12 D100 SWEEP OWNERS MANUAL

Transcription

1 12 D100 SWEEP OWNERS MANUAL IMPORTANT: Read before using! 2002 Kingbird Avenue P.O. Box 8 George, IA (712) Toll Free SUDENGA FAX (721) OM-BU3523 J22AM

2 CAUTION DO NOT OPERATE THIS EQUIPMENT BEFORE READING AND UNDERSTANDING THE OPERATORS MANUAL. READ ALL SAFETY PRECAUTIONS. DO NOT OPERATE THIS EQUIPMENT UNLESS ALL SAFETY DEVICES AND GUARDS ARE IN PLACE. VISUALLY INSPECT ALL OF THIS EQUIPMENT PRIOR TO OPERATION. CORRECT ANY HAZARDOUS SITUATION. REPAIR ANY FAULTY EQUIPMENT. DO NOT ADJUST, SERVICE, LUBRICATE, CLEAN, UNCLOG OR MOVE THIS EQUIPMENT WHILE IT IS IN OPERATION. AVOID WEARING LOOSE FITTING CLOTHING WHEN WORKING AROUND THIS EQUIPMENT. KEEP HANDS, FEET AND CLOTHING CLEAR OF ALL MOVING PARTS WHILE THIS EQUIPMENT IS IN OPERATION. MAKE CERTAIN EVERYONE IS CLEAR OF THIS EQUIPMENT BEFORE APPLYING THE POWER. NEVER ALLOW CHILDREN IN THE WORK AREA. MAKE CERTAIN A QUALIFIED OPERATOR IS IN ATTENDANCE AT ALL TIMES WHILE EQUIPMENT IS IN OPERATION. MAKE CERTAIN THE POWER SOURCE IS SHUT OFF BEFORE ANY MAINTENANCE OR REPAIRS ARE PERFORMED. BIN SWEEP AUGERS - MAKE SURE THE POWER SOURCE IS SHUT OFF BEFORE ENTERING THE BIN. DO NOT, UNDER ANY CIRCUMSTANCE, ENTER THE BIN WHILE THE EQUIPMENT IS IN OPERATION. SUPPLEMENTAL INSTRUCTIONS - ADDITIONAL SAFETY INFORMATION WILL BE FOUND IN OTHER AREAS OF MOST MANUALS. READ AND OBEY THESE INSTRUCTIONS. ORDER INFORMATION When ordering replacement parts for this equipment, please furnish the following: Part Number Description Quantity Required box at right) EQUIPMENT IDENTIFICATION INFORMATION Model No. Serial No. Date of Purchase Drive Type: Electric Gas PTO Hydraulic Length Diameter

3 INTRODUCTION Congratulations on the purchase of your new equipment. You have acquired what we feel is some are to read and understand this manual. We would like to emphasize that you pay special attention to the section involving safety. It is the responsibility of the OPERATORS, OWNERS, and SUPERVISORS to read this manual and to know the proper operating precautions and requirements and to make them known to all who may work with the equipment or be in the working area. Unsafe practices may result in serious injury or death and equipment damage! Failure to read this manual by owner, operator, & supervisors is a misuse of the equipment SAFETY ALERT SYMBOL Watch for this symbol. It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The SAFETY ALERT SYMBOL is used to identify potential hazards and to call your attention to instructions concerning your personal safety. Read the instructions that accompany this symbol and be aware that to disobey or disregard the message may result in personal injury or death. PLEASE NOTE: The words DANGER, WARNING, and CAUTION are used throughout this manual to designate the level of a hazards seriousness. DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. iii

4 OPERATOR QUALIFICATION Operation, transporting, maintenance, etc. of this machine shall be limited to competent and experienced persons. Anyone who will operate or work around this equipment must use good judge- ments, such as: 1. There are some regulations which specify that no one under the age of 16 may operate power these regulations for your own area or situation. 2. Current OSHA regulations state in part: At the time of initial assignment and at least annually thereafter, the employer shall instruct every employee in the safe operation and servicing of all equipment with which the employee is, or will be involved. * We have included the sign off sheet below for your convenience and personal record keeping. stay out of the work area at all times. 4. A person who has not read and understood all operating and safety instructions is not quali- is in the area in the event of an emergency. SIGN-OFF SHEET DATE EMPLOYER SIGNATURE EMPLOYEE SIGNATURE iv

