OPERATOR S MANUAL & PARTS LIST

Transcription

1 OPERATOR S MANUAL & PARTS LIST Verti-cutter MODEL VC60 FIRST PRODUCTS INC. P.O. Box 1425 Tifton, Georgia U.S.A. Phone (229) Fax (229) Web: Sales@1stproducts.com Ser. 100 thru 200 Printed in U.S.A. PBREV0702

2 INTRODUCTION Thank you for purchasing a Verti-cutter. This piece of equipment has been carefully engineered and manufactured to provide years of reliable service. The Verti-cutter is one of the most unique and versatile pieces of equipment on the market today. It is designed for the practice of removing thatch from grass in order to allow healthy turf to grow. However, unlike most competing thatchers, the Verti-cutter allows the operator to maneuver around obstacles effortlessly utilizing the patented First Products swing hitch. We recommend that you carefully read the owner s and operator s manual prior to operation. Also ensure that all future operators read this manual and become fully trained before allowing them to use or maintain this equipment. Time spent becoming acquainted with the safe operation, performance, and maintenance of the Verti-cutter will add longer life and greater satisfaction to your new purchase. Terminology: right or left as used in this manual is determined by facing the direction the machine will travel while in use unless otherwise specified. This machine is designed with safety in mind. However, if the machine is handled carelessly and not as instructed, it can be a dangerous piece of equipment. Observe all safety information in this manual and decals on the equipment. The illustrations and data used in the manual were current at the time of printing. The manufacturer reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. REMEMBER SAFETY IS ALWAYS FIRST! ATTENTION: Read and understand the instructions and warnings carefully before using this machine. Read the warranty located on page 16. Fill in the required information on the warranty registration provided, and return it to the address on the front of this manual. The warranty registration must be returned to validate warranty. 1

3 TABLE OF CONTENTS SAFETY SYMBOLS...3 SAFETY DECALS...4 OPERATION SAFETY...4 OPERATOR INSTRUCTIONS...6 TRACTOR SELECTION AND OPERATION...6 UNDERSTANDING HOW THE SWING HITCH OPERATES (Prior To Hitching To Tractor)...6 CORRECTLY ADJUSTING THE HITCH TO THE TRACTOR...7 DEPTH GAGE ADJUSTMENT...7 GAGE WHEEL ADJUSTMENT...8 FIELD OPERATION...8 PRE-OPERATION CHECK LIST...9 MAINTENANCE SAFETY...9 OPERATOR MAINTENANCE...10 SHOP MAINTENANCE...11 Skid Shoe Replacement...11 Skid Shoe Alignment to Prevent Blade Interference...11 Blade Shaft Bearing Replacement...11 Blade Replacement...12 Blade Removal...12 Blade Shaft Re-assembly...13 Blade Timing...14 WARRANTY INFORMATION...16 VC60 HITCH...17 VC60 HITCH (Parts List)...18 VC60 MAIN FRAME...19 VC60 MAIN FRAME (Parts List)...20 VC60 BLADE SHAFT...21 GEARBOX...22 VC60 DEPTH GAGE...23 DRIVE LINE COMPONENTS...24 VC60 GAGE WHEEL...25 VC60 GAGE WHEEL COUNTER WEIGHT...26 VC60 SWING HITCH LOCK-0UT

4 SAFETY SYMBOLS This is a standard safety alert symbol meaning ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! CAUTION WARNING DANGER Indicates hazardous situation, injury may occur, used to alert against carelessness. Indicates potentially hazardous situation. Death or serious injury may occur if proper procedures are not followed. Indicates most hazardous situation. Death or serious injury will occur if proper procedures are not followed. 3

