LELY WELGER V 160 User manual

LELY WELGER
V 160
V 160
1758.99.03.01 02.08
Operating Manual

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:
V 160
........................................................................
Machine no. on the data plate (e. g. 1758.00.001): ........................................................................
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. 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!
The following components must be reinstalled prior to first commissioning:
Wheels see spare parts list page A10 (items 13-18)
Pick-up guide wheel, left and right see spare parts list page C10 (items 1-10)
Drawbar head see spare parts list page B10 (items 1-15)
Support foot see spare parts list page B30 (items 1-15)
Bale ejector see spare parts list page B70 (items 1-19)
..................................... ...........................................................................
Date Customer's signature

Send back to:
Lely International N.V.
TSS (Technical Service Support)
Postfach 1965
D-38289 Wolfenbüttel
M
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:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
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:
V 160
........................................................................
Machine no. on the data plate (e. g. 1758.00.001): ........................................................................
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. 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!
The following components must be reinstalled prior to first commissioning:
Wheels see spare parts list page A10 (items 13-18)
Pick-up guide wheel, left and right see spare parts list page C10 (items 1-10)
Drawbar head see spare parts list page B10 (items 1-15)
Support foot see spare parts list page B30 (items 1-15)
Bale ejector see spare parts list page B70 (items 1-19)
..................................... ...........................................................................
Date Customer's signature

M
Complete this document when the machine is delivered and keep it.
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 3 (Copy for the Trader)
Complete this document when the machine is delivered and keep it.
Date of delivery: ........................................................................
Machine type:
V 160
........................................................................
Machine no. on the data plate (e. g. 1758.00.001): ........................................................................
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. 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!
The following components must be reinstalled prior to first commissioning:
Wheels see spare parts list page A10 (items 13-18)
Pick-up guide wheel, left and right see spare parts list page C10 (items 1-10)
Drawbar head see spare parts list page B10 (items 1-15)
Support foot see spare parts list page B30 (items 1-15)
Bale ejector see spare parts list page B70 (items 1-19)
..................................... ...........................................................................
Date Customer's signature

M
Complete this document when the machine is delivered and keep it.
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:
V 160
........................................................................
Machine no. on the data plate (e. g. 1758.00.001): ........................................................................
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. 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!
The following components must be reinstalled prior to first commissioning:
Wheels see spare parts list page A10 (items 13-18)
Pick-up guide wheel, left and right see spare parts list page C10 (items 1-10)
Drawbar head see spare parts list page B10 (items 1-15)
Support foot see spare parts list page B30 (items 1-15)
Bale ejector see spare parts list page B70 (items 1-19)
..................................... ...........................................................................
Date Customer's signature

M
Complete this document when the machine is delivered and keep it.
Customer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
Marketing partner/Importer
Name:
..................................................................................
Postcode/Place:
..................................................................................
Phone:
..................................................................................
Street:
...................................................................................
Land/State:
...................................................................................
eMail:
...................................................................................
.............................. .............................................................
Date Signature Customer Service

WELGER • V 160 3
The vehicle (identification) number is stated on the data
plate attached to the right side of the machine. Warranty
claims and queries cannot be dealt with unless the serial
number is stated. Please enter this number here immediately
after delivery:
Veh-Ident-No.: ...........................................................
Read and heed the operating instruction and safety instructions prior to commission the machine. In
this operating instruction all positions required for safety reasons are marked with a warning sign. Instruct
all other operators in safety instructions! The warning- and information signs located at the machine give
information for safe operation. Watch them for safety reasons!
* Please note that the equipment marked with a [*] in this operating manual are only part of the standard
equipment of certain machine versions or are only available as additional equipment for certain machine
versions.
Copy is not permitted – copyright and technical changes are reserved.
Illustrations are not binding on form and design.
©2008 by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany.
Maschinenfabrik GmbH
Gebrüder-Welger-Straße 3 • D-38304 Wolfenbüttel
Phone: (+49) 53 31 / 404-142 • Fax: (+49) 53 31 / 404-143
eMail: [email protected]