5 GENERAL SAFETY PRECAUTIONS We strongly recommend that all persons who will be operating or work around this equipment be trained in the proper operational and safety procedures required. Also the use of this equipment in any other environment other then a grain bin voids the warranty and could also cause serious injury. We also recommend that all operators perform periodic reviews of those procedures. A IMPORTANT: READ CAREFULLY BEFORE SERVICING OR REPAIRING! UNTRAINED OPERATORS SUBJECT THEMSELVES AND OTHERS TO SERIOUS INJURY OR DEATH! It is important that those who will operate this equipment use good common sense and always be aware of and understand the following safety rules: PERSONNEL SAFETY: equipment until all persons are clear of the equipment. must wear a proper breathing apparatus for the material that is in the bin. Initially and periodically thereafter, insist all operating personnel review the safety sections of this manual. Any worker who is tired and/or under pressure is more apt to have an accident. Give extra breaks and/or varied jobs to all workers. If necessary, delay operation of this equipment until the operator is adequately rested. Keep hair, loose clothing, shoe strings, etc. away from rotating and moving parts. Wear close Always wear protective clothing and substantial shoes. And ear protection EQUIPMENT MAINTENANCE & REPAIR: ALWAYS shut off, disconnect and lock out power before adjusting, servicing or cleaning. Use suitable precautionary measures when repairing or replacing equipment parts. Make sure all safety signs are readable and tightly attached. Ensure that electric motors, are operating at the proper speed. Make sure any electrical wiring is not frayed or cracked and meets proper wiring codes. Maintain proper adjustments on any chains and belts. Mount controls for any electric motors at a convenient place, which is a safe distance from the machine. Make sure controls are readily accessible in the event of an emergency. Check lifting devices periodically for signs or wear. Make sure all components are in good working condition before using. v

6 GENERAL SAFETY PRECAUTIONS CONT... Keeping the equipment clean and painted will prolong the life of the product. Where replacement parts are necessary for periodic maintenance and servicing, genuine Sudenga Industries, Inc. will not claim responsibility for use of unapproved parts, accessories and/or any alterations from the original design and damages resulting from their use. OPERATIONAL SAFETY: NEVER allow anyone inside a bin, which is being unloaded by an auger or conveyor. Flowing grain can trap and suffocate in seconds. Make sure someone is nearby who is aware of the proper shutdown sequence in the event of an accident or emergency. NEVER work alone. THINK - Never act impulsively around equipment. Make sure all guards and shields are in place before operating. DO NOT operate without guards and shields properly attached. Keep hands and feet away from auger intake and other moving parts. NEVER attempt to assist machinery operations or to remove trash from equipment while in operation. Use ample overhead lights after dark to illuminate work area. NEVER step or reach over moving parts. IMPORTANT: READ MANUAL CAREFULLY BEFORE OPERATING! Be Careful... THE LIFE YOU SAVE MAY BE YOUR OWN! vi

7 CAUTION AUGERS CAN BE DANGEROUS USE THEM CAREFULLY 1. Stop Auger, Disconnect and Lock Out Power Before Entering A Grain Bin Or Making Adjustments. 2. Sweep Augers Cannot Be Guarded In Front Of Flighting - It Will Not Work - Knowing This: -Do Not Enter Grain Bin While Sweep Is In Operation. -Keep All Guards In Place. -Stop Auger Before Moving Or Adjusting. 3. Keep Children And Other Unauthorized Personnel Away From Augers. 4. Remember If You Remove Our Guards: YOU ARE RESPONSIBLE! vii

8 OPERATING NEW AUGERS DO NOT OPERATE NEW AUGERS EMPTY BECAUSE THEY WILL VIBRATE SEVERELY, JAM TIGHT, AND BREAK! RUN ABOUT 200 BUSHELS OF DRY SHELLED CORN IN NEW AUGERS TO POLISH FLIGHTING AND TUBE. NOTICE Some Augers Equipped with Gear Boxes are SHIPPED DRY, Some are full. BEFORE OPERATING You Must Check to Make Sure Gear Box Is Full With The Proper Gear Lubricant. Refer To The Gear Box Manual, Lube Instructions, Furnished With The Gear Box For Proper Fill Amounts and Type of Lube to Use. IMPORTANT; AFTER SWEEP HAS MOVED 45 METRIC TONS CHECK THE FOL- LOWING ALL SET SCREWS AND FASTENERS FOR TIGHTNESS. ALL SET SCREWS MUST HAVE LOCK TIGHT ON THEM. SPROCKETS AND PULLEYS FOR PROPER ALIGNMENT. viii

