SERIES 3.0 OPERATING & INSTALLATION INSTRUCTIONS PARTS LISTS

Transcription

1 Standard Sawtooth Dual-Cut SERIES.0 OPERATING & INSTALLATION INSTRUCTIONS PARTS LISTS FOR JOHN DEERE FORAGE HARVESTERS HORNING MFG LLC 0 TWIN SPRINGS CT NEW HOLLAND, PA

2 OPERATING INSTRUCTIONS. Shut off all power to machine before servicing.. Grease all bearings and zerks every 8 to 0 hours (Roll bearings / to pump each).. Bearings should operate under 00 F. Spit Test: If it doesn't sizzle ( ), assume normal operation.. New belts should be checked every hour for the first 5 hours of operation, daily thereafter. 5. Check roll clearance daily. 6. Roll clearance should be /6 as a starting point. 7. Increase roll gap according to moisture. 8. It may be necessary to lightly tap adjustment blocks downward when decreasing roll gap. 9. Recommended cut length for corn silage is /. 0. You will need to lower forage head in order to be able to open cutterhead lid.. Emergency stop (/ bolt with coupler nut between taper blocks) is factory set to keep rolls from hitting each other. See illustration.. Large processor springs should be compressed to 7/8. (Rolls should not open under normal conditions.). If knives, etc go through processor, measure springs. (Free length should be 5 /8. Replace springs if less.). Wash down unit at end of season and apply a coating of oil or grease to all unpainted surfaces, especially rolls. CHANGEOVER TO HAYLAGE. Raise forage head, release spring loaded pins, slide pan forward, and remove pan between auger and blower shaft. (You may have to rotate auger to clear pan handle and latches.). Remove belts for haylage.. When putting pan back in for corn, pan slides underneath front pan. BELT TENSION Tensioner spring should be compressed to /8 gap between spacer and washer. If your machine doesn't have a spacer, press down all belts at once. Belts should deflect / with 0 lbs. down pressure (-belt model), and / with 5 lbs. down pressure (-belt model). See illustration below. For ease of belt installation adjust rolls completely together.

3 TROUBLESHOOTING PROBLEM POSSIBLE CAUSE Hot Bearings CORRECTION Side strain from improper installation Loosen locking collars to release strain, then re-tighten Plugging in front of rolls Processor rattles excessively when under load, from springs opening up Over greasing Use only ½ to pump of grease per bearing Feed pan not installed properly Position properly Dried material on pan from previous season Clean pan Knives too far from pan Reset knives Roll teeth worn dull Replace rolls Springs too loose Measure free length of springs. If less than 5 /8, replace springs. Too long cob pieces Reduce cut length to / Rolls set too close for volume of crop Adjust roll gap Belts twisting, breaking, or getting hot Misaligned sheaves Align sheaves Belts too tight Properly adjust belt tension Plugging behind rolls Auger not taking feed away Run blower and auger high speed Excessive over feed coming out of front of cutterhead Chopping with corn head up too high Rotate axles to raise harvester, then lower head at least / of the way. Chopping with a full set of knives Remove half of the knives and cut at / cut length. Contact your dealer about any additional problems.

4 PARTS LISTS FIGURE PARTS for ITEM NO PART NUMBER S008 S005 S006 S00 S00 S00 77 FW8SAE CS8xG CBx FN FBxG5 FW FBxSTD CBx FB8x58G5 FW8 HC7 D00 D00 D09 D059 D065 D05 D008 DESCRIPTION JD 950 Top Back Hood JD 950 Top front shield JD 950 Bottom center Return lid JD Left shield JD Lower Right shield JD Top Right shield Left shield spacer /8 SAE Flat Washer /8 x NC Gr.5 Cap screw zinc plated JD Lower right threaded block JD Lower Right shield bracket / x/ NC Carriage bolt zinc coated ¼ NC Serrated Flange Nut zinc / x/ NC Gr.5 Serrated Flange bolt zinc plated / Zinc Plated Flat Washer /x/ Self Tapping & drilling Flange Bolt zinc / x/ NC Carriage bolt zinc coated /8 x5/8 NC Gr.5 Serrated Flange bolt zinc plated /8 Flat washer (zinc coated) Rubber Hood catcher Small gray roll adjustment Decal Warning rotating parts (orange & white) Warning sharp rolls (orange & white) Horning Kp.0 series for JD (bright yellow) Yellow Horning Krop Processor Logo x Red Reflective Decal Horning Address label QTY. 5 5 FIGURE PARTS for ITEM NO. PART NUMBER DESCRIPTION S009 JD 970 Top Back Hood S00 JD 970 Top front shield S007 JD 970 Bottom center Return lid QTY.

