Silage Wagon Original Instruction
IMPORTANT Read this manual before operation HUSTLER EQUIPMENT INTERNATIONAL LIMITED
CONTENTS
Introduction................................................................................. 2 Important..................................................................................... 2 Warranty ...................................................................................... 3 Warnings...................................................................................... 4 Operational Instructions.....................................................4-10 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.
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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. It is also Manditory that All bolts are checked and tightened, weekly for the first 4 weeks (or every 20hours of operation), then monthly (or every 100 hours operation). • • • • •
M8 - 16 ft-lbs M10 - 31 ft-lbs M12 - 55 ft-lbs M16 - 137 ft-lbs M20 - 267 ft-lbs
With Load Cell weighing machines, this is crucial to maintain accurate weighing and to eliminate failure.
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
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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 Feeding / Starting up 1. Ensure hoses are coupled in correct couplings before starting. 2. If tractor can deliver more than 60 litres/min [13 GPM] restrict output flow down to 60 litres/min, or less on tractors control, to eliminate overspeeding of the elevator. Normal operating speed of the elevator should be 60 rpm with a maximum of 100 rpm. When the machine is running with no product the pressure gauge at the front should read less than 500 psi. If the pressure is greater than 500 psi, then it is probable that the oil flow is too high. 3. Turn floor control fully closed (0 on speed dial) for electric controls. 4. Engage tractor hydraulic lever into correct direction to rotate elevator. (check elevator is rotating). IMPORTANT: If elevator does not rotate, make sure elevator is not frozen or jammed. CAUTON: Never activate hydraulic lever forwards and backwards to ‘free’ elevator. 5. When elevator is rotating with feed material flowing, gradually open floor control (1-9 on speed dial) until feed material flow reaches desired amount. 6. To decrease feed rate gradually close (9-1 on speed dial).
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OPERATING INSTRUCTIONS CONT. Reversing the Floor Note: Elevator and Side Conveyor will not turn in reverse. • 1 . Release tail door. • 2. Engage tractor hydraulics lever into the opposite direction to feeding position. NOTE: The electric speed controller does not affect the floor reversing speed. (Only the oil flow from the tractor does).
Floor Chain • Slacken the 1 inch lock nuts on the floor idler assemblies. • Adjust the 1 inch adjuster nuts until floor slats strike guide rails in or about 20mm from the top of the chain guide rails (see fig 2). • Retighten the 1 inch lock nuts. • Test run. CAUTION: • Floor chains too tight will cause unnecessary wear to sprockets and chain. • Floor chains too slack will cause danger of floor slat falling off the drive & idler sprockets or getting caught under the chain guide. Fig 2.
Correct.
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Elevator • Slacken off 10mm pan head bolts and nuts on shaft cover. • Undo 30mm top lock nut on elevator chain adjuster on both shaft holders. (refer manual section A-2-2-1) • Adjust bottom 30mm lock nut so that the elevator chain has about 50mm total play. Note Do small adjustments. (See Fig 3)
Fig 3.
• 4. Tighten up top lock nuts. • • 5. Check that both chains have the same tension and is not any tighter (re-adjust to suit). • • 6. Adjust top cover so there is about 10mm clearance between the slat when it is at the top of the sprocket. (see Fig 4) and tighten pan head bolts.
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OPERATING INSTRUCTIONS CONT.
Correct.
Fig 4.
• 7 . Loosen 2 12mm Nylock nuts that hold the motor scraper and move it up in to the motor sprocket and tighten 12mm Nylock nuts. CAUTION: • 1. Elevator chain too tight will cause unnecessary wear to sprockets and chain and place excessive load on hydraulic motor shaft seals.
Side Conveyor Belt • Check that the drive roller is sitting square to the machine (This might have to be measured off the chassis rail behind the roller) and adjust the roller to suit. • Adjust the rear idler roller so that it is square wind the roller out so that the belt is tensioned well
10mm -20mm Clearance 7
Fig 5.
• Run the machine and make very small adjustments to the belt tensioners to get the belt tracking in the middle of the roller. Note the belt will move to the slackest side of the roller. See Fig.6
Idler End
Fig 6.
Sensor Valve • The DHS sensor is designed to sense the amount of oil pressure it takes to run the elevator motor. When the elevator requires more than 80bar (set from factory) to run, the valve block stops the floor motor from moving until the pressure drops from the elevator motor. So if there is an excessive amount of material or an obstruction at the elevator the floor will stop. Note: This valve only stops & starts the floor if there is an obstruction of the floor chains, the hydraulic overload valve will stop the oil flow going to the floor hydraulic motor. The elevator speed is only governed by the amount of oil the tractor can deliver, this can be adjusted by increasing/decreasing tractor RPM or adjusting the tractors flow control controls (if it has one).