4 WELGER • V 160
Table of Contents
1Variants........................................................................................................................................................ 6
2Safety ........................................................................................................................................................... 7
2.1 General safety instructions................................................................................................................. 7
2.2 Noise level.......................................................................................................................................... 9
2.3 Instructions for fire protection............................................................................................................. 9
2.4 Tail gate locking device.................................................................................................................... 10
2.5 Maintenance platforms and ladders................................................................................................. 10
2.6 Hydraulic System ............................................................................................................................. 11
2.7 Net knife safeguard .......................................................................................................................... 11
2.8 Guard casings .................................................................................................................................. 12
2.9 Warning symbols.............................................................................................................................. 13
2.10 Symbolised operating instructions ................................................................................................... 17
2.11 Proper use........................................................................................................................................ 20
2.12 Electromagnetic compatibility........................................................................................................... 20
2.13 To be observed when driving on the road........................................................................................ 21
2.14 Environment/Disposal ...................................................................................................................... 23
3Assembly groups ..................................................................................................................................... 24
4Start Up...................................................................................................................................................... 25
4.1 Coupling the machine ...................................................................................................................... 25
4.2 Drive shaft ........................................................................................................................................ 28
4.3 Hydraulic System ............................................................................................................................. 30
4.4 Electrical system .............................................................................................................................. 31
5Twine tying*............................................................................................................................................... 32
5.1 Threading the twine.......................................................................................................................... 32
5.2 Adjusting the twine brake ................................................................................................................. 35
5.3 Setting the edge clearances............................................................................................................. 36
5.4 Adjusting the wrapping distance ...................................................................................................... 36
5.5 Edge wrapping adjustment............................................................................................................... 37
6Net tying* ................................................................................................................................................... 38
6.1 Inserting the net................................................................................................................................ 38
6.2 Tightening the net knife.................................................................................................................... 42
6.3 Adjusting the net length.................................................................................................................... 43
7FIELD DEPLOYMENT ............................................................................................................................... 44
7.1 Locking the tail gate ......................................................................................................................... 45
7.2 Adjusting the bale diameter.............................................................................................................. 46
7.3 Setting the bale density.................................................................................................................... 47
7.4 Raising / lowering the pick-up .......................................................................................................... 47
7.5 Pick-up guide wheels ....................................................................................................................... 47
7.6 Windguard / Pick-up shield* ............................................................................................................. 48
7.7 PTO speed ....................................................................................................................................... 48
7.8 Driving style...................................................................................................................................... 49
7.9 Safety clutch..................................................................................................................................... 51

WELGER • V 160 5
8Operation / Tying ...................................................................................................................................... 52
8.1 BALERCONTROL E control box......................................................................................................52
8.2 Eject bales........................................................................................................................................ 55
8.3 Emergency operation ....................................................................................................................... 56
9Removing a material jam ......................................................................................................................... 57
9.1 Main drive reversing ......................................................................................................................... 57
10 Maintenance / Setting............................................................................................................................... 58
10.1 General notes................................................................................................................................... 58
10.2 Tensioners........................................................................................................................................ 59
10.3 Maintenance of the net tying unit ..................................................................................................... 59
10.4 Tensioning the roller chains ............................................................................................................. 60
10.5 Hydraulic layout................................................................................................................................ 61
10.6 Tire air pressure V 160..................................................................................................................... 62
10.7 Chain lubrication (oil lubrication) ...................................................................................................... 63
10.8 Winter pause .................................................................................................................................... 66
10.9 Lubrication chart............................................................................................................................... 67
10.10 Lubrication points ............................................................................................................................. 68
11 Technical Data .......................................................................................................................................... 69

