HD-Series Joker. Owner s Manual HD 20 / 30 / 40.

Transcription

1 Issued May 2015 HD-Series Joker HD 20 / 30 / 40 Owner s Manual Serial Numbers: HD20 SN Current HD30 SN Current HD40 SN Current 200 Knutson St. Mapleton, ND 58059, USA (T) 855-4HORSCH (F) (E) info.us@horsch.com HD-Series Joker Joker Owner s Owner s Manual Manual Ver. Ver / /2016 HD-Series

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4 Contents Introduction - Safety & Guidelines... 8 Machine Registration (Important Notice to Dealer/Owner!)... 8 Warranty Guidelines... 9 Machine Registration Form: Customer s Copy...11 Machine Registration Form: Dealer s Copy...13 Machine Registration Form: HORSCH s Copy...15 Delivery Form: DEALERS s Copy...17 Product Specification...19 In These Operating Instructions...20 Authorized Operators...20 Protective Clothing...20 Information Regarding Safety...21 Safety Symbols on the Machine:...21 Operational Safety...22 Road Traffic Safety...22 Hydraulic connections...22 Pressure Accumulator...23 Changing Implements...23 In Operation...23 Service and Maintenance...23 Tire Information...23 Transport/Installation...24 Delivery...24 Installation...24 Depending on scope of equipment:...24 Transport...25 Technical Data...26 Road Lighting Equipment...28 Setting/Operation...29 Roll-Flex Packer...31 Hitching/Unhitching the Machine HD Series Joker Owner s Manual Version /2016

5 Hitching-up:...32 Folding/Unfolding...33 Folding Manual HD:...33 Unfolding:...33 Phasing the Hydraulic Cylinders...34 Parking the Machine...37 Setting Wing Pressure...38 Depth Setting Manual Depth Control...39 Tracking Manual Depth Control...40 Gauge Wheels...41 Setting Gauge Wheels:...41 Maintenance and Servicing...42 Cleaning...42 Maintenance Periods...42 Storage...42 Lubricating Machine...43 Hygiene...43 Exposure to Lubricants...43 Service...43 Maintenance Schedule...44 Preventative Maintenance...45 Lubrication Points...46 Troubleshooting...48 Bolt Tightening Torques Metric Bolts...49 Bolt Tightening Torques Imperial Bolts...50 Notes:...51 Index...53 HD Series Joker Owner s Manual Version /2016 5

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8 Introduction - Safety & Guidelines Safety is YOUR responsibility! READ AND UNDERSTAND THIS MANUAL BEFORE YOU OPERATE THIS MACHINE Learn how to operate and service your machine correctly. Failure to do so could result in personal injury and/or equipment and property damage. HORSCH will not accept any responsibility for any damage or malfunctions resulting from failure to comply with the Operator s Manual. If the information found in this manual is not completely understood or if there are any questions, contact HORSCH Customer Service. HORSCH cares about your safety! This machine is designed to provide maximum possible safety; but no machine design can prevent operator error or carelessness. The Owner s Manual provides instructions for the safe operation and maintenance of this machine. Make sure the machine is in good operating condition. Check service schedule in book. This manual should be considered a permanent part of your machine and should remain with the machine if you no longer own it. Right hand and left hand are determined by facing the direction of forward travel respectively. HORSCH reserves the right to alter illustrations as well as technical data and weights contained in this manual at any time without notice. This data is the property of HORSCH. All use and/or reproduction not specifically authorized by HORSCH are prohibited. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. Some illustrations may show optional equipment. Illustrations may show shields, guards, etc., opened or removed. All shields, guards, etc. must be in place during operation. Machine Registration (Important Notice to Dealer/Owner!) Please complete the Machine Registration Form on the next few pages and return to HORSCH within 10 (ten) business days, from date of delivery to owner. Accurately record all the numbers to help in tracing the machine. Your dealer needs these numbers when you order parts. NO WARRANTY CLAIMS WILL BE ACCEPTED IF THIS MACHINE REGISTRATION IS NOT RETURNED. The warranty period begins on the date of delivery. See further noted information in the Warranty Guidelines section on the following pages. 8 HD Series Joker Owner s Manual Version /2016

9 Warranty Guidelines 1. The period of warranty for material defects relating to HORSCH products will be 12 months. In the case of written deviations from the statutory provisions, these agreements shall apply. They shall become effective upon delivery of the machine to the end customer, unless the unit is stored during seasonal months, whereas the machine is not utilized. The machine will then have a warranty start date when it is put in to service. During this waiver period the machine is not to be used or show evidence of usage or the warranty date will be set back to the original sold or delivery date. Registration must be completed within 10 days of machine usage. Failure to comply may result in warranty start date reverting back to original purchase or delivery date. All wear item parts are excluded from the warranty. 2. Warranty claims must be submitted to the HORSCH Customer Service Department in Mapleton, ND via your dealer. It is only possible to process claims which have been completed correctly and submitted no later than four weeks after the damage occurred. No warranty claims will be accepted to machines under the warranty waiver start date, except any related Technical Service Bulletins. 3. In the case of deliveries made under the warranty which are subject to the return of the old parts, the warranty claim, together with the old parts, must be returned to HORSCH within 4 weeks after the damage occurred. 4. In the case of deliveries made under the warranty, which are not subject to the return of the old parts, these parts must be kept for the purpose of further decisions for a period of four weeks after receipt of the warranty claim. 5. Warranty repairs to be carried out by outside companies, or repairs which are expected to take more than 2 working hours, must be approved in advance with HORSCH Customer Service Department. HORSCH, LLC 200 Knutson St. Mapleton, ND USA service.us@horsch.com For other related warranty items such as tire warranty issues, contact your nearest distributor. A complete list of dealers can be found at the following web sites. Firestone Tires - or Titan Tires - or USA-BEAR. HD Series Joker Owner s Manual Version /2016 9