5 FIGURE Shields 5

6 FIGURE PARTS for belt ITEM NO PART NUMBER P6BJD PBSB P6BK 7 CS58x5G5 BB8K FN N 5 N58 FW58 SP5 76 LN58S CB8x FN8 9 R KEYxx SS8x 5 CP6x MW DESCRIPTION.6 B custom drilled center to fit JD950 KP. -B Pulley w/ " straight bore with /" keyway 6. Groove SD Sheave w/" bushing and keyway JD -groove Drive Adapter 5/8 x5 / NC GR.5 Cap screw zinc plated BB8K Belts set of JD 950 Large pan JD 950 Return hood 950 Spacer pipe w/ shield mount 950 Spacer pipe 950 redi-rod for spacer pipe 6" / NC Serrated Flange Nut zinc / NC Nut (zinc coated) 5/8 x6 NC Ready Rod W/ Nut Welded 5/8 NC Nut (zinc coated) 5/8 Flat washer (zinc coated) Groove belt tension spacer.75" L #5 zinc/yellow Die spring Idler tightener belt tightener bracket 5/8 Stover (steel) Locknut (zinc coated) /8 x NC Carriage bolt zinc coated /8 NC Serrated Flange Nut zinc JD left end frame Horning JD Roll Several styles available JD right end frame /x/x Key /8"-6 x /" set screw.0 -Groove Idler Arm /6 x / Plated cotter pin Machinery washer Ga. QTY. A/R FIGURE PARTS for ITEM NO PART NUMBER R970.0 DESCRIPTION JD 970 Large pan JD 970 Return Hood 970 Spacer pipe w/ shield mount 970 Spacer pipe 970 redi-rod for spacer pipe 0'' Horning JD Roll Several styles available QTY. FIGURE PARTS for FIBER-TECH Model ITEM NO. PART NUMBER DESCRIPTION P0BSB.0 B groove '' Straight bore P66BK 6.6 B SD pulley 6 w/" bushing and keyway QTY.

7 FIGURE PARTS for -belt Model ITEM NO PART NUMBER P6BJD PBSB P6BK 7 CS58x6G5 BB8K KEYxx FIGURE Processor DESCRIPTION.6 B custom drilled center to fit JD970 KP. -B Pulley w/ " straight bore with /" keyway 6. Groove SD Sheave w/" bushing and keyway JD -groove Drive Adapter 5/8 x6 NC GR.5 Cap screw zinc plated BB8K Belts set of Groove belt tension spacer.8" L.0 -Groove Idler Arm /x/x Key 7 QTY.

8 FIGURE PARTS LIST ITEM NO. PART NUMBERDESCRIPTION QTY. CSx5 / x5 NC Gr.8 Cap screw Z/Y CSx / x NC Gr.8 Cap screw Z/Y LNS / Stover (steel) Locknut (zinc coated) FWG8 / Flat washer Gr.8 (Y/Z coated) 5 SP55 Heavy 5.5" KP spring Zinc Yellow 6 0 Back End Bolt Support Bushing 7 BRPBHD HD 's Eccentric Lock Wide race HD Pillow Block Bearing 8 8 JD right end frame 9 Taper Block Assembly 0 GH-J Grease hose /8 NPT Male both ends GF009 /8 NPT straight female grease zerk 8 Back end bolt support 89 JD Rear slot cover 90 JD Front slot cover 5 8 Return hood catcher plate 6 80 Catcher plate spacer 7 FB8xG5 /8 x NC Gr.5 Serrated Flange bolt zinc plated 8 CB8x /8 x NC Carriage bolt zinc coated 9 FB8x /8''x/'' Gr5 serrated flange bolt zinc plated 0 FN8 /8 NC Serrated Flange Nut zinc D06 Belt part # BB8k- decal D08 Belt Routing decal D06 Custom serial # plate (Aluminum) M58 's Heavy Duty Pillowblock bearing casting 5 BR SKF 's Eccentric Lock Wide race Bearing insert 6 GF00 /8 NPT 90 Degree Male grease Zerk 7 TB58xNFG8 5/8 x NF Gr.8 Tapping bolt (chamfered end) 8 Adjustment Lockplate 9 SP50 Lock plate Spring Taper Block Assembly D08 Belt part # BB8k- decal 8

