Comby | Super Comby | Super Comby EX
Feedout Wagon Original Instruction
IMPORTANT Read this manual before operation HUSTLER EQUIPMENT INTERNATIONAL LIMITED
CONTENTS
Introduction................................................................................. 2 Important..................................................................................... 2 Warranty ...................................................................................... 3 Warnings...................................................................................... 4 Operational Instructions....................................................... 4-5 Adjustments..........................................................................6-10 Hydraulic Hosing............................................................... 11-17 Wiring Diagram................................................................... 18-23 Greasing Chart................................................................... 24-34 Trouble Shooting............................................................... 35-36
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INTRODUCTION We take this opportunity of welcoming you as the owner of a Hustler Equipment Machine. We want your machine to be the most efficient and productive piece of equipment you have. This small manual will help you to achieve this objective The correct parts and maintenance of your machine is very important to prevent downtime and equipment damage. Please take special note of the warnings on page 4 and troubleshooting on page 35-36. Correctly maintained and operated this machine will give many years of service. If you have any questions please contact the dealer who supplied you this machine. They have trained technicians who will be able to help you.
IMPORTANT • Please ensure this booklet is read and understood by every operator of this machine. • Also ensure that this booklet goes with the machine if it is resold and is read and understood by owner. • This manual is based on the Super Comby EX, included in this manual are the parts that differ to the Comby and Super Comby machines. Where Super Comby EX is stated in this manual it is most likely that the instruction/part applies to the Comby and Super Comby also. If there is any doubt in the information you are looking for in this manual, please contact Hustler Equipment Int (0800 487 853).
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WARRANTY Hustler warrants new products sold by us to be free from defects in material and workmanship twenty four months after delivery to the initial user. This warranty is for the replacement or repair of any part found to be defective during the warranty period. This warranty excludes any freight cost incurred by the dealer in giving effect to the warranty and specifically excludes all normal maintenance costs. Replacement parts provided under the terms of this warranty are covered for the remainder of the warranty period applicable to the product in which they are installed as if such parts were original components of that product.
Tools Required For Maintaining Operation • • • • • •
1 1/2 Ring Spanner x 2 30mm Ring Spanner x 2 24mm Ring Spanner x 2 19mm Ring Spanner 18mm Ring Spanner 13mm Ring Spanner
• Flexi Tube Grease Gun
3
WARNINGS To operate this machine on the open road it must comply with the LTSA regulations. To operate this machine in other off road operations it must comply with farm safety regulations. Do not operate while standing in or close to the machine or moving parts. Do not make any adjustments while the machine is operating. Beware of surroundings when operating the machine to prevent injury to personnel & prevent damage to the machine.
OPERATION INSTRUCTIONS Connection of the machine • Connect Super Comby EX to tractor via drawbar, quick hitch or Euro hitch connection. Connect towing safety chains when required ( public road use) • Clean hydraulic connectors and couple in to tractor in correct hydraulic banks. If your tractor has a priority system couple the Tilt/Fork hoses into hydraulic bank 1 and machine in to hydraulic bank 2. • Connect electrics. • Adjust tractor hydraulic oil flow rate to 60-80 litres per minute. • Check direction of elevator rotation prior to feeding. • Load feed material in to machine. Note when feeding silage material load the Cross Feed Chamber and Bed Storage Chamber separate to minimize knitting together of long material across the compartments .This decreases the pressure on the drives to separate the load when feeding out with the cross feed chamber.
Operating tip and tricks: • When loading bales with the fork assembly. Use an electric fence dropper mounted into a bale a few back to see where to line the bales up with the machine. • If bales don’t roll on to the bed chamber properly off the forks and become stuck in the gap, reverse the bed storage floor back carefully, this will straighten up the bale in to position. 4
OPERATING INSTRUCTIONS CONT. Do not: • Operate the X-Floor or the Bed Storage Floor in the backward direction with material in the machine. • Actuate the control levers backward and forwards to ‘free’ the load if the floor or elevator chains become jammed. As this can cause damage to drives and hydraulics. • Apply excessive pressure with fork/bin assembly when rising, while storage floor is fully loaded. • Overload the machine with material. 10 tonne the maximum capacity. • Use the elevator in the traveling position to feed out. Always extend the elevator out to feed. Note if the bed storage chain fails to move, extend the elevator fully so the rear flaps are out of the machine then retract into feeding position. • Ride on the drawbar • Water blast the load cell head unit or load cells or junction box. • Apply excessive material pressure on to elevator with XFloor load. • Weld on the machine with a load cell assembly, without first contacting Hustler Equipment Technical staff.
