INTRODUCTION Thank you for purchasing a Maurer Revolver. Proper care and use will result in many years of service. WARNING: TO AVOID PERSONAL INJURY O

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1 /04/0 8A000049, Rev. AC REVOLVER JD-7: JOHN DEERE STS OPERATOR S MANUAL FITS: 60 & 70 SERIES STS COMBINE WITH HIGH UNLOAD RATE AUGER (7 DIA.) READ complete manual CAREFULLY BEFORE attempting operation. ASSEMBLY OPERATION REPLACEMENT PARTS PLACE IN COMBINE CAB AFTER ASSEMBLY FOR FUTURE REFERENCE. Maurer Manufacturing th Ave. West P.O. Box 60 Spencer, IA 530 PH: (7) 6-99 FAX: (7) Page

2 INTRODUCTION Thank you for purchasing a Maurer Revolver. Proper care and use will result in many years of service. WARNING: TO AVOID PERSONAL INJURY OR DEATH, OBSERVE THE FOLLOWING INSTRUCTIONS: Before applying power to any machinery used in conjunction with a Maurer Revolver, make sure the area is clear of all bystanders. Never allow anyone in or near the grain wagon/cart/trailer during loading or unloading of grain. The accumulation of grain is dangerous and can cause entrapment, resulting in serious injury or death by suffocation. GENERAL INFORMATION. Read assembly instructions carefully. Study assembly procedures and all illustrations before you begin assembly. Note which parts are used in each step. This unit must be assembled in proper sequence or complications will result.. Whenever terms "LEFT" and "RIGHT" are used in this manual it means from a position behind combine and facing forward. 3. When placing a parts order, refer to this manual for proper part numbers and place order by PART NO. and DESCRIPTION. TABLE OF CONTENTS General Information... Safety, Signal Words... 3 Product Safety Guideline... 4 Product Disclaimer... 4 Safety Sign Locations... 5 Safety Sign Care... 5 General Assembly / General Electrical... 6 Parts List... 7 Assembly / Parts List Cable Routing... 0 Wire Diagram... 8 Wire Routing and Connections Operation Instructions... 4 Page

3 SAFETY TAKE NOTE! THIS SAFETY ALERT SYMBOL FOUND THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY AND SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH! THIS SYMBOL MEANS ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED! SIGNAL WORDS Note use of following signal words DANGER, WARNING, and CAUTION with safety messages. The appropriate signal word for each has been selected using the following guidelines: DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to most extreme situations typically for machine components which, for functional purposes, cannot be guarded. WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. If you have questions not answered in this manual, require additional copies, or if your manual is damaged, please contact your dealer or Maurer Manufacturing, P.O. Box 60, th Ave. West, Spencer, Iowa 530, Ph: (7) 6-99 Fax: (7) Page 3

4 PRODUCT SAFETY GUIDELINES Every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator, can avoid many accidents by observing the following precautions in this section. To avoid personal injury, study the following precautions and insist those working with you, or you yourself, follow them. Replace any danger, warning, or caution decal that is not legible or is missing. Location of such decals are indicated in this manual. Review all safety instructions with all users annually. The operator should be a responsible adult. DO NOT allow persons to operate or assemble this unit until they have developed an understanding of all safety precautions. Never leave running equipment unattended. Before applying power to any equipment clear the area of all bystanders. Never exceed the limits of a piece of machinery. If it s ability to do a job safely is in question DO NOT attempt it. PERFORMING MAINTENANCE Good maintenance is your responsibility. Poor maintenance is an invitation to trouble. Always wear gloves when checking the tension of cables. Frays on cables can cause minor cuts and are susceptible to infection from dirt and grease. Periodically check all wiring, cables, and plastic components for wear. When installing any wiring, disconnect power supply. If equipment has been altered in any way from the original design, Maurer Mfg. does not accept any liability for injury or warranty. PRODUCT DISCLAIMER Installing a Maurer Revolver on any combine is at the discretion of the owner. Although Maurer Mfg. has included all the necessary mounting components and has included or recommended various electrical components, it does not assume liabilities, or make any warranties pertaining to the structural aspects of the combines unloading auger or the combines electrical system. See the combines owner s/operator s manual for additional combine specifications and safety information not listed in this manual. Page 4