9 TABLE OF CONTENTS SUDENGA INDUS IES, INC. ix

10 NOMENCLATURE

11 Back Shield NOMENCLATURE Panel Flighting Pivot Bracket # Drive Shaft # or # Push Tractor Weight # End Shaft # Connector Shaft # # End Hanger Bracke # & #02936 Bearing Saddle # Wood Bearing # Bearing Strap #043809

12 BIN PREPARATION

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14 12 D100 DRIVE ASSEMBLY To remove the springs:

15 D100 DRIVE ASSEMBLY 7 1/2 & & 20 hp Item hp (3282) (4282) Part # Seal Protector Seal Protector

16 3282 DRIVES U D G S. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C 4282 DRIVES U D G S. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C. S A C

17 12 D100 EXTENSION ASSEMBLY

18 12 D100 EXTENSION ASSEMBLY Item 10 5 Part #

19 TRACTOR EXTENSION ASSEMBLY

20 TRACTOR EXTENSION ASSEMBLY Item

21 12 D100 PUSH TRACTOR ASSY

22 12 D100 PUSH TRACTOR ASSY I N D N. C AIN. NU I. UNC E. I E I ASS. I E I ASS ASS D AC D I E UNI E D D AC S EE UN A E D AC E N A E D AC E N A E D AC E EA A E D AC U E SIDE S D AC C SS C ANNE E D D AC C SS E E ASS D AC EA A E E D D AC IN IN D AC I E D D AC C E ASS D AC EA UNI S D AC EA ACCESS E D D AC C AIN EIG S D AC SIDE EIN U E D AC C SS.. D G D C NU E. UNC G ADE C AS E. IDE E A INC C E IN.. E C NN. IN.. EE I.. D.. D G D

23 D100 TRACTOR UPPER DRIVE ASSY I N D N E S.. S US ING. S A D AC A E DD A E D I E E D D AC D I E UNI A E.. D G D C NU E. UNC G ADE C E S.. EA ING ANGE C A. D S S C E

24 D100 TRACTOR LOWER DRIVE ASSY I N D N C AIN I C E D D AC D I E U E E D D AC GEA UN S A D AC AC S A.. D G D.. D G D.. D G D.. D G D C NU E. UNC G ADE C NU. UNC E C IDE AS E. AS E. IDE E A INC AS E C. E C NN. IN E S UA E.. EA ING ANGE C A.. S C E S C E.. S C E C. ID E G ID E S C E C. E S C E. E INS I GEA E E EC IC,,

25 I N D N 12 D100 CARRIER WHEEL S A D CA IE EE A E. AC E. U D E D D CA IE UN E D D CA IE A E A E D AC S ING AS E. IDE E A INC C E IN... C C A C S ING... SE I NEU A IC EE

26 ASSEMBLY INSTRUCTIONS WARNING DANGER

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28 NOTE: The sweep height is automatically controlled. After the desired clearance the majority of the grain load is removed, the springs will lift the sweep into operating position. SPRING ADJUSTMENT BOLT SPRING ADJUSTMENT BOLT

29 DO NOT ATTEMT TO REMOVE OR REPLACE THE SPRINGS UNTIL YOU HAVE READ AND UNDERSTOOD THE INSTRUCTIONS ON PAGE #14. IMPROPER REMOVAL MAY RESULT IN PARTS EXPLODING FROM THE UNIT, CAUSING SERIOUS DAMAGE, INJURY OR DEATH.

30 6" Extension 1. Flat Plate 7-1/2" Long Flight 13-1/2" Long Flight 12" Extension 1. Formed Plate 2. Brace Plate 18" Extension 1. Formed Plate 2. Brace Plate 3. Flat Plate 19-1/2" Long Flight 25-1/2" Long Flight LOCK THE POWER OUT

31 OPTIONAL ELECTRICAL COLLECTOR RING ASSEMBLY INSTRUCTIONS

32 OPERATING INSTRUCTIONS lock out and tag out the power Note: The sweep will automatically lift itself into operating position if set up correctly. OBEY ALL OSHA AND COMPANY REGULATIONS FOR BIN ENTRY lock out and tag out the power. Continuous tractor operation will wear the tires off the push tractor and/or cause mechanical failure.