5 SAFETY DECALS OPERATION SAFETY 4

6 Your Safety Is Always First! Familiarize yourself with the safety symbols and decals on pages 3 and 4. All operators should read and understand the following sections of this manual prior to adjusting, maintaining, hitching to, or operating the Verti-cutter: OPERATION SAFETY, OPERATOR INSTRUCTIONS, PRE-OPERATION CHECKS, MAINTENANCE SAFETY & OPERATOR MAINTENANCE. In addition, remove and read the driveline safety and maintenance manual taped to the driveline shield. After reading the driveline manual, place it inside this manual for reference. For the safety and instruction of all operators, keep this manual stored on the Verticutter at all times. Never attempt to adjust, maintain, or remove debris from any moving part of this machine while it is attached to a tractor or other power source with the engine running. After operating, always disengage the power take off and switch the engine off prior to dismounting from the tractor or other power source and approaching the unit. Prior to starting, always inspect operating area for any hazards such as large rocks, steep slopes, low tree branches or wires. Flag objects difficult to see such as irrigation heads and water meters. Instruct all people in the work area to stay clear of the operating unit at least 10 feet on the sides and 20 feet on the rear. Consult your tractor Operator's Manual regarding operation on slopes. Do not lift the unit while the tractor is moving (or parked) sideways on slopes above 5. The swing hitch may allow the unit to swing to the downhill side and cause the tractor to roll over. On slopes from 5 to 15 always aim the tractor uphill before lifting the unit. We do not recommend the unit being used on slopes above 15. Use extreme care and maintain moderate ground speed when transporting or operating on slopes, over rough surfaces, or close to trees, ditches, and fences. Only operate during daylight hours or with good artificial light. The Verti-cutter is not equipped for highway use. Be careful of traffic when operating near or crossing roadways. Perform all pre-operation checks (page 9) prior to start up. 5

7 OPERATOR INSTRUCTIONS TRACTOR SELECTION AND OPERATION The VC-60 Verti-cutter is designed to attach to a tractor with a category one three - point hitch, 540 PTO, and a minimum of 20 horsepower (depth of cut determines horsepower required for operation). Check the tractor owner and operator s manual for lift capacity. The weight of the VC-60 is 755 lbs. Before hitching to the Verti-cutter familiarize yourself with all of the tractors control functions. Be prepared to stop the tractor movement, PTO operation, and the engine quickly in an emergency. UNDERSTANDING HOW THE SWING HITCH OPERATES (Prior To Hitching To Tractor) With the swing stand lowered and the swing mast rearward to disengage the swing lock, grasp the hitch pins and rotate the A frame to simulate operation in a sharp turn. Release the hitch pins and slowly pull the swing Swing Mast mast forward as it would be pulled by the top link during lifting. Notice how one mast chain "A" Frame tightens causing the A frame Hitch Pin and unit to realign and the spring on the lock link is compressed to make the swing lock engage upon alignment. Now push the swing mast rearward against the lock link tab to disengage the Figure 1. Swing Hitch Operation swing lock and loosen the chains to allow sharp turns again. This demonstrates how the top link of the tractor lift-system switches the Verti-cutter between the trail and lift modes. Swing Lock Swing Stand Mast Chains 6

8 CORRECTLY ADJUSTING THE HITCH TO THE TRACTOR A category 1 hitch tractor is required with the lower links stabilized. With the Verticutter swing stand lowered connect the lower lift links to the A Frame and top link to the swing mast. Push the lift control lever on the tractor to the completely lowered position. Lengthen the adjustable top link until the swing mast closes tight against the A Frame and the Verti-cutter swing stand is lifted 1/8 to 1/4 inch off the ground. This causes the combined weight of the Verti-cutter and the tractor hitch components to be transferred to the blades. The Figure 2. Hitch Adjustment lengthened top link also causes the Verti-cutter to tilt backwards when lifting, allowing gravity to assist the swing chains in aligning the unit with the tractor. NOTE: Always shorten the top link to lift the rear of the Verti-cutter before driving or backing a tractor and unit up or down load ramps. DEPTH GAGE ADJUSTMENT CAUTION The lower section (shoe assembly) must be supported with one hand when removing and relocating pin. Refer to the decal located on the jack shaft cover (seen right). The decal shows ten hole positions numbered Hole 1 represents the shallowest cutting depth and the depth increases 3/16 with each higher number. To assemble pin in the desired location, insert pin into outer tube and slowly slide inner tube up or down until holes align then insert pin full depth through both tubes. SHOE ASSEMBLY MUST BE SUPPORTED WITH ONE HAND WHEN RELOCATING PIN. Depth Gage Decal 7