5 SAFETY SIGN LOCATIONS Types of safety signs and locations on equipment are shown in the illustration below. Good safety requires that you familiarize yourself with various safety signs, type of warning, and area or particular function related to that area, that requires your SAFETY AWARENESS. AQAR00000 SAFETY SIGN CARE Keep safety signs clean and legible at all times. Replace safety signs that are missing or have become illegible. Be sure that replacment parts contain safety signs, if the original part was provided with a safety sign. Safety signs are available from Maurer Mfg. Page 5

6 ASSEMBLY SAFETY: Assemble in an area with sufficient space to handle the largest of components related to this product. When necessary, have someone assist you during the assembly of this product. REVOLVER GENERAL ASSEMBLY There are many aspects to take into consideration before mounting your Revolver on the combine s unloading auger. First decide the angle of the chute relative to the ground that will benefit you the most once the unloading auger is fully extended. Due to the clearance slots on the sleeve the angle of the chute can vary 5 to 0 degrees. The Revolver should be located as close to the end of the unloading auger as possible, and ideally, the back of the sleeve ring will be flush with the end of the auger tube, however, due to production tolerances (welding, bending, etc.) the Revolver may not be exactly at the end of the auger tube but there will not be an adverse effect on the operation of the Revolver. The Revolver rotates the chute 30 degrees from its downward position. If possible, mount chute perpendicular with the ground. This will allow you to get full rotation from your Revolver. Do not over-tighten cables or bolts. Over-tightening will add unwanted friction to moving parts and may prevent chute from rotating. GENERAL ELECTRICAL INFORMATION The Revolver uses 6 ga. wire for the power harness. The actuator harness uses 0 ga. wire The foot switch and foot switch harness use 6 ga. wire. The relay is connected to the battery, foot switch, and linear actuator. See electrical schematic on page 8 for proper power supply. Cables are driven by a v DC 0 linear actuator located inside the actuator cover assembly. Use care and keep all wiring clear of sharp edges and moving parts. Maurer Mfg. recommends using grommets in any holes that are drilled to run wire. This will prevent the wiring from making contact with sharp edges. Page 6

7 Figure PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. NO. PART NO. QTY. DESCRIPTION. AFC0CACH0 49 CABLE. AFC0CBDF0 74 CABLE 3. AFC05F /8 Center Lock Nut 4. AFCF00L5 4 3/8 x 3/4 Hex Head Bolt 5. AFC8F0000 3/8 Hex Nut Nylock 6. R5A00008PO JD 7 Auger Sleeve Assembly 7. R5A00009PO JD 7 Drive Ring Assembly 8. R5A000030PO Actuator Cover Assy. - 0 Stroke, Short Mount Base Unit Parts List Page 7

8 REVOLVER ASSEMBLY STEP ONE Remove nine bolts using a 3mm wrench to remove factory chute and two bolts to remove factory grain saver door. Remove two top bearing hanger bolts using a 5mm wrench. Use 3mm wrench to loosen auger light band and slide back if needed. This will allow the sleeve to slide on with ease. SLEEVE STEP TWO Make sure all four / bolts are removed from legs of sleeve. Next, slide sleeve onto auger tube until the bearing hanger bolts fit into the clearance slots on the sleeve. Adjust the sleeve as desired and refasten the two 5mm bolts that were removed from the bearing hanger. Once 5mm bolts are refastened, center bearing hanger bolts between clearance slots on sleeve. Fasten four / bolts to legs on sleeve. See Figure. / NUTS & BOLTS Figure NOTE: The 3mm bolts used to mount the chute and grain saver door have retaining washers on them. The washers will need to be removed in order to remove the bolts. Save all 3mm bolts. They will be used to mount the factory chute to the Revolver. Factory grain saver door does not get reused. STEP THREE With the sleeve secured, place the face of drive ring and drive ring spacer against face of sleeve ring and fasten the drive ring retainers, spacers, and bushings to the drive ring using the 3/8 x hex bolts and 3/8 nylock nuts provided. DO NOT over-tighten bolts. Again, this could cause added friction. There should be a /6 gap between the drive ring and sleeve ring. This will allow the drive ring to rotate smoothly. If there is no gap, back-off nuts until the drive ring rotates with ease. See Figure 3. SLEEVE STEP FOUR Place the actuator cover assembly on sleeve where cover mounts are located. With the cable pulley end of the actuator cover over the drive ring assembly, secure actuator cover using 3/8 x 3/4 hex head bolts and 3/8 lock nuts provided. See Figure 4. DRIVE RING & SPACER Figure 3 Page 8