9 FIGURE Right End Frame Note: All parts on left end frame are also in this view. 9

10 FIGURE PARTS LIST ITEM NO. PART NUMBER DESCRIPTION JD Left Frame Brace 8 JD L. mount plate JD Right Side Panel 0 JD Left Side Panel 5 95 JD Front Pan pin 6 9 JD 950 Front Pan 7 9 JD 970 Front Pan 8 JD Cutterhead box 9 JD Cutterhead box 0 0 JD Light bracket 98 Jd axle extension 0 JD R. shield holder 0 JD R. shield mount 96 JD Auger Lid Hinge 5 97 JD R. frame nut 0 QTY.

11 FIGURE Other Parts

12 FIGURE 5 PARTS LIST ITEM NO PART NUMBER M6 67 CP6x MW GF0 GF0 P6BIP BR60 M69 M57 CS0x80MM0.9 DESCRIPTION Cast Iron idler arm Idler Pin /6 x / Plated cotter pin Machinery washer Ga. /8'' NPT 5 deg. male zerk /8 NPT Straight male grease zerk.6" -Groove Idler Pulley w/ Bearings 60 Idler bearing.6" -Groove Idler Pulley SD Idler spacer 0x80mm 0.9 zinc.5pitch bolt QTY. FIGURE 6 PARTS LIST ITEM NO PART NUMBER M6 67 CP6x MW GF0 GF0 P6BIP BR60 M69 M57 CS0x80MM0.9 DESCRIPTION Cast Iron idler arm Idler Pin /6 x / Plated cotter pin Machinery washer Ga. /8'' NPT 5 deg. male zerk /8 NPT Straight male grease zerk.6" -Groove Idler Pulley w/ Bearings 60 Idler bearing.6" -Groove Idler Pulley SD Idler spacer 0x80mm 0.9 zinc.5pitch bolt QTY.

13 FIGURE 5 5 Idler Arm FIGURE 6 06 Idler Arm

14 INSTALLATION INSTRUCTIONS. Remove auger cover.. Remove large right-hand shield.. Remove small shield. (Figure A-). Remove cutterhead box. (Figure A-) 5. Remove 5 bolts.(figure A-) 6. Remove shield below cutterhead.(figure B-) 7. Remove half of the knives for / cut length. Put knife bolts back in or remove threaded bolt blocks. 8. Remove blower drive belt and rear pulley. FIGURE B FIGURE A

15 9. Cut notch out of auger trough as shown. Vertical cut at left is measured not with contour. For standard auger, run bottom cut straight out to end of trough. For cantilever auger, cut across corner at right as shown. 0. Cut auger cover. Remove 7 /8 for 90-55, and /8 for Cut off / of flange at front auger trough panel as shown.. Drill 5 holes Ø 9/6 using 0 JD Left Template as a pattern.. Align holes in JD Right Template with existing holes. You may need to cut off some of auger lid support to get template to lay flat on sheet metal. Cut along top edge of template.. Cut down at corners of blower bearing mount, then left to meet template cut as shown. 5. Cut right hand flange off cutterhead lid, flush with cutterhead housing. Measure 8 / up from end of flange. 6. Cut / off end of cutterhead lid. 7. Cut / X / corner out of small shield. 8. Move auger cover latch to the left. (Figure C-5) 9. Remove top bearing bolt, and replace with CHBx plow share bolt. Tighten until head is flush with frame.(figure C-6) 0. Rotate grease zerk straight forward.(figure C-7) FIGURE C 5