9 GAGE WHEEL ADJUSTMENT Loosen the gauge wheel assm. allowing it to pivot freely. Set the skid shoes to desired depth on machine. Run the machine at full P.T.O. speed for a short distance at a slow ground speed to get the blades at the working depth. Place one hand on gauge wheel tire and put about lbs of down pressure and tighten the nut over square slot first and then the other at the pivot. Operate the machine at desired operating speeds and check cutting depth across the machine. If not correct, adjust wheel until there is a consistent cutting depth. (See Page 25 for Parts Idenification) FIELD OPERATION The geometry of tractor lift linkages varies, and a trial run over uneven ground is recommended. Ideally the swing lock will not engage when operating over the crown of a hill and the tractor hitch is always free to float upward at all times. The blades should clear curbs etc., when lifted. When lowering for operation, lower slowly until the blades touch the ground. Then swiftly push the lift control lever on the tractor to the completely lowered position to instantly unlock the hitch. This is especially true when lowering the unit in a sharp turn. Failure to do this may cause the swing hitch not to disengage, resulting in damage to the machine and/or turf damage. In the event the unit should fail to unlock for trail mode, stop the tractor and repeat the lowering procedure. Do not turn the tractor with the Verti-cutter in the ground and the swing lock engaged. Damage to equipment may occur! When operating diagonally downhill or transversely (sideways) on a hillside slope above 5 the mast chains will not swing the unit uphill to center and lock on the tractor when the unit is lifted. Occasionally the unit will swing farther to the downhill side of the tractor creating the hazard of tractor roll over. If the tractor ever seems unstable, immediately lower the hitch and steer the tractor uphill or on a more level surface where it will center and lock when lifted. Do not back the unit up with the Verti-cutter touching the ground. Always raise the unit, back to desired location, and then lower the machine. When lowering the unit for operation reduce the engine speed and engage the PTO prior to the blades contacting the ground otherwise damage to the drive components may occur. High tractor ground speeds relative to low blade RPM may cause the Verti-cutter to overrun the tractor thereby causing the "A" frame to tilt rearward engaging the swing lock. Should this happen change to a lower gear and/or reduce cutting depth. 8

10 PRE-OPERATION CHECK LIST (With the Verti-cutter lowered and the tractor engine switched off...) Be sure that the implement is hitched to the tractor properly with all pins in place. Pin the swing stand in the up position. Be sure the driveline is correctly assembled. (The end stenciled as the tractor end is connected to the tractor and not to the Verti-cutter). Check to see that the end yokes are locked to the tractor PTO and gearbox shafts. Drive shields must turn freely on the driveline. Be sure all safety shields and covers are correctly installed. Remove any debris caught in the blades and depth gage shoes. Select the desired depth gage setting. Check gearbox oil level before first operation and every 200 hours of operation thereafter. (Refer to operator maintenance section.) MAINTENANCE SAFETY Read and understand all safety decals prior to performing any maintenance. Replace any safety decals that are not legible. Never attempt to clean, adjust, lubricate or perform any maintenance on the Verti-cutter while it is attached to the tractor or any other power source with the engine running or while in the raised position unless safety blocks are inserted under the frame. When not attached to the tractor, always use the lifting hook to hoist the machine onto safety blocks for maintenance. (See Figure 3). Figure 3. Lifting Hook/Lubrication 9

11 OPERATOR MAINTENANCE Check gearbox oil level before first operation and every 200 hours of operation thereafter. With frame level, remove oil level plug on front left side of gearbox using 5/16 x 6 allen wrench through slots in the frame post. If required, add 90w-gear oil through plug in top of box until it appears at oil level plug. Replace both plugs securely. Grease driveline parts after the number of hours used as shown below (Fig. 4). Figure 4. Drive Line Lube Chart The hitch flex joints at the top of the A frame and above the gearbox (Fig. 3) should be lubricated before first operation and weekly thereafter. Check belt tension after 4 hrs. of operation and every 40 hrs. thereafter. See tightening decal located on belt cover. The Verti-cutter shaft bearings are sealed and permanently lubricated requiring no routine maintenance. Grease Jack Shaft U Joint at 40 hour intervals. U-JOINT GREASE FITTING JACK SHAFT SHIELD CAUTION BE SURE ALL SAFETY SHIELDS ARE INSTALLED PRIOR TO RETURNING THIS MACHINE TO SERVICE. 10