9 STEP FIVE With actuator cover assembly secured, place threaded end of cables through bushings on drive ring and fasten with 3/8 nylock nut. See Figure 7. Avoid over-tightening cables or tightening one cable more than the other. This will cause the cable trolley to prop up on one end. The cable trolley should be sitting parallel with the actuator cover. Use Figures 5A and 5B as a reference. COVER ASSEMBLY STEP SIX Install factory plastic chute on drive ring assembly using the nine bolts that were removed in step one. Figure 4 Incorrect Figure 5A Correct Figure 5B Page 9

10 CABLE ROUTING NOTE: Use Figures 6 & 7 to help with cable routing and securing threaded ends of cables to drive ring. Long Cable Short Cable Figure 6 Figure 7 NOTE: Chute should line up with dashed line in figure 7 when mounted. Page 0

11 3 Figure 8 PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AFCHAAD5 4 / x -/4 Hex Bolt. AFC8H / Nylock Nut 3. R5A000037P0 Auger Sleeve Weldment - JD 7 Auger Sleeve Assembly Parts List Page

12 Figure 9 PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AFCFBA05 8 3/8 x Hex Bolt. AFC8F /8 Hex Nut Nylock 3. AR Drive Ring Spacer - John Deere 7 4. R5A00000P0 4 Drive Ring Retainer Assembly 5. R5A000038P0 Drive Ring Weldment - JD 7 Drive Ring Assembly Parts List Page

13 Figure 0 PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AFC04HBAD5 / x -/4 Carriage Bolt. AFC05H0000 / -3 Center Lock Nut 3. AFCHAAL5 3 / x -3/4 Hex Bolt 4. AFCHBA05 / x Hex Head Cap Screw, GR 5 5. AFCHCA05 / x 3 Hex Bolt 6. AFC8H / Nylock Nut 7. AQAR00000 Pinch Point Decal 8. AYE0700Z Actuator - 0 Stroke, 0: 9. R3A000070P0 Bolt Bushing - Trolley Bottom 0. R5A00005P0 3 Sheave Assembly. R5A00003P0 Actuator Trolley Assembly. R5A000036P0 Actuator Cover Weldment - 0, Short Actuator Cover Assembly Parts List Page 3

14 3 3 Figure PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AR Drive Ring Retainer Spacer. R3A00003P0 Drive Ring Retainer 3. R3A000068P0 Drive Ring Retainer Bushing Drive Ring Retainer Assembly Parts List Page 4

15 3 Figure PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AL00H09000 Sheave Bushing. AR Cable Sheave 3. R3A000034P0 Cable Retainer Sheave Assembly Parts List Page 5

16 Figure 3 PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AR Trolley Top Spacer - Plastic. AR Trolley Bottom Spacer - Plastic 3. R3A000035P0 Trolley Top 4. R3A000058P0 Actuator Trolley Bottom 5. R3A00007P0 Actuator Trolley Spacer 6. R5A00005P0 Sheave Assembly Actuator Trolley Assembly Parts List Page 6

17 Figure 4 PARTS LIST Please order replacement parts by PART NO. and DESCRIPTION. REF. PART NO. NO. QTY. ASSY. DESCRIPTION. AEF00460 Strain Relief - Dome Nut, / NPT. AEF00464 Strain Relief Lock Nut 3. AES0000LS Lektro-Lok Foot Switch, L--S 4. AESR00V RF Relay 5. AEXD0000 Foot Switch Harness 6. AEXD Power Harness 7. AEXD Actuator Harness 8. AR58GROMET 5/8 Grommet 9. R3A000080LO Foot Switch Riser 0. AEU Alternator Boot Electrical Component Parts List Page 7

18 NOTE: White wires are shown as a solid red line. Green wires are shown as a dashed red line. White Green Figure 5 Page 8

