Safety ............................................................................................................................................................ 15
2.1Safety Instructions ............................................................................................................................................ 15
2.2Safety Alert Symbols ......................................................................................................................................... 15
2.3Safety Massages ............................................................................................................................................... 16
General Safety........................................................................................................................................... 16
2.3.1
Installation Safety ..................................................................................................................................... 17 2.3.2
Driving Safety............................................................................................................................................ 17 2.3.3
Operating Safety ....................................................................................................................................... 18 2.3.4
2.4 Safety Decals..................................................................................................................................................... 21
Location of the safety decals .................................................................................................................... 21
2.4.1
Safety Decal messages.............................................................................................................................. 22 2.4.2
Maintenance of the safety decals............................................................................................................. 25 2.4.3
3Operation ...................................................................................................................................................... 26
3.1 Operator positions at the machine ................................................................................................................... 26
3.2 Functional principle........................................................................................................................................... 27
3.3 Commissioning.................................................................................................................................................. 28
Start up ..................................................................................................................................................... 29
3.3.1
Coupling and uncoupling the baler to the tractor .................................................................................... 30 3.3.2
Coupling the hydraulic lines*.................................................................................................................... 31 3.3.3
Connect the drive shaft............................................................................................................................. 32 3.3.4
Connect the electrics* .............................................................................................................................. 32 3.3.5
Connect control unit P23 bale thrower* .................................................................................................. 32 3.3.6
Trailer hitch*............................................................................................................................................. 32 3.3.7
Wire tying.................................................................................................................................................. 33 3.3.8
Twine tying................................................................................................................................................ 34 3.3.9
Shutdown procedure ................................................................................................................................ 37 3.3.10
Depressurize hydraulic system ................................................................................................................. 37 3.3.11
3.4 Driving and Transport ....................................................................................................................................... 39
Moving to working position...................................................................................................................... 40
3.4.1
Moving to transport position.................................................................................................................... 40 3.4.2

4 LELY WELGER AP 530 AP 630 AP 730 AP 830
3.5 Operation instruction in the field...................................................................................................................... 41
Laying of swaths........................................................................................................................................ 41
3.5.1
Speed of PTO shaft.................................................................................................................................... 42 3.5.2
Adjusting the pick-up................................................................................................................................ 42 3.5.3
Setting bale density .................................................................................................................................. 44 3.5.4
Setting bale length.................................................................................................................................... 44 3.5.5
Bale thrower P23* .................................................................................................................................... 45 3.5.6
Clearing blockages .................................................................................................................................... 46 3.5.7
4Troubleshooting............................................................................................................................................. 47
4.1 Faults and Remedies ......................................................................................................................................... 47
4.2 Tying faults and remedies................................................................................................................................. 48
Twine Tying............................................................................................................................................... 49
4.2.1
Wire Tying................................................................................................................................................. 51 4.2.2
4.3 Bale Thrower faults and remedy....................................................................................................................... 53
5Maintenance and adjustments ....................................................................................................................... 55
5.1 Maintenance schedules .................................................................................................................................... 55
5.2 Maintenance procedure.................................................................................................................................... 56
Wheels ...................................................................................................................................................... 56
5.2.1
Changing the transmission oil................................................................................................................... 56 5.2.2
Examining and adjusting the cutting mechanism ..................................................................................... 57 5.2.3
Examining and adjusting timing................................................................................................................ 59 5.2.4
Timing the cross-feeder in relation to the packer .................................................................................... 61 5.2.5
Examining ram movement........................................................................................................................ 63 5.2.6
Examining needle brake............................................................................................................................ 64 5.2.7
Examine the main drive ............................................................................................................................ 65 5.2.8
Maintain and adjust tying unit.................................................................................................................. 67 5.2.9
Freeing up the deflecting cross-feeder..................................................................................................... 73 5.2.10
Wire tying service and lubrication ............................................................................................................ 74 5.2.11
Hydraulic System ...................................................................................................................................... 79 5.2.12
Thrower belt tensioning............................................................................................................................ 79 5.2.13
5.3 Lubrication Chart .............................................................................................................................................. 80
5.4 Environment...................................................................................................................................................... 82
Lubricants.................................................................................................................................................. 82
5.4.1
Consumables............................................................................................................................................. 82 5.4.2
Hydraulic oil .............................................................................................................................................. 82 5.4.3
5.5 Specification...................................................................................................................................................... 83
5.6 Tightening Torques ........................................................................................................................................... 84
6Index.............................................................................................................................................................. 85