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OPERATING INSTRUCTIONS CONT. Setting up of load sensing valve • • • • • • • •
1. Check elevator is running free. 2. Load wagon. 3. Slacken lock nut. (see fig 7) 4. Back off (unscrew out) adjustment screw so there is about 10 clear threads exposed from the lock nut. 5. Open floor speed controls to 1/2 throttle. 6. Engage hydraulics (elevator will turn). 7. Screw in adjustment screw until floor starts to move and then give an extra 1/2 a turn. 8. Tighten lock nut.
Note • Side Feed silage wagon, fit grub screw bung under orifice port. Centre Feed silage wagon, no bung under orifice port.
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CAUTION: The load sensing valve is per set from factory and should not under normal conditions need adjusting. If the adjuster is screwed in too far it will bypass the elevator sensing pressure and overload the hydraulic system. If it is screwed in too little the floor will not have enough power to bring the load forward. If you have any queries please contact Hustler Equipment for assistance.
Explanation of the floor overload valve. Under normal conditions this valve will not need adjusting, as it is set from factory to 1000psi. If you are operating the silage wagon and the load is not moving forward, and the elevator is running free from material, the floor safety relief valve will be relieving the oil to the floor motor. The gauge on the block will be reading above 1500psi. Check for obstruction on the floor chain and floor drive assembly to make sure that there is no components jammed and the machine is correctly adjusted.
Note: Under normal operation conditions when the machine is feeding material thegauge can rise up to tractor operating pressure.
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HYDRAULIC HOSING LIST
11
Hose Number
From Valve Block Port No.
To
1
FE
Top Port of Elevator Motor
2
TE
Bottom Port Of Elevator Motor
3
TF
Bottom Port of Floor Motor
4
FF
Top Port of Floor Motor
5 PRE
Tractor Pressure
6T
Tractor Tank
HIGH FLOW PARALLEL HYDRAULIC HOSING LIST. Pressure
Tank
Floor Motor
Elevator Motor Side Conveyor
12
Hose Number
From Valve Block Port No.
To
1
FE
Top Port of Elevator Motor
2
TE
Bottom Port Of Elevator Motor
3
TF
Bottom Port of Floor Motor
4
FF
Top Port of Floor Motor
5 PRE
SS
Tractor Pressure
6T
ANK
Tractor Tank
7T
SC
To Side Conveyor
8
FSC
From Side Conveyor
HIGH FLOW PARALLEL HYDRAULIC CARTRIDGE LAYOUT Floor Maximum Speed Adjust
Elevator Load Adjust
CAUTION: The load sensing valve is per set from factory and should not under normal conditions need adjusting. If the adjuster is screwed in too far it will bypass the elevator sensing pressure and overload the hydraulic system. If it is screwed in too little the floor will not have enough power to bring the load forward. If you have any queries please contact Hustler Equipment for assistance. 13
HIGH FLOW PARRALLEL HYDRAULIC SET UP INSTRUCTIONS Here are the instructions for the setting of the hydraulic block. There is two adjustments, and these will greatly improve performance once set correctly. Basically the floor shaft should be doing about 2 revs per minute, then by setting the load sensing valve to adjust the amount of product to be fed out. And the load sensing on the elevator should be 1500 psi. S1. If the floor is set two fast it will rob to much oil and cause the elevator to surge it’s speed. S2. If the load sensing is to high it will force the load into the elevator and stall. S3. If the load sensing is to low, the floor will not come forward. S4. If the floor is too fast and the load sense is too high, the whole machine will stall. S5. If the floor is too fast and the load sense is to low, the floor will stop and start violently
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HOSING MACHINE MANUAL STANDARD WITH FORK OPTION In “Setting floor speed mode” The floor speed is· set at the minimum speed (heaviest part of load). Feed rate will vary if material is not picked up or is picked up in lumps by the elevator. Floor speed is- slow and constant and will not increase for the last 1/3 of the load, so feed rate decreases and last 1/3 of the load takes as long to feed out as the first 2/3 did. If the elevator overloads the sequence valve will slow the floor to stop jam ups. This was the objective 20 years ago when designing Valves in NZ, since then a lot of new developments have improved efficiency. If the floor is set a little faster to counteract the slow feed at the last third of the load, then during the. first 2/3 of the load most of the set floor oil flow is diverted inefficiently to tank. In this mode setting the floor fast enough for the (end of load speed) is grossly inefficient and reduces the fully loaded elevator capacity significantly because so much oil is wasted to tank during the initial loading, but the floor will speed up at the end. This option is inefficient from dumping loaded oil to tank and not as powerful feeding out because the elevator never achieves maximum speed.