19 JOHN DEERE 60 SERIES WIRE ROUTINGS AND CONNECTIONS NOTE: Use the following steps when routing wires and connecting to relay. WARNING: Use caution when routing all wiring to the relay. Avoid moving parts and sharp surfaces that can damage the wires. STEP ONE Using a 3/8 wrench, mount the relay on the right side frame panel behind the cab next to the electrical bulkhead using the /4 x flange bolt and /4 lock nut provided. Factory holes in panel will work for mounting the relay. See Figure 6. SSTEP TWO Disconnect wiring harnesses from electrical bulkhead and remove bulkhead panel using a 8mm wrench. Drill a 0.83 hole in one of the knock-outs on the bulkhead panel and fasten strain relief to hole using the plastic nut provided. See Figure 6. STEP THREE Place foot switch and foot switch riser in cab where desired. Feed end of foot switch harness through strain relief and attatch connections to relay using a 0mm wrench. The black wire will fasten to post, white wire to spade A, and green wire to spade C as shown in Figure 5. Re-attatch bulkhead panel to cab and plug factory harnesses back in. Feed any extra wire back through strain relief and tighten dome nut on strain relief to create a seal on the wire. Locate foot switch harness in cab and connect to foot switch. NOTE: Foot switch harness will be located behind the seat where it was ran through the bulkhead. STEP FOUR Connect actuator harness to actuator located at end of unloading auger. Run harness along unloading auger. As you go along use cable ties provided to secure actuator harness to factory auger light harness that also run the lenth of the auger. At elbow of auger, drill a 3/8 hole and use cable tie to secure actuator harness as shown in Figure 7. Next, open side body panel and run wire along top of body panel hinges as shown in Figure 8. Run wire along back side of cab to relay. The black wire will fasten to post 4 and white wire will fasten to post 3. See Figure 5. STEP FIVE Open right rear body panel on combine and pull out ladder. Climb ladder and locate combine battery on the driver side. Run power harness following hydraulic line that runs from bottom of oil reservoir. See Figure 0. Open grain tank platform s access panel and continue following hydraulic line. Next, open right side body panels and run wire down to backside of frame tube and over to relay. See Figure. Cut harness to length, separate red and black wiring back five inches, slide one alternator boot on red wire and one on black wire. Strip jacketing / on red and black wires. Crimp /4 stud copper eyelet on each wire. The black wire will fasten to post and red wire to post. Slide alternator boots up wire to cover posts &. On combine battery, attatch red wire to postive terminal and black wire to negative terminal using a 3mm wrench. See Figure 5. NOTE: There are hangers used for factory harnesses that can be used to hang the power harness. Secure power harness to factory harnesses using the cable ties provided. Page 9

20 JOHN DEERE 70 SERIES WIRE ROUTINGS AND CONNECTIONS NOTE: Use the following steps when routing wires and connecting to relay. WARNING: Use caution when routing all wiring to the relay. Avoid moving parts and sharp surfaces that can damage the wires. STEP ONE Using a 3/8 wrench, mount the relay on the right side frame panel behind the cab next to the electrical bulkhead using the /4 x flange bolt and /4 lock nut provided. Factory holes in panel will work for mounting the relay. See Figure 6. STEP TWO Disconnect wiring harnesses from electrical bulkhead and remove bulkhead panel using a 8mm wrench. Drill a 0.83 hole in one of the knock-outs on the bulkhead panel and fasten strain relief to hole using the plastic nut provided. See Figure 6. STEP THREE Place foot switch and foot switch riser in cab where desired. Feed end of harness through strain relief and attatch connections to relay using a 0mm wrench. The black wire will fasten to post, white wire to spade A, and green wire to spade C as shown in Figure 5. Re-attatch bulkhead panel to cab and plug factory harnesses back in. Feed any extra wire back through strain relief and tighten dome nut on strain relief to create a seal on the wire. Locate foot switch harness in cab and connect to foot switch. NOTE: Foot switch harness will be located behind the seat where it was ran through the bulkhead. STEP FOUR Connect actuator harness to actuator located at end of unloading auger. Run harness along unloading auger. As you go along use cable ties provided to secure actuator harness to factory auger light harness that also run the lenth of the auger. At elbow of auger use cable tie to secure actuator harness as shown in Figure 7. Next, open side body panel and run wire along top of body panel hinges as shown in Figure 8. Run wire along back side of cab to relay. The black wire will fasten to post 4 and white wire will fasten to post 3. See Figure 5. STEP FIVE Remove battery box cover using a 5mm wrench. Drill a.00 hole in battery box near power supply shut-off switch and fit 5/8 grommet into hole. Run power harness through grommet. Next, run harness along factory wiring to backside of frame tube and over to relay. See Figure 9. Cut harness to length, separate red and black wiring back five inches, slide one alternator boot on red wire and one on black wire. Strip jacketing / on red and black wires. Crimp /4 stud copper eyelets on wires. The black wire will fasten to post and red wire to post. Slide alternator boots up wire to cover posts &. On combine battery, attatch red wire to postive terminal and black wire to negative terminal using a 3mm wrench. See Figure 5. NOTE: There are hangers used for factory harnesses that can be used to hang the power harness. Secure power harness to factory harnesses using the cable ties provided. Page 0