6 WELGER • V 160
1 Variants
V160
1700 Nm – Shear bolt ●
1700 Nm – Shear bolt and free wheel mechanism 
Drive shaft
1700 Nm – Cam-type cut-out clutch 
Pick-up width 2.00 m ●
no chain lubrication ●
Chain lubrication
mechanical chain lubrication (automatic) 
Net tying ●
Tying
Twine tying 
no bale ejector ●
Bale ejector
bale ejector with pressure spring 
Standard windguard ●
Crop material windguard
Roller windguard 
Control / Operation Control box Balercontrol E (with control for Balercontrol E) ●
Conveyor channel
bottom plate
Bottom plate (fixed) ●
11.5/80-15.3 3.5 bar ●
15.0/55-17 2.5 bar 
19.0/45-17 1.5 bar 
Tyres
(max. speed 25 km/h)
19.0/45-17 Flotation 1.5 bar 
●Series equipment
Variant

WELGER • V 160 7
2 Safety
2.1 General safety instructions
Attention!
Even if all instructions are observed the machine involves
residual dangers. Always handle the machine with care to avoid
danger to yourself and others!
• Before starting work perform a visual inspection of the
machine. Check whether any device has been changed or is
missing and pay attention to any unusual noise or leaks
which occur during operation.
• All protective devices, as for example casing sheets, rubber
skirts or distance brackets are for your safety! Never operate
the machine with defective or removed protective devices e.
• Keep all safety relevant parts always in correct function.
Before commissioning all guard casings must be mounted
and closed!
• Never perform maintenance- and repair works during
machine is in operation.
• In case of all work on movable parts or in the range of action
of movable parts: Switch off power take-off shaft, switch off
tractor engine, remove ignition key and disconnect drive
shaft from power take-off shaft end. Interrupt electrical
connection between tractor and machine.
• Bring no metal parts close to the machine, as long the
electric control is in operation (e.g. tools, safety boots with
metal caps). Reason: unintentional triggering of proximity
switches and thus unexpected machine moves.
• When carrying out work on the opened tail gate: use tail gate
locking device (chapter „2.4 Tail gate locking device“).
• When carrying out work in the vicinity of the net knife: use
net knife safeguard (chapter "2.7 Net knife safeguard").
• Never remove any crop material from the machine while the
drive is running, or while the disconnected machine is still
moving. Always switch-off power take-off shaft and tractor
engine first.
• During work only the driver must be on the tractor. Riding on
the machine is prohibited!
• Never step on the maintenance platforms during machine is
in motion. Before stepping on the maintenance platforms:
stop machine, switch-off power take-off shaft and tractor
motor, take out ignition key and wait for standstill of the
machine.

8 WELGER • V 160
• Never climb onto the drawbar (drawbar head, hitch) or any
other parts of the machine while the machine is in operation.
Keep sufficient distance to the machine (pick-up, running
gear, bale unloading area).
• Before threading the tying material: stop machine, switch-off
power take-off shaft and tractor motor, take out ignition key
and wait for standstill of the machine. Make the control
powerless (disconnect electrical connection to the tractor).
• All protection devices must be attached to the machine and
must be in correct state. Before opening the protections:
switch-off power take-off shaft and tractor engine and wait
for standstill of the machine.
• Block the wheels of the machine with wheel chocks when
the machine is parked. Carry the chocks on the machine
when transporting it or during field use.
• When opening the tail gate keep a minimum distance of 2 m
from electrical high-voltage lines.
• There is danger of injury by cutting during work on the net
knife. Wear protective gloves.
• Maintenance work may be carried out by trained persons
only. All maintenance- and repair works that are not part of
this operating instruction must be carried out by authorised
personnel only.
• Prior to disassembling the complete pick-up the machine
must be secured against backward tilt.
• In case of locations on a slope: place the round bales always
so that they cannot move automatically.

