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

LELY WELGER AP 530 Specifications

General

Brand	LELY WELGER
Model	AP 530
Category	Accessories
Language	English

Summary

Introduction to the Lely Welger AP Baler

The Lely Welger AP Baler Overview

Describes the Lely Welger AP baler, its purpose, and key features like the packer feed and clutches.

Trademarks, Copyright, and Disclaimer

Lists Lely trademarks, copyright information, and disclaimer regarding manual accuracy and product variations.

Warranty Restrictions Explained

Outlines exclusions from warranty coverage, including abnormal use, unauthorized modifications, and specific incidents.

Applicability of the Manual

Shows type numbers of Lely Welger AP baler and P23 thrower for which the manual is applicable.

Product Registration and Identification

Explains where to find the serial number plate and suggests recording product details for service and spare parts.

How to Read This Operating Manual

Guides users on how to interpret the manual, including directions, technical data, and modification warnings.

Proper Use Guidelines

Defines the intended use of the AP baler and emphasizes adherence to operating, maintenance, and safety instructions.

Foreseeable Misuse of Equipment

Lists prohibited uses of the AP baler and thrower P23, such as stationary operation or processing refuse.

End of Life Procedures

Outlines proper decommissioning procedures for the machine in compliance with regulations.

Safety Information and Precautions

Safety Instructions Overview

Emphasizes user responsibility for safe operation and maintenance, ensuring all personnel are informed.

Understanding Safety Alert Symbols

Explains the meaning of signal icons (Danger, Warning, Caution, Note) used in the manual for hazard communication.

General Safety Practices

Provides general safety rules, including reading the manual, following regulations, and wearing protective equipment.

Installation Safety Guidelines

Safety precautions for connecting the baler/thrower to the tractor, emphasizing engine status and parked machine safety.

Driving Safety Procedures

Safety guidelines for travelling, including road regulations, warning lights, passenger safety, and hillside driving.

Operating Safety Procedures

Safety measures before, during, and after operation, such as visual inspections and maintaining safe distances.

Safety During Maintenance

Safety rules specifically for maintenance and adjustment work on the baler and thrower.

Fire Prevention Measures

Measures to prevent fires, including removing crop remains and checking for leaks.

Noise Protection Information

Information about noise levels generated by the machine and tractor during operation.

Safety Decals and Their Locations

Identifies safety decals and their locations on the machine for hazard awareness.

Interpreting Safety Decal Messages

Explains the meaning of various safety decals, including danger and warning messages.

Maintenance of Safety Decals

Instructions for keeping safety decals clean, legible, and ensuring they are replaced if missing or illegible.

Operating the Lely Welger AP Baler

Operator Positions and Machine Ranges

Identifies safe operator positions and dangerous areas around the machine during operation.

Functional Principle of the Baler

Explains the 5-step bale cycle and how the baler ejects bales, including the bale thrower.

Commissioning the Baler

Covers initial setup steps, including adapting the drive shaft and ensuring guard casings are correctly fitted.

Adapting the Drive Shaft

Provides instructions for adjusting the drive shaft length for optimal overlap and safe operation.

Guard Casings Installation and Safety

Details how to open, close, and secure guard casings on the baler for safety.

Starting Up the Baler

Safety procedures and checks before starting the baler, including visual inspections and hazard awareness.

Coupling and Uncoupling the Baler

Step-by-step guide for safely connecting and disconnecting the baler from the tractor.

Coupling Hydraulic Lines

Instructions for connecting the hydraulic hoses, emphasizing depressurizing systems and identifying hose functions.

Connecting the Drive Shaft

Procedure for connecting the PTO drive shaft to the tractor and baler, including safety checks.

Connecting Electrical Systems

Guidance on connecting the electrical system, including lighting checks and road traffic regulations.

Connecting the Bale Thrower Control Unit

Instructions for fitting the control unit for the P23 bale thrower to the tractor.

Trailer Hitch Requirements

Information on the adjustable trailer hitch and its use with loading chutes or bale throwers.

Wire Tying Procedures

Detailed steps for threading and pulling wire into the tying unit for bale formation.

Threading the Wire for Tying

Instructions on preparing and threading wire coils into the tying mechanism.

Pulling Wire into the Tying Unit

Steps for drawing the wire through the tying unit after threading.

Twine Tying Operations

Procedures for cleaning the knotter and inserting twine for proper bale tying.

Cleaning the Knotter Mechanism

Guidance on cleaning the knotter to ensure it functions correctly during baling.

Inserting Twine into the Tying Unit

Steps for securing the knotter and placing twine rolls correctly for baling.

Setting the Twine Tension

Adjusting the twine tensioning springs to ensure proper bale formation and tying.

Tripping the Tying Cycle

Procedure for initiating the tying cycle to test the knotter mechanism.

Drawing Twine into the Knotter

Steps to ensure twine is correctly drawn into the knotter after it has been set up.

Bale Thrower P23 Operation

Operating instructions for the P23 bale thrower, including adjustments for throwing distance and slewing motion.

Bale Deposition with P23 Thrower

How to change the bale thrower's function from throwing to depositing bales on the field.

Clearing Blockages in the Machine

Procedures for clearing blockages, including stopping the tractor and reducing PTO speed.

Troubleshooting Common Issues

Faults and Remedies Guide

A table listing common faults, their possible causes, and suggested remedies for the baler.

Tying Faults and Remedies

Specific troubleshooting steps for issues related to the knotting mechanism and twine.