21 relay strain relief foot switch harness bulkhead Figure 6 cable tie actuator harness unloading auger elbow Figure 7 Page

22 actuator harness body panel hinges actuator harness Figure 8 frame tube power harness battery box 5/8 grommet Figure 9 Page

23 hydraulic line oil reservoir battery Figure 0 power harness frame tube Figure Page 3

24 OPERATION The Maurer Revolver is designed to mount on the end of the combines unloading auger. The Revolver is also designed to replace the factory grain saver door. Power is provided by the combine s battery. OPERATING SAFETY Read and follow this Owner s/operator s Manual before operation. Install and secure all guards and shields before operation. Keep hands, feet, hair, and clothing away from all moving parts. Before applying power to any equipment, clear the area of all bystanders Be sure all electrical components and connections are tight before and during operation. Disconnect power supply before connecting any wiring. INITIAL OPERATION STEP ONE Once the Revolver has been properly installed to the combine s unloading auger, connect power harness to battery. This will apply power to the Revolver. STEP TWO Extend unloading auger so that it is away from combine body and in position where you can best see the Revolver from inside the cab. STEP THREE Use the foot switch to rotate the chute up and down. Check for inconsistantcies in the rotating motion. If chute does not transition smoothly you may need to adjust nuts on the drive ring retainers and/or cables. If the chute is operating as desired, your new Maurer Revolver is ready for use in the field. OPERATING THE REVOLVER STEP ONE With the combine s unloading auger folded in the chute should be in the up position. STEP TWO When you are ready to unload grain tank, extend the combine s unloading auger and use the foot switch to rotate chute to the down position once unloading auger is fully extended. STEP THREE When finished unloading, use foot switch to rotate chute back to the up postion and fold unloading auger in. Page 4

25 Figure 0 Page 5

26 TROUBLESHOOTING Revolver is not rotating all the way up or down:.) You may need to adjust the cables or retainers on the drive ring. If the cables or retainers are too tight or too loose it will put added strain on the drive ring and prevent it from rotating..) Remove the plastic spacer from between the drive ring and sleeve ring. After a few uses residue can accumulate between the spacer and cause the drive ring to tighten up. Revolver is not rotating at all:.) Check all wiring connections and fuses. Loose connections can prevent power flow to components..) Check all wiring for cuts or wear. If not routed correctly or cautiously the wiring can get caught in moving parts or worn on sharp edges. Fuses keep blowing:.) Replace the 5 amp fuse with a 30 amp fuse. We do not recommend using a fuse stronger than 30 amps. How do I make adjustments to the drive ring? Step. Make sure the spout is in the down position so that it is perpendicular to the ground. With all drive ring retainer bolts snug, back them off /4 turn. Step. Rotate the spout 90 degrees so that it is now parallel to the ground. Check tension on the retainers by wiggling the drive ring up & down and side to side. If any retainers feel stiff, back them off /4 turn. Step 3. With the combine running, rotate the spout up and down to observe if there are any positions where the motor seems to pull hard. If so, you will need to stop the spout in that position, locate the retainer that is causing the pull, and back the nuts off on that retainer an additional /4 turn. NOTE: Loosening the retainers too much can have a negative impact on how the spout will rotate. It may take some time loosening and tightening bolts before you find an adjustment that allows the Revolver to function properly. 5/6/09 Page 6