LELY WELGER AP 530 AP 630 AP 730 AP 830 5
1 Introduction
Welcome to the Lely manual, the place where you can find
technical information, operating instructions, maintenance
procedures and troubleshooting information for the
Lely Welger AP baler.
Study and understand this information thoroughly before you
operate the Lely Welger AP baler. Failure to do so could result
in personal injury or damage to equipment. Please consult your
local Lely service provider if you do not understand the
information in this manual, or if you need additional information.
All information in this manual has been compiled with care. Lely
shall not be liable for errors or faults in this manual. The
recommendations are meant to serve as guidelines. All
instructions, pictures and specifications in this manual are
based on the latest information that was available at the time of
publication. Your Lely Welger AP baler may comprise
improvements, features or options that are not covered in this
manual.

6 LELY WELGER AP 530 AP 630 AP 730 AP 830
1.1 The Lely Welger AP baler
The Lely Welger AP baler is a baler that produces small square
bales from dry agricultural material such as wheat straw, hay
and alfalfa.
The Lely Welger AP baler is pulled by a tractor.
The packer, cross-feeder, ram, knotter device and pick up are
driven entirely via torsionally rigid shafts and gears. This
ensures high performance baling results, quality bales and a
long life time.
The Packer Feed consists of two (AP 830 has 3) self-deflecting
packers which prevent blockage caused by foreign objects or
damage to the machine. In case of an overload the packers can
mostly deflect and then automatically reposition themselves
ready for operation. After several ram strokes, the blockage will
be cleared. The benefits are clear due to the use of a patented
hydro packer, a further development of the tried and tested self-
deflecting packers.
Two friction clutches; one in front and one behind the flywheel
protect the universal joint and the tractor as well as the baler
drive. On the AP 530 and the AP 630, an additional shear bolt
protects the drive should an unforeseen blockage occur. On the
AP 730 / 830, this function is fully automated with an auto-reset
clutch.
The bale thrower P23, is an accessory. The thrower is driven
via its own hydraulic system and allows maximum use of the
baler’s performance. The baler is no longer restricted by the
speed of a manual worker during loading.

LELY WELGER AP 530 AP 630 AP 730 AP 830 7
1.2 Trademarks, Copyright and Disclaimer
(2010-12)
Lely, Astronaut, Astri, Atlantis, Attis, AWS, C4C, Calm, Caltive,
Commodus, Compedes, Cosmix, Discovery, F4C, Fertiliner,
Gravitor, Grazeway, Hibiscus, Hubble, Juno, L4C, Lely Center,
Lelywash, Lotus, Luna, Nautilus, Orbiter, Quaress, Qwes, SAE,
Shuttle, Splendimo, Storm, T4C, Tigo, Vector, Viseo, Voyager,
Walkway and Welger are registered trademarks of the Lely
Group.
The right of exclusive use belongs to the companies of the Lely
Group. All rights reserved. The information given in this
publication is provided for information purposes only and does
not constitute an offer for sale. Certain products may not be
available in individual countries and products supplied may
differ from those illustrated. No part of this publication may be
copied or published by means of printing, photocopying,
microfilm or any other process whatsoever without prior
permission in writing by Lely Holding S.à.r.l. Although the
contents of this publication have been compiled with the
greatest possible care, Lely cannot accept liability for any
damage that might arise from errors or omissions in this
publication.
The English language manual is the original manual.
Translations into other languages use the English language
manual as the source document. Lely accepts no liability for
discrepancies between the original English language manual
and versions in other languages. If there is a conflict over the
content and accuracy of any translated manual, the English
language manual is the authority document.
© 2014 by Lely Vermeer Maschinenfabrik GmbH Wolfenbüttel
Made in Germany
All rights reserved
Lely Vermeer Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3
D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142
Fax: (+49) 53 31 / 404-143
* The equipment marked with a [*] in this operating manual are
only part of the standard equipment of certain machine versions
or are available as additional equipment only for certain
machine versions.
1132.99.03.03 Rev 07.14 Print 07.14

8 LELY WELGER AP 530 AP 630 AP 730 AP 830
1.3 Warranty Restriction
Excluded from this warranty are any costs or expenses due to:
• Abnormal use of the equipment which is not according to the
specifications stated in the Operator Manual.
• The result of any intervention by technicians other than Lely
service technicians or technicians who have Lely’s approval to
perform certain duties.
• The result of any modification done by the operator or third
parties without Lely's foreknowledge and/or authorization.
• Incidents such as freezing, ice, fire, lightning, flood, inundation
or any other form of excessive water.
• The use of cleaning agents for washing of the Lely Welger AP
baler / P23 bale thrower. This can cause damage to Lely
Welger AP baler. All parts damaged as a result of the use of
cleaning agents will be excluded from warranty.
• Damage to the electrical system as a result of vermin or the
like.
The warranty shall not apply if the instructions mentioned in this
manual have not been followed completely or correctly. Nor will
the warranty apply if you or third parties modify the machine
without our foreknowledge and/or authorization.
Warranty does not apply to consequential damage which does
not involve the machine itself.
All the systems are tested. However in the event of a
malfunction Lely cannot be held responsible for consequential
damage.