5
ADJUSTMENTS Bed Storage Floor Chains
It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components. Follow the short instruction below to correctly adjust the bed floor storage chain assemblies. • Check to see if the chains need to be adjusted • Tighten up Nut 1 whilst holding Nut 2 with a 24mm ring spanner until the floor slats are just sitting on the rear chain guides or contacting the chain guide 20 mm down on the front side (see drawing). Adjust Nut 1 at small intervals.
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ADJUSTMENT
Elevator Chains
It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components. Follow the short instruction below to correctly adjust the bed floor storage chain assemblies. • Check to see if the chains need to be adjusted • Loosen off the bolts that clamp the elevator shaft cover to the elevator screen • Loosen off the 4 x M12 locking bolts on the Drive Shaft Idler Bearing • Loosen off Adjuster Lock Nuts 1 & 3 • Adjust the chain tension adjuster Nuts 2 & 4 until the chain/slat is at the desired tension of 75mm total travel. Check that the drive shaft is close to parallel. • Tighten up Adjuster Lock Nuts 1 & 3. Tighten up the 4 x M12 locking bolts on the Drive Shaft Idler Bearing • Recheck elevator tension is still correct • Re-clamp elevator shaft cover so there is a minimum 5mm gap between the elevator slat and the elevator shaft cover. Refer to drawings on next page for part locations
DO NOT OVER TENSION THE ELEVATOR & FLOOR CHAINS. DAMAGE & EXTENSIVE WEAR WILL OCCUR
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8
ADJUSTMENT ADJUSTMENT OF THE X-FLOOR CHAINS It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components. Follow the short instruction below to correctly adjust the bed floor storage chain assemblies. • Check to see if the chains need to be adjusted. • Loosen off the large Nut 1 locking nut. • Tighten up the large Nut 2 until the X-Floor slats are just sitting on the lower panel returns (see drawing). Adjust Nut 2 at small intervals and adjust both nuts at the same time to get an even chain tension on both sides. • Tighten up large Nut 1 to lock up the shaft idler shaft assembly. • Recheck chain tension is still correct.
Nut 1
Slat Just Touching
9
Nut 2
LOADED MACHINE BALE LAYOUT
10
HOSING MACHINE MANUAL Port 1
Port 2
DETAIL A
A
B
C
Port 1
Port 2
Port 1
Port 2
DETAIL B 11
DETAIL C
HOSING MACHINE MANUAL Comby standard machine
Fork Ram
Elevator Motor c
c 5
8
c 3
c
Valve Top Upwards
4
c
7
Power Beyond Valve 6 Port Valve c 6
X-Floor Motor
12
c
2
c 1
To Tractor Remotes
c 9
HOSING MACHINE MANUAL Standard machine Elevator Motor SCEX
5 SCEX
3 SCEX
9 SCEX
Valve Top Upwards
4
Bed Motor
SCEX
8 SCEX
7
Power Beyond Valve 6 Port Valve SCEX
6
X-Floor Motor
SCEX
SCEX
2
1
To Tractor Remotes
To increase system pressure, loosen the lock nut, then screw in relief valve on Power Beyond Valve. This increases pressure to all motors, except the cross floor. Apply same logic to increase cross floor pressure on the 6 Port Valve, however the pressure is unable to exceed pressure set on Power Beyond Valve. WARNING! Standard pressure is set at 1800PSI, and can safely be upgraded to 2200PSI. However any higher than this exceeds hydraulic motor specifications. Adjustment tools require a ring spanner set and allen keys. 13
HOSING MACHINE MANUAL STANDARD MACHINE WITH TILTING ELEVATOR OPTION
Supply
1
Supply
2
TILT
3
TILT
2 TILT
1
TILT
6
TILT
4
TILT
5
Tilt Ram Front
14
Tilt Ram Rear
To Tractor Remotes