In “Setting elevator load mode” STD The floor speed adjust is set for the max speed required (for the last part of the load). When starting with a full load the sequence valve kicks in immediately and continuously controls the floor movement to maintain a constant load on the elevator. Surplus oil not going through the floor motor is efficiently diverted to the elevator where the max horsepower is required. And as the floor motor only consumes a litre or two the change in elevator speed is undetectable until the end when the elevator load drops below the sequence setting when the floor will speed up and elevator will slow down to quickly clear the last part of the load. This option has no inefficient bleeding oil to tank during heavy loading. The elevator always works at its maximum horsepower potential, up to 100% when the floor actually stops, which it will do on a regular basis when the trailer is full.
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NEW MACHINE IN SERVICE OPERATIONAL CHECKS With a new machine components will often move as they settle in to operation. This causes nuts, bolts and grubscrews to become loose in operation. Please check periodically the following components for the first few weeks of operation. • • • • • • • • • • • •
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Wheel Nuts Axle Bolts and Nuts 45 Tooth Floor Drive Sprocket Grubscrews Reduction Drive Shaft Support Grubscrews Lock Nuts on Floor Adjuster Idler Shafts Lock Nuts on Conveyor Belt Adjusters Lock Nuts on Elevator Chain Adjuster The Elevator Chains might have to be adjusted as they settle in to operation. Bolts and Nuts on the bolt on drawbar tongue if fitted Load cell mount castings Check that the wiring & hydraulic hoses are not hanging low or pinching Check for oil leaks
TROUBLE SHOOTING Common Check Procedures • • • •
Condition Of Tractor Hydraulics And Electrics Wiring On Drawbar Not Broken (for electric control option) Is There Power To The System (for electric control option) Condition Of Plug-Socket Electrical Connection (Flare Contacts In Plug Socket With Small Screwdriver, for electric control option) • Objects Jammed In Chains Or Chain Thrown Off Sprockets Including Reduction Boxes • Is The Machine Plugged Into The Correct Electrical Plug On Tractor (for electric control option) • Is The Fuse Working (for electric control option)
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 Tractor Lever Engaged? (No, Hydraulic (Yes,Electrical Failure) 2. Connect 12 Volts Directly To Coil On Control Block (Floor Moving, Electrical Failure (Floor Stationery, Hydraulic)
Checking the condition of hydraulic motors • Remove Motor Tank Hose (Motor Low Pressure Side) • 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.
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Load Cell Fruit 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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WIRING DETAILS MANUAL PARTS LIST
Chain 2
Nipple 3
Chain 3
Nipple 4
Nipple 1
Nipple 2
Nipple 5
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
FRONT GREASING POINTS
Nipple 10
Nipple 11
Nipple 7
Nipple 8 Nipple 9
Nipple 6
20
ELEVATOR GREASING POINTS
Nipple 12
Nipple 10
21
Nipple 13
Nipple 3
FLOOR GREASING POINTS
Nipple 17 Nipple 16
Nipple 15 Nipple 14
22
CONVEYOR GREASING POINTS
Nipple 19
Nipple 18
Nipple 21
Nipple 20
23
AXLE AND JACK GREASING POINTS
Nipple 25 Nipple 24 Nipple 23 Nipple 22
Nipple 26
24
GREASING CHART PARTS LIST Nipple Number
Greasing Duration
Manual Section
Comments
1
2 Hours
2
2 Hours
Floor Drive Assembly
3
2 Hours
Elevator Idler Sprocket Shaft
4
10 Hours
Floor Drive Shaft Bearing
5
2 Hours
Floor Drive Assembly
6
10 Hours
Floor Drive Shaft Bush
7
10 Hours
Floor Drive Shaft Bush
8
10 Hours
Floor Drive Shaft Bush
Floor Drive Assembly
9
10 Hours
Floor Drive Shaft Bush
10
2 Hours
Elevator Idler Sprocket Shaft
11
10 Hours
Floor Drive Shaft Bearing
12
5 Hours
Elevator Drive Shaft Bush
13
5 Hours
Elevator Drive Shaft Bush
14
10 Hours
Floor Idler Sprocket Bush
15
10 Hours
Floor Idler Sprocket Bush
16
10 Hours
Floor Idler Sprocket Bush
17
10 Hours
Floor Idler Sprocket Bush
18
10 Hours
Conveyor Bearing
19
10 Hours
Conveyor Bearing
20
10 Hours
Conveyor Bearing
21
10 Hours
Conveyor Bearing
22
10 Hours
Axle Pivot Casting
23
10 Hours
Axle Pivot Casting
24
10 Hours
Axle Pivot Casting
25
10 Hours
Axle Pivot Casting
26
Weekly
Parking Jack Bearing & Thread
Chain Number
Greasing Duration
1
10 Hours
2
10 Hours
3
10 Hours
Manual Section
Comments
Note: Oil elevator & floor chains weekly with waste oil. This helps to extend the life of the link chain and keep’s the chains noise down 25
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Silage Wagon
Hustler Equipment LTD PO Box 2127, 1416 Omahu Road Hastings, 4153, New Zealand. Phone +64 6 879 7926 www.hustlerequipment.co.nz