LELY WELGER AP 530 AP 630 AP 730 AP 830 9
1.4 Applicability
The table below shows the type numbers of the Lely Welger AP
baler and Lely P23 for which this manual is applicable.
Types AP 530 AP 630 AP 730 AP 830 P 23
Serial
Number
Identification
1132.xx.xxx 1135.xx.xxx 1133.xx.xxx 1134.xx.xxx 3164.xx.xxx
The Lely Welger P23 bale thrower is optional equipment.
Please note that equipment features indicated with [*] in this
manual are standard for certain model versions only or are only
available for certain models as extra equipment.

10 LELY WELGER AP 530 AP 630 AP 730 AP 830
1.5 Registration
The Serial Number Plate of the Lely Welger AP baler is on the
left side of the chassis frame.
Always include the type and the serial numbers of your product
when you contact your local Lely service provider or order spare
parts.
We suggest you complete the table below with the model type,
and the serial number of your product. This makes sure you can
easily find the information.
The Serial Number Plate of the P23 bale thrower is on the top
of the thrower chassis frame.
Always include the type and the serial numbers of your product
when you contact your local Lely service provider or order spare
parts.
We suggest you complete the table below with the model type,
and the serial number of your product. This makes sure you can
easily find the information.
Note!
The “Hand over Declaration” has to be filled out and send back.
Machine Type
Fz-Ident-Nr.
Machine Type
Ident-Nr.

LELY WELGER AP 530 AP 630 AP 730 AP 830 11
1.6 How to read this operating manual!
This operating manual is subject to all users of this machine. It
provides important information on the use, operation,
maintenance, cleaning, transport and safety of the machine.
Omission of maintenance and cleaning or wrong operation will
cause an increased safety risk, a higher wear and tear as well
as decreased performance.
Read and understand the operating manual very carefully
before you start operating the machine. If personnel lack of
required knowledge is missing, the knowledge must be received
by training and instructions.
The operating manual must always be available wherever the
machine is in use.
Directions mentioned in the text such as left, right, front, rear,
up, down are understood in direction of travel.
Technical data:
All technical date, measurements and weights are for
informational usage only and are not binding.
On road driving:
Each country has own on road regulations. In case of
deviations between the manufacturer and country where the
machine is used, the country regulations are obliged.
The speed limit of the machine during road transport complies
with country regulations. The manufacturer speed limit may be
set higher.
Modification:
Any modifications that interfere with the country or manufacturer
regulations will cause a loss of general operating license and
type-approval.
The Lely Welger AP baler is hereinafter referred to as
“AP baler”.
The Lely Welger P23 thrower is hereinafter referred to as
“thrower”.
In addition, the following rule is applicable too:
The Lely Welger AP baler and the Lely Welger P23 thrower are
hereinafter referred to as “machine”.
The Power-Take-Off shaft is hereinafter referred to as “PTO” or
“PTO shaft”.

12 LELY WELGER AP 530 AP 630 AP 730 AP 830
1.7 Proper use
The AP baler has been built exclusively for the production
of bales compressed from grain crops or hay from grasses
lying on the ground (proper use). Usage going beyond that
does not constitute proper use. The manufacturer is not
liable for damage resulting from improper use; the operator
alone bears the risk.
Proper use also includes adherence to the operating,
maintenance and servicing conditions prescribed by the
manufacturer.
The attachment of auxiliary equipment to the machine other
than at the positions provided by the factory is prohibited.
The relevant accident prevention regulations, regional
safety standards and other generally recognized safety
regulations in particular, are to be adhered to.
Unauthorized alterations and the installation of non-
approved parts and equipment on the machine exclude any
liability on the part of the manufacturer for damage resulting
from this. Only original Lely spare parts are to be used.
Components covered by CE regulations must conform to
these regulations.
The machine may only be operated, maintained and
repaired by persons who are familiar with such work and
instructed on the dangers involved.
The relevant accident prevention regulations and all other
generally accepted safety rules must be observed.
The basic requirements concerning safety and health
protection must be fulfilled. The generally accepted safety
rules must be observed.