16 . Install 0 JD R. Shield Mount / higher than top edge of sheet metal, and / back from front edge. Drill front / hole where needed.. Install 76 Belt Tightener Bracket with /8 X carriage bolts and flange nuts.. If chopper has no axle extension, install 98 axle extension using / X / bolts at top and / X / or 6 / bolts at bottom. On 955 and 975 replace light bracket with 0.. Replace shield holder with Reinstall rear blower pulley and put belt around front pulley, but wait to tighten belt until driver pulley is installed. 6. Install driver pulley along with 7 or 7 Drive Adapter and longer bolts. Turn small side of tapered hole in center of pulley toward cutterhead. You might need to move idler pulley in to clear driver pulley. FIGURE D 6

17 7. Weld 0 weld on handle to sharpener cover. Make sure you can still close the cutterhead lid without the brace inside the lid hitting the handle. 8. Install or Cutterhead Box with () / X / bolts, and () / X bolts and flange nuts. 9. Raise head. 0. Clean dirt buildup out of channels on each side of cutterhead.. Slide 0 Left Side Panel and Right Side Panel between cutterhead and frame on each side of cutterhead. The angle iron on rear end of side panel hooks into channel. FIGURE E FIGURE F. Install 9 or 9 Front Pan underneath shear bar using 95 Front Pan Pins, M5 bushings, / X bolts and flat washers. You may need to clean threads with a tap. Pan pin goes through frame, 0 or Side Panel, and front pan. Use machinery washers to fill gap between side panel and front pan if needed. 7

18 . Install left bracket from bottom up, between auger trough and main frame. Assemble bracket and back plate loosely to main frame with 5/8 X 8 bolts.. For cantilever auger models, remove the /6 thick spacer. (Figure G-8) 5. Lift processor onto chopper as shown.(figure H) 6. Install 97 Right Frame Nuts over the large holes on each side of blower shaft on the outside of auger housing, behind blower bearing frame. Use / wrench to hold nut in place while fastening. Install the other bolts from inside as shown. 7. Install / X / bolts at left frame bracket, and tighten all mounting bolts. 8. Center rolls behind cutterhead and tighten locking collars same direction as shaft rotation. 9. Align pulley on rear roll shaft, and tighten bolts to 9 ft. lbs. 0. Align front roll pulley, tighten set screws on the key, remove the other set screws, and drill Ø 5/6 X /6 deep into shaft. Use thread locker and torque all set screws to 0 ft. lbs. Note: Special bit included in parts box.. Align idler pulley by moving machinery washers on idler pivot pin as needed.. Install belts. See operating instructions for proper tension and routing diagram. FIGURE G FIGURE H 8

19 . Install pan. With head raised,block up front pan, then slide pan underneath. You may need to rotate auger to clear handle and latches. The spring loaded pins latch into bushings on processor frames.. Install new auger lid hinge. Clamp into place to drill holes as needed. Fasten with / X / carriage bolts and flange nuts at front and / X / carriage bolts and flange nuts at rear. FIGURE J FIGURE I FIGURE K 9

20 5. Install S00 or S005 Top Front Shield and S008 or S009 Top Back Hood with / X / carriage bolts and flange nuts. 6. Install S006 or S007 Lower Back Lid using / X / carriage bolts and flange nuts, clamp into place to drill holes. On cantilever auger models, use self-tapping screw in far right hole. 7. Install S00 Left Shield with 77 Left Shield Spacers, /8 X bolts and SAE flat washers. 8. Bolt S00 and S00 Right Shields loosely together with / X / carriage bolts, then assemble 00 (Figure K) to shield. Use () /8 X / flange bolts and SAE flat washers at top. Clamp 00 into place and tighten bolts. Bolt 99 to inside of frame as shown. Drill 9/ holes as needed. If belts hit top front corner of shield, bend 0 up. (Figure D) 9. Apply decals as shown. Apply D0 to chopper only. For Fiber-tech model, apply D059 just under bend in shield, then apply D06 Fiber-tech decal directly under D059. (on front) (on side) FIGURE L 0

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