WELGER • V 160 9
2.2 Noise level
The EC directive 2003/10/EC (old designation: 86/188/EEC)
concerning noise at the workplace requires from employers and
employees to assess noise at the place of work and to control it.
The noise level during normal field work is subject to variations
which depend on the one hand on the noise level of the tractor
and on the other hand on the deployment conditions of the
machine.
The noise level generated by WELGER balers, measured at the
head height of the driver with the tractor cabin window open, is,
under normal operating conditions, less than 70 dB (A). The
combined noise level of baler and tractor primarily depends on
the level of the noise from the tractor (radios are an additional
source of noise). We recommend that the tractor is operated
with closed windows.
2.3 Instructions for fire protection
The harvested crop can easily ignite! To prevent fire:
• remove crop remains and oil leaks.
• If any machine parts run hot: find and remove cause.
• Keep the electrical systems of tractor and machine and the
exhaust system of the tractor in proper condition.
• The existing wiring must not be used for any other
consumers than those installed in the factory or approved by
the manufacturer. Overloading the electrical lines leads to
excessive heating.
• Do not smoke in the vicinity of the machine.
• Keep fire extinguisher within reach.
Figure 1

10 WELGER • V 160
2.4 Tail gate locking device
If any short-time maintenance or assembly work is carried out
with the tail gate open, the tail gate must be hydraulically
secured against lowering (hydraulic tail gate locking device):
use the shut-off valve (near the support foot). When the valve is
shut off, the actuating lever is at right angles to the flow
direction (Figure 2).
In case of longer maintenance or assembly work with the tail
gate open, the tail gate must (in addition to the hydraulic
safeguard) be mechanically secured against lowering - using
suitable means.
After completion of any maintenance and/or assembly work
reset the shut-off valve to its initial position (along flow direction,
Figure 3) and/or remove the mechanical safeguard.
2.5 Maintenance platforms and ladders
Attention, danger of falling!
Never step on the maintenance platforms [14] (Figure 4) while
the machine is in motion. Before stepping on the maintenance
platforms: stop machine, switch-off power take-off shaft and
tractor motor and wait for standstill of the machine.
Climb and leave the maintenance platforms exclusively via the
ladders [10]. Never climb the ladder while the ladder is turned
up - always turn down the ladder first.
 (Figure 4) To climb the maintenance platforms: fold down
ladders [10].
Figure 2
Figure 3
Figure 4

WELGER • V 160 11
2.6 Hydraulic System
Max. operating pressure of the hydraulic system:
• 210 bar (Figure 5)
When carrying out assembly work on the hydraulic system:
 depressurise the hydraulic system (control unit to "Lower")
 secure hydraulically operated parts (pick-up, tail gate)
mechanically against uncontrolled movements.
According to DIN 20066 hydraulic hoses must not be older than
six years, including storage time. The storage time alone should
not be longer than two years.
2.7 Net knife safeguard
Attention, danger of injury by cutting! When carrying out
work in the vicinity of the net knife: use net knife safeguard!
When maintenance and assembly work is being carried out in
the vicinity of the net knife, the net knife must be mechanically
secured against accidental falling down:
 (Figure 6) fit and secure safety chain with spring clip.
 After completion of maintenance and assembly work:
remove net knife safeguard.
Figure 5
Figure 6

12 WELGER • V 160
2.8 Guard casings
The guard casings on the left and sight sides can be folded up.
Open guard casings:
 Hold the handle on the guard casing with one hand to
prevent the guard casing from flying open after unlocking.
 (Figure 7) Turn the hexagon head of the locking device
slightly counterclockwise using a 13 mm spanner – the
guard casing is unlocked and opens with spring pressure.
Close guard casings:
 Press guard casing against the machine – until the catch
engages audibly.
Attention, danger of injury!
Never operate the machine with open guard casing!
Open guard casings only, when a free swivelling area is
available.
Never operate the machine with defective or removed protective
devices (e. g. guard casings and distance bracket). Before
opening the protections: Switch off p.t.o. shaft drive and tractor
engine, wait until machine has stopped, remove the ignition
key.
Figure 7