HOSING MACHINE MANUAL STANDARD WITH FORK OPTION
Supply Fork
2
2
To Tractor Remotes
Supply
1
Fork Ram
Fork
1
15
HOSING MACHINE MANUAL STANDARD WITH TILTING ELEVATOR, FORK & DIVERTER OPTION Fork Ram
Fork
Fork
2
1
To Tractor Remote
Diverter Valve
Supply
1
Supply
2
TILT
3
TILT
2 TILT
1
TILT
6
TILT
5
TILT
4
Tilt Ram Front 16
Tilt Ram Rear
HOSING MACHINE MANUAL
STANDARD MACHINE WITH COMBY SPREAD/GRAIN OPTION Elevator Motor SCEX
4
SCEX
6 Port Power Beyond Valve
3 SCEX
9
Bed Motor
Valves Top Upwards
SCEX
4
SCEX
8 CS
1/2 Nipple
1
6 Port Valve CS
2
SCEX SCEX
6
2 SCEX
SCEX
7 CS3
X-Floor Motor
To Tractor Remotes
1
CS4
Comby Spread Motor
17
1
Comby Spread/ Grain Bin Valve
WIRING DETAILS MANUAL PARTS LIST Brown Black Purple Jumper 1
Yellow
Black Bed Forward Front Coil Brings oil out front port
Bed Back Rear Coil Brings oil out rear port
7 Core WIre Grey Red
Purple Jumper 1
White Green
Diverter Valve Plug
18
Colour
Operation
Trailer Plug Pin Number
7 Core Black
Earth Return
Pin 5
7 Core White
Earth Return
Pin 3
7 Core Yellow
Direction bed forward
Pin 1
7 Core Brown
Direction bed backwards
Pin 7
7 Core Red
Direction X floor backwards
Pin 6
7 Core Green
Direction X floor feed
Pin 4
7 Core Blue
Dirverter Switch Control
Pin 2
WIRING DETAILS MANUAL PARTS LIST
19
Colour
Operation
Trailer Plug Pin Number
7 Core Black
Earth Return
Pin 5
7 Core White
Earth Return
Pin 3
7 Core Yellow
Direction bed forward
Pin 1
7 Core Brown
Direction bed backwards
Pin 7
7 Core Red
Direction X floor backwards
Pin 6
7 Core Green
Direction X floor feed
Pin 4
7 Core Blue
Dirverter Switch Control
Pin 2
WIRING DETAILS MANUAL PARTS LIST
Wire 3. Green
Wire 3. Brown Wire 3. Blue Wire 7. Yellow
Wire 2. Red
20
Wire 7. Green Wire 7. Red
WIRING DETAILS MANUAL PARTS LIST
Wire J5
Wire 1 Red
Wire J3
Wire J2 Wire J1 Wire J4 Wire J7 Wire 3. Green
21
WIRING DETAILS MANUAL PARTS LIST
Wire 1 Red
Wire 1 Black Wire 2 Black Wire 7 White
Wire 2 Red
Wire 7 Black
Wire 7 Brown 7 Core Cable
Wire 7 Green Wire 7 Yellow Wire 3 Blue 2 Core Cable Wire 3 Brown
3 Core Cable
22
WIRING DETAILS MANUAL PARTS LIST
Wire ID
From component ID
From Compnent Terminal
Wire 1 Black
Earth Joiner Heat Shrink
1
Center Light Contact
1c
Wire 1 Red
Panel Mount Fuse
2
Joystick Contact Switch
3a
Wire J1
Joystick contact Switch
2a
Joystick contact Switch
4c
Wire J2
Joystick contact Switch
2c
Joystick contact Switch
1c
Wire J3
Joystick contact Switch
1a
Joystick contact Switch
3c
Wire J4
SPST Normally Closed
1a
Joystick contact Switch
4a
Wire J5
Center Light Contact
2b
SPST Normally Closed
2b
Wire J6
Contact P9B10VN
4a
Center Light Contact
1c
Wire J7
Center Light Contact
1c
Center Light Contact
1c
Wire J8
Joystick contact Switch
1b
Contact P9B10VN
3c
Wire 2 Black
6mm Crimp Eyelet
1
Earth Joiner Heat Shrink
a
Wire 2 Red
6mm Crimp Eyelet
1
Panel Mount Fuse
1
Wire 3 Blue
Duraplug 3 pin Female
N
SPST Normally Closed
2a
Wire 3 Brown
Duraplug 3 pin Female
L
SPST Normally Closed
2c
Wire 3 Green
Duraplug 3 pin Female
Earth
Center Light Contact
1b
Wire 7 Black
Earth Joiner Heat Shrink
b
Female 7 Pin Trailer Plug
5
Wire 7 Blue
Contact P9B10VN
4c
Female 7 Pin Trailer Plug
2
Wire 7 Brown
Joystick contact Switch
3b
Female 7 Pin Trailer Plug
7
Wire 7 green
Joystick contact Switch
2b
Female 7 Pin Trailer Plug
4
Wire 7 Red
Joystick contact Switch
4b
Female 7 Pin Trailer Plug
6
Wire 7 White
Earth Joiner Heat Shrink
c
Female 7 Pin Trailer Plug
3
Wire 7 yellow
Joystick contact Switch
1b
Female 7 Pin Trailer Plug
1
23
To Component ID
To
GREASING CHART MANUAL
24