12 SHOP MAINTENANCE Skid Shoe Replacement 1. Remove depth gage pin to drop out skid shoe assembly and then drive out roll pins (Fig. 5). 2. Replace shoes and re-assemble pins. Figure 5. Skid Shoe Replacement Skid Shoe Alignment to Prevent Blade Interference 1. For minor adjustments in alignment loosen the ½ flange lock nuts which bolt the depth gage assembly to the main frame (Fig. 5). 2. If more extensive adjustment is required, loosen the locking collars on the blade shaft bearings and shift the blade shaft assembly sideways as required. Blade Shaft Bearing Replacement NOTE: When replacing both bearings, considerable time is saved by completing one end bearing replacement without unlocking the bearing collar on the other end (Fig. 7). This would eliminate the time required to re-align the blade shaft assembly on the skid shoes. 1. Remove belt cover and release belt tension. If left (drive) end bearing is to be replaced, remove the belts and scribe mark the shaft to relocate the pulley prior to removing it. 2. To remove either end bearing: a) Loosen setscrew, unlock and remove bearing collar b) Use small file and emery cloth to remove setscrew burr, rust, paint, etc. c) Spray WD-40 between shaft and bearing bore. d) Remove bearing flange bolts. e) Insert sharp chisels or pry bars between inside bearing flange and end plate to break bearing loose and remove. When the bearing refuses to move, try one or more of the following: Use a bearing-pulling adapter in conjunction with a gear puller. Use a torch to heat up the bearing inner ring. Following the procedure in step 7 of blade removal, use the 1 ½ blade retaining nut to break the bearing loose. 3. To complete the bearing replacement, apply "NEVER SEEZ " to the shaft then reverse the applicable removal steps. 11

13 Blade Replacement Blade Removal 1. Connect unit to 3-point hitch tractor. DO NOT connect driveline. Lift & lower unit to rotate blade shaft as required. KEEP HANDS CLEAR WHEN LIFTING & LOWERING. 2. Remove Pins from Depth Gage Assemblies, and allow Shoe Assemblies to drop out with unit lifted. 3. With unit sitting on floor, remove Belt cover, Jack Shaft Shield and Rear Shield. 4. Remove weight from right end of frame. 5. Loosen and remove bearing locking collar on right end of shaft. Remove collar setscrew burr with a file. With Emery cloth remove any rust from shaft extension. (Apply spray lubricant to shaft extension & bearing bore). 6. Remove bearing flange nuts and bolts on right end of shaft. 7. a) Apply wrench (1) (Fig 6) to left end nut with handle facing forward, rotated upward against the frame to prevent left 5' EXTENSION end nut and shaft from turning. REAR b) Apply wrench (2) to right end nut, handle facing rear. LOOSEN c) Apply approx. 5 ft. extension to wrench (2) WRENCH (2) (right end) and rotate handle downward to Figure 6. Right End View (Rt. End Plate Not Shown) loosen nut. Continue to loosen nut until nut forces bearing toward end of shaft (Fig. 7). 8. Use 2 crowfoot pry bars to pry bearing off shaft, being careful not to damage inner seal. A bearing puller may be required. 9. Remove belt tension nut (Fig. 8). 10. Remove idler pivot bolt, idler and take up rod assembly. 11. Remove all belts from pulleys. 12. Scribe a location mark on shaft (to relocate pulley during reassembly) then remove pulley from blade shaft. WRENCH (1) BRACED AGAINST FRAME FRONT BLADES PRESSED AGAINST FLOOR TO PREVENT ROTATION 13. Loosen bearing flange nuts from drive end ½ turn. 14. Raise the unit up until the frame clears right end of shaft (Fig 9). Figure 7. Right End Bearing Removal STEP STEP 9 STEP 13 STEP 12 STEP 11

14 15. Roll right end of shaft rearward to clear right frame end. 16. Block up left end of frame so that blades on that end clear the floor. 17. Place additional block under a blade approximately mid length of shaft assembly. 18. Remove right end nut and begin removal of spacers and worn blades. Figure 8. Left End NOTE for Re-Assembly: Observe how blades are timed (teeth are staggered). 19. After removal of last blade, leave the short spacer on the shaft. Roll Shaft Out STEP 15 Lift Frame STEP 14 Figure 9. Shaft Rolled Rearward Blade Shaft Re-assembly 1. Wipe down blade shaft and begin shaft reassembly by installing new blades and spacers with teeth staggered for timing. See Blade Timing, pg After installing short spacer on right end, apply "NEVER SEEZ " to threaded section. 3. Install nut hand-tight. 4. Remove blocks under shaft assembly and frame. 5. Roll shaft back into position under the frame. 6. Lower the frame to align end plate bearing hole with shaft. 7. Apply "NEVER SEEZ " to smooth end of shaft then add machinery bushing (Fig. 7). 8. Assemble bearing & flanges onto shaft. 9. Bolt the bearing assembly using (4) ½ x 1 carriage bolts and flange locknuts, with nuts facing outside of frame. 10. Retighten the 4 previously loosened bearing flange nuts on drive end. 11. Re-assemble locking collar to right end bearing