33 Auto Advance Operating Instructions The If the sweep is not performing as indicated, If the sweep auger was not emptied, the main auger may not start due to the away from the grain pile. stop advance To resume automatic operation LOCK THE POWER OUT.

34 NOTICE SHUTDOWN INSTRUCTIONS 1.While draining the bin: Close the slide gate and let the under bin run itself empty before shutting down the system. 2.While sweeping the bin: Disengage the sweep arm by using the clutch control lever to take the sweep arm out of gear. Let the system run itself empty before shutting of the system. DO NOT USE THE SLIDE GATE TO SHUT OFF FLOW TO THE UNDER- BIN AUGER WHILE THE SWEEP IS RUNNING SUDENGA INDUS IES, INC.

35 General Electrical Responsibilities D S T T Category 1 customer furnished controls Customer furnished Customer furnished Customer furnished ON O Customer furnished ON O Customer furnished Customer furnished Customer furnished Customer furnished A Customer furnished Category 1A customer furnished controls with Optional Electrical Slip Ring Customer furnished Customer furnished Customer furnished ON O Customer furnished ON O Customer furnished Customer furnished E S R S Customer furnished A E Customer furnished A E Customer furnished A Customer furnished Category 2 Optional Sudenga Auto Advance control Customer furnished

36 S ON O ON O Customer furnished Customer furnished A Customer furnished Category 2A Optional Sudenga Auto Advance control with Optional Electrical Slip Ring Customer furnished S ON O ON O Customer furnished E S R S A E Customer furnished A E Customer furnished A Customer furnished

37 D150 SUGGESTED WIRING D150 OPERATION PROCEDURE - - -

38 SUDENGA tractor auger

39 AUTO ADVANCE 1 CONTROL BOX OPERATION DANGER Make sure all personnel who will operate this equipment have read and understand this manual. Failure to heed these warnings will result in death or serious injury. WARNING When the machine is in Automatic Mode it will operate automatically. It may start up or run without notice. If left unattended the tractor will continue to drive the auger around the bin until the stop button is pressed or off mode is selected.

40 AUTO ADVANCE 1 CONTROL BOX ADJUSTMENT to the highest setting. Start the auger running and slowly adjust the Threshold down until the WARNING THE FOLLOWING OPERATIONS MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN. operation of the sweep is that it will drive forward into the pile of grain until it experiences a running. Once the tractor senses the auger loading down it should stop driving and wait until the amperage falls low enough that there is no more grain left in front of the auger. CAUTION!!! Adjust the Hysteresis so that the auger drives far enough into the pile of grain to load the auger drive motor close to Full Load Amps (as rated on the auger drive motor nameplate). DO NOT drive so far into the pile of grain that the auger motor exceeds its Full to drain down to the sweep after the tractor has shut off. Avoid overloading the auger motor until the Tractor Drive is switched off.

41 AUTO ADVANCE 1SWEEP TRACTOR DRIVE OPERATION PANEL L SUDENGA START K F STOP I AUGER ON J ON H TRACTOR AUTO G FORWARD A G OFF MANUAL REVERSE LETTER PART # DESCRIPTION G I

42 AUTO ADVANCE 1 SWEEP TRACTOR DRIVE FUSE BOX DIAGRAM LID, INSIDE BOX, INSIDE F M A K C D C D B L G H I J N E E L LETTER PART # DESCRIPTION B C D E G I M N

43 L1L2 L3 A L1 L2 A1 L1L2 14 L3 A2 L3 L1 L2 L3 A1 L1 L2 L3 A1 AUGER TRACTOR TRACTOR 13 L1L2 14 L3 A2 13 A1 11 E1 12 M A1 AUTO ADVANCE 1 SWEEP TRACTOR DRIVE RELAY DIAGRAM 460VAC 3 PHASE FUSE BLOCK FORWARD REVERSE 240VAC 3 PHASE 380VAC 3 PHASE 460VAC 1 PHASE 380VAC 1 PHASE 240VAC 1 PHASE FUSE FUSE 115VAC 1 PHASE INCOMING POWER CURRENT RELAY TRANSFORMER