4 3 23 2 1
24
GREASING CHART MANUAL
27
25
25
5
6
7 26
8
9
28
GREASING CHART MANUAL
29 12
11 10
26
GREASING CHART MANUAL
15
13
27
14
GREASING CHART MANUAL
16
28
GREASING CHART MANUAL
17
29
GREASING CHART MANUAL
32
31
30
GREASING CHART MANUAL
18 19 20 21
31
GREASING CHART MANUAL
22
32
GREASING CHART PARTS LIST
Nipple Number
Greasing Duration
Manual Section
1
8 Hours
A-1
2
4 Hours
A-8-1
3
4 Hours
A-8-1
4
8 Hours
A-1
5
4 Hours
A-18-8-1
6
4 Hours
A-14
7
4 Hours
A-4-3
8
4 Hours
A-18-8-1
9
4 Hours
A-9
10
8 Hours
A-18-1
11
4 Hours
A-10-4
12
8 Hours
A-18-4
13
4 Hours
A-10-4
14
8 Hours
A-18-3
15
8 Hours
A-10-1-1
16
4 Hours
A-18-7-1
17
4 Hours
A-4-2
18
8 Hours
C-1
19
8 Hours
C-1
20
8 Hours
C-1
21
8 Hours
C-1
22
8 Hours
A-2-2
23
20 Hours
A-7
Waste Oil Chains
24
20 Hours
A-7
Waste Oil Chains
25
20 Hours
A-18-6
Waste Oil Chains
26
20 Hours
A-18-6
Waste Oil Chains
27
8 Hours
A-5
Waste Oil Chains
28
8 Hours
A-9-2
Waste Oil Chains
33
Comments
Remote Grease Nipple
Access Underside of Gearbox
Servicing Wheel Bearings: Wheel bearings have to be checked as part of the general maintenance of the machine, and be serviced when required. The time frame for this varies greatly depending on what conditions they are exposed to. Under normal circumstances once a year is adequate, but if the wheel bearings are exposed to water while in operation or other adverse conditions, the bearings will have to be serviced more frequently to avoid damage and down time. If damage has occurred due to lack of maintenance, warranty claims will de declined.
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TROUBLE SHOOTING Super Comby EX Trouble Shooting Common Check Procedures • Condition Of Tractor Hydraulics And Electrics • Wiring On Drawbar Not Broken • Is There Power To The System? • Condition Of Plug-Socket Electrical Connection (Flare Contacts In Plug Socket With Small Screwdriver) • Objects Jammed In Chains Or Chain Thrown Off Sprockets Including Reduction Boxes • Is The Machine Plugged Into The Correct Electrical Plug On Tractor • Is The Fuse Working?
Electrical Vs Hydraulic Failure • Before Undertaking Testing Make Sure That The Tractor Is Running At The Following Specifications • Dead Head Pressure 2500psi – 3000psi • Oil Flow 60-80 Litres Per Min Quick Diagnose 1. Do Hoses Move When Joystick Activated? (No, Electrical Failure (Yes, Hydraulic) 2. Swap Coils On Valve Block Banks (Yes, But Controls Backwards, Hydraulic Failure) 3. Pressing Overriding Buttons On Valve Spool Ends (Yes, Electrical) (No, Hydraulic)
Checking The Condition Of Hydraulic Motor 1. Remove Motor Tank Hose (Motor Low Pressure Side) 2. Supply Oil To Motor Result Large Oil Flow Without Tractor Working Hard To Supply Oil, Motor Damaged. Minimal Oil Flow While Tractor Working Hard. Motors Good, Look For Jam Up Of Drive. 35
Load Cell Fault Finding • • • • • • • • •
Check For Mechanical Damage To Cells Check For Objects Jamming Cells Check For Loose Bolts Check To See If Machine Has Had Welding Repairs Check Wiring Check For Water Damage In Junction Box Check For Water Damage In Plugs Check Head Unit Calibration (See Manual) Check To See That Battery Hasn’t Been Charged With Power Supply To Head Unit Attached • For More Information On Checking Load Cells Contact Hustler Equipment
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Comby | Super Comby | Super Comby EX Feedout Wagon
Hustler Equipment LTD PO Box 2127, 1416 Omahu Road Hastings, 4153, New Zealand. Phone +64 6 879 7926 www.hustlerequipment.co.nz