15 a) Place tractor and lowered Verti-cutter in sharp left turn for wrench clearance (see Fig at right). Using the 2 wrenches (from Blade Shaft Removal) apply wrench (1) to left end nut with handle facing rear, rotated upward against the frame. b) Then apply wrench (2) to right end nut with handle facing forward (Fig. 10). c) Use a 5 extension on wrench (2) and tighten nut to approx 1000 ft. lbs (200 lbs at end of 5 ft extension). 13. Re-assemble weight to right end of frame. 14. Reinsert the Shoe assemblies and pin gage to desired depth. 15. Re-assemble Pulley and taper lock bushing (refer to scribed line, Step 12 in Blade Removal). Pulley grooves must line up with each other. 16. Re-assemble idler and take up rod assembly. Only hand tighten pivot bolt. 17. Re-install belts onto pulleys. Tighten the Stover nut until belts are properly tensioned (refer to decal on belt cover). 18. Fully tighten the idler pivot bolt. 19. Re-assemble Rear Shield first then Belt Cover and Jack Shaft Shield. WRENCH (1) BRACED AGAINST FRAME 5' EXTENSION BLADES PRESSED AGAINST FLOOR TO PREVENT ROTATION TIGHTEN WRENCH (2) Figure 10. Right End View (Reassembly) Blade Timing 1. Stack two blades together so that they match exactly. Take the top and rotate it to its other side as seen on Figure

16 2. Note as you align the hex holes that the blades are now out of phase. This pattern is repeated throughout the shaft assembly. FLIP OVER SAME POINT OF BLADE FOR BOTH VIEWS ON OPPOSITE SIDES OF CENTER LINE FRONT BACK NOTICE THE SAME FLAT SIDE OF THE HEX IS ON TOP FOR BOTH VIEWS OF THE SAME BLADE Figure 11. Blade Timing IF THE BLADES ARE NOT TIMED PROPERLY, THE VERTI-CUTTER WILL NOT OPERATE SMOOTHLY. 15

17 WARRANTY INFORMATION ONE YEAR LIMITED WARRANTY FIRST PRODUCTS INC. WARRANTS THIS PRODUCT TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF TWELVE MONTHS FROM THE ORIGINAL DELIVERY DATE. THIS WARRANTY DOES NOT COVER PARTS CAUSED TO BE DEFICIENT DUE TO NORMAL WEAR, MISUSE, ACCIDENTS, OR LACK OF PROPER MAINTENANCE. ANY PARTS THOUGHT TO BE DEFECTIVE MUST BE RETURNED TO THE DEALER/DISTRIBUTOR FOR WARRANTY CONSIDERATION JOINTLY WITH FACTORY REPRESENTATIVES. A RETURN AUTHORIZATION NUMBER MUST BE OBTAINED AND CLEARLY MARKED ON ALL PACKAGES OF PARTS REQUIRING RETURN TO THE FACTORY. Comment [u22]: THE OBLIGATION OF FIRST PRODUCTS INC. UNDER THIS WARRANTY SHALL BE EXCLUSIVELY LIMITED TO REPLACEMENT OF PARTS DETERMINED TO BE DEFECTIVE BY FIRST PRODUCTS INC. WITH FREIGHT PREPAID. IN NO EVENT SHALL FIRST PRODUCTS INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH THE USE OF THIS PRODUCT. FIRST PRODUCTS INC. RESERVES THE RIGHT TO MAKE CHANGES OR ADD IMPROVEMENTS TO ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO MAKE SUCH CHANGES OR IMPROVEMENTS ON PRODUCTS SOLD PREVIOUSLY. 16

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