44 INDUSTRIAL SWEEP ELECTRICAL DIAGRAM VAC FUSE 5A START AUGER CNTR AUGER A2 A1 M OVERLOAD N 02 AUGER ON AUGER CNTR STOP A DIRECTION SWITCH REVERSE TRACTOR FORWARD TRACTOR FORWARD OVERLOAD TRACTOR CNTR A2 M A1 FORWARD MAN. OFF AUTO TRACTOR DRIVE SWITCH TRACTOR REVERSE OVERLOAD TRACTOR CNTR A2 M A1 REVERSE E1 CURRENT RELAY M 10 NOTE: TRANSFORMER GOES ON ONE LEG OF THE AUGER MOTOR AFTER THE MOTOR OVERLOAD 11 CURRENT RELAY N.O. CONTACTS CURRENT TRANSFORMER CURRENT RELAY 12 A2 CR A1 13 TR. FRW CNTR TRACTOR ON G 14 TR. REV CNTR

45 Before starting the sweep: OBEY ALL OSHA, COMPANY, AND ANY OTHE REGULATIONS THAT APPLY FOR BIN ENTRY

46 D150 OPERATION PROCEDURE

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48 SHAFT MOUNT GEARBOX MAINTENACE INSTRUCTIONS LUBRICANT FILL LEVEL & DRAIN PLUGS WARNING: OPERATION AND MAINTENANCE CHECKLIST OIL SPECIFICATIONS STANDARD BEARING GREASE NLGI 2EP Lithium STANDARD OIL - ISO VG220

49 LUBRICANT CAPACITY Mounting Position H1 SK 3282 quarts 3.33 liters 3.15 SK 4282 quarts 4.97 liters 4.70 SK 5282 quarts 7.93 liters 7.50 SK 6282 quarts liters 17.0 WARNING: LOCK OUT POWER before any maintenance is performed. Make absolutely sure that no voltage is applied while work is being done on the gearbox

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51 TROUBLESHOOTING PROBLEM WITH REDUCER POSSIBLE CAUSES SUGGESTED REMEDY reducer recommended damage autovent

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53 TROUBLE SHOOTING GUIDE where the material is caked together, this sweep will not perform at maximum Sweep will not advance into the grain pile. 2. Auto Advance not working properly 4. Push tractor tires worn smooth Replace tires 5. Push tractor tires slipping on grain 6. Adverse grain conditions

54 Sweep will not start 1. Not enough intermediate sumps Reduced Capacity 2. Incorrect sweep extension installed Sweep does not work like last year 1. Different grain from last year 2. Different grain conditions from last year 1. Grain chunk (frozen or crusted) fell onto sweep 2. Too deep of grain depth

55 D100 SWEEP PARTS CHART

56 WARRANTY SUDENGA INDUSTRIES, INC. warrants each New Unit against operational failure caused by defective material or faulty workmanship which occurs during normal use and operation within 180 days from date of purchase by user. Our obligation under this warranty consists only of repairing or replacing without charge to the customer or, at our option, allowing credit for any part which has failed during the above stated period as a result of being defective at the time of manufacture. All other costs incurred during replacement such as crane rental, labor, loss of income due to work stoppage, etc. are not covered under this warranty. We reserve the right to require the return of the defective material to verify the claim. All material returned to the factory, including any and all parts shipped with the defective part or parts, must be shipped freight prepaid. The repaired or replaced part or parts, plus any and all parts being returned to the user, will be shipped F.O.B., the factory. Electric motors, gas engines, and hydraulic motors are not covered by this warranty, these are covered under their own only warranties made by the manufacturer. No other warranties, expressed or implied, are given on this product. The manufacturer hereby expressly denies the existence of, or liability for, warranties, either expressed or implied, pertaining to the material - handling capacity or horsepower requirements - of this product. Capacities quoted in catalogs and literature, whether supplied by manufacturer or any other person or agency, are intended to be informational only. Conditions such as temperature, humidity, type of material, weight, moisture content, and equipment maintenance, which effect product capacity and horsepower requirements are beyond manufacturers control. The purchaser shall be solely responsible for determining the adequacy of this product for any and all uses to which the purchaser shall apply it, and the application of the product by the purchaser shall not be

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60 A complete line of GRAIN & FEED HANDLING and PROCESSING SYSTEMS for your farm, elevator, or mill tons