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11 Machine Registration Form: Customer s Copy NOTE: No Warranty Claims will be accepted if this Machine Registration Form is not returned! To: HORSCH, LLC 200 Knutson St. Tel: service.us@horsch.com Mapleton, ND Fax: Machine Product & Model: Serial Number: New Machine Final Sale Initial use Customer s Machine Transfer Demonstration Machine Initial use Sold Date: In Service Date: Est. Acres: Operating Instructions: I hereby confirm receipt of the Owner s Manual and Parts Catalog for the above mentioned machine. I have been instructed and informed by a HORSCH factory trained Service Technician / authorized Dealer representative in the operation and functions of the machine, as well as in the safety requirements. Name of the Service Technician / Dealer representative Dealer Name: Address: City/State/Zip: County: Tel: Fax: Customer Name: Address: City/State/Zip: County: Tel: Fax: Customer No: Customer No: I am aware that a Warranty Claim will only be valid if, after the receipt of the machine, this form has been fully completed, signed and returned to HORSCH, LLC. Place, Date Customer s Signature NOTE: After Signing, remove and/or copy this page. Keep signed delivery checklist in machine file at the dealership. HD Series Joker Owner s Manual Version /

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13 Machine Registration Form: Dealer s Copy NOTE: No Warranty Claims will be accepted if this Machine Registration Form is not returned! To: HORSCH, LLC 200 Knutson St. Tel: service.us@horsch.com Mapleton, ND Fax: Machine Product & Model: Serial Number: New Machine Final Sale Initial use Customer s Machine Transfer Demonstration Machine Initial use Sold Date: In Service Date: Est. Acres: Operating Instructions: I hereby confirm receipt of the Owner s Manual and Parts Catalog for the above mentioned machine. I have been instructed and informed by a HORSCH factory trained Service Technician / authorized Dealer representative in the operation and functions of the machine, as well as in the safety requirements. Name of the Service Technician / Dealer representative Dealer Name: Address: City/State/Zip: County: Tel: Fax: Customer Name: Address: City/State/Zip: County: Tel: Fax: Customer No: Customer No: I am aware that a Warranty Claim will only be valid if, after the receipt of the machine, this form has been fully completed, signed and returned to HORSCH, LLC. Place, Date Customer s Signature NOTE: After Signing, remove and/or copy this page. Keep signed delivery checklist in machine file at the dealership. HD Series Joker Owner s Manual Version /

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15 Machine Registration Form: HORSCH s Copy NOTE: No Warranty Claims will be accepted if this Machine Registration Form is not returned! To: HORSCH, LLC 200 Knutson St. Tel: service.us@horsch.com Mapleton, ND Fax: Machine Product & Model: Serial Number: New Machine Final Sale Initial use Customer s Machine Transfer Demonstration Machine Initial use Sold Date: In Service Date: Est. Acres: Operating Instructions: I hereby confirm receipt of the Owner s Manual and Parts Catalog for the above mentioned machine. I have been instructed and informed by a HORSCH factory trained Service Technician / authorized Dealer representative in the operation and functions of the machine, as well as in the safety requirements. Name of the Service Technician / Dealer representative Dealer Name: Address: City/State/Zip: County: Tel: Fax: Customer Name: Address: City/State/Zip: County: Tel: Fax: Customer No: Customer No: I am aware that a Warranty Claim will only be valid if, after the receipt of the machine, this form has been fully completed, signed and returned to HORSCH, LLC. Place, Date Customer s Signature NOTE: After Signing, remove and/or copy this page. Keep signed delivery checklist in machine file at the dealership. HD Series Joker Owner s Manual Version /

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17 Delivery Form: DEALERS s Copy Serial Number:.. At the time the machine is delivered, the following checklist is a reminder of information which should be conveyed directly to the customer. Check off each item as it is fully explained to customer. [ ] Make the customer aware of all safety precautions that must be exercised while using this machine. Point out all Warning and Caution safety labels/decals on the machine. [ ] Point out the location of the Serial Number Tag (product identification numbers), for future reference of the machine. [ ] Give the Operator s Manual to the customer. Encourage customer to read the manual in its entirety. [ ] Explain all operating adjustments. [ ] Review recommended procedures for attaching and detaching machine from tractor. [ ] Make the customer aware of all safety precautions that must be observed when transporting the machine in field and on public roads. [ ] When the machine is transported on a road or highway at night, or during the day, accessory lighting and devices should be used for adequate warning to operators of other vehicles. In this regard, tell the customer to check local governmental regulations. The machine should be equipped with road lighting and slow moving vehicle sign. [ ] Explain to the customer that the life expectancy of this or any other machine depends on regular lubrication as directed in the Operator s Manual. Follow all maintenance and lubrication schedules for the machine. [ ] Discuss with the customer the use of proper tools and equipment for service of the machine. [ ] Have customer record Serial Number(s) in the Product Specification section. [ ] To the best of my knowledge, this machine has been delivered ready for field use and the customer has been fully informed as to proper operation and care. Signed:... (Customer) Signed:... (Dealer Representative) Date:... HD Series Joker Owner s Manual Version /

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19 Product Specification Each machine manufactured and assembled is serialized and provided a number for tracking purposes. There is a model number, which is the category for product family of the machine, and there is a serial number. The serial number may also be known as, or part of, a Product Identification Number. This number is a formulated number which details the machines build information for tracking purposes and easy identification later during time of service, maintenance and replacement part ordering. The Serial number, along with Model number of the machine, can be found on the Serial