Twine Tying Faults and Solutions

Details common twine tying faults, their causes, and the necessary adjustments or remedies.

Wire Tying Faults and Solutions

Troubleshooting guide for wire tying issues, including common faults, causes, and remedies.

Bale Thrower Faults and Remedies

Lists faults related to the bale thrower, their causes, and the corresponding remedies.

Maintenance and Adjustments

Maintenance Schedules and Intervals

Outlines maintenance tasks at different service intervals (20, 50, 100, 500 working hours).

Maintenance Procedures Overview

General maintenance procedures covering wheels, transmission oil, and other components.

Wheel Maintenance and Torque

Instructions for checking and tightening wheel nuts to the specified torque values.

Changing Transmission Oil

Step-by-step guide for draining and refilling the transmission oil, including oil capacity.

Adjusting the Cutting Mechanism

Procedures for examining, adjusting, and potentially regrinding knives for optimal cutting performance.

Adjusting Knives and Setting Play

Detailed steps for installing or adjusting knives and setting the correct play in the ram.

Timing the Packer and Ram

Ensures correct timing between the packer and ram for efficient baling, detailing adjustment steps.

Timing Needles Relative to the Ram

Procedure for timing the needles in relation to the ram to ensure correct bale tying.

Timing Cross-Feeder to Packer

Ensures correct timing between the cross-feeder and packer to prevent collisions.

Timing Cross-Feeder for AP 830

Specific timing procedure for the cross-feeder in relation to the packer for the AP 830 model.

Examining Ram Movement

Checks for proper ram movement, cleaning slide rails, and checking ram pins for tightness.

Packer Quick Adjustment

Adjusting the packer linkage to influence bale shape and filling.

Examining Needle Brake Adjustment

Adjusting needle brakes to ensure needles do not run beyond their highest or lowest positions.

Examine the Main Drive System

Checking the main drive, including friction clutches and shear bolt, for correct operation.

Freeing the Conical Clutch

Procedure for freeing the conical clutch at the beginning of the season for AP 530 and AP 630 models.

Maintain and Adjust Tying Unit

Ensuring control measurements of the tying unit agree with machine measurements after repairs.

Protection of the Knotter Drive

Details on protecting the knotter drive from overloading via a shear bolt.

Adjusting the Needles

Procedure for adjusting needle length and position relative to the twister hook shaft.

Examining Twine Holder and Knotter

Instructions for examining the twine holder and knotter, including greasing shafts.

Adjusting Knotter Tension

Setting the correct spring height for the knotter tensioning mechanism.

Adjusting Twine Holder Tension

Setting the twine tensioning spring to the specified control measurement.

Readjusting the Twine Flicker

Procedure for readjusting the twine flicker to ensure correct operation.

Examining Twine Retaining Spring

Checking the twine retaining spring for proper fit and tension against the twine guide plate.

Replacing the Twine Guide Plate

Steps for replacing the twine guide plate and checking/adjusting the spacing.

Adjusting Knotter Shaft Pawl Spring

Adjusting the knotter shaft pawl spring for correct engagement with the ratchet.

Adjusting the Twine Brake

Setting the twine brake wing nut to achieve the specified spring length.

Positioning the Knotter Mechanism

Checking and adjusting the knotter position after maintenance and repairs.

Freeing Deflecting Cross-Feeder

Procedure to free up the deflecting cross-feeder by 'bottoming the springs' to prevent exceeding torque.

Wire Tying Service and Lubrication

Instructions for servicing wire tying components, including lubrication and inspection.

Wire Tier Timing Checks

Checking timing after repairs to the ram, packer, and knotter drive, ensuring correct distances.

Adjusting Needles for Wire Tier

Adjusting needles for correct timing and clearance with the twister hook shaft.

Adjusting the Shear Lever

Adjusting the shear lever to ensure proper clamping of the wire during bale formation.

Twister Hook Setting

Procedure for aligning and locking the chain wheels for the twister hook.

Setting Knotter Shaft Lock

Adjusting the knotter shaft lock to ensure proper engagement of the leaf spring.

Setting Needles to Ram Alignment

Aligning needles to the ram to ensure correct timing and clearance for bale formation.

Hydraulic System Checks and Maintenance

Procedures for checking hydraulic lines, oil levels, and filter replacement for both baler and thrower.

Thrower Belt Tensioning

Instructions for maintaining proper tension in the thrower belts to prevent bale slippage.

Lubrication Chart and Procedures

Provides a detailed lubrication chart for daily and weekly tasks, including lubricants and greasing points.

Daily Lubrication Tasks

Tasks to be performed daily for lubrication of machine parts like bearings and rods.

Weekly Lubrication Tasks

Tasks to be performed weekly for lubrication of machine parts like tying mechanism and PTO shaft.

Environmental Considerations

Guidelines for proper disposal of lubricants and consumables to protect the environment.

Lubricant Handling and Disposal

Information on the environmental impact of lubricants and proper disposal methods.

Consumables Disposal

Instructions for disposing of used twines and machine parts in an environmentally responsible manner.

Hydraulic Oil Handling

Precautions regarding hydraulic oil spillage or leakage and safe maintenance practices.

Technical Specifications

Key technical specifications for different baler models, including bale chamber dimensions and PTO speed.

Tightening Torques Reference

A table listing tightening torques for various bolt sizes (M6 to M18) based on quality class.

Document Index

An alphabetical index of topics covered in the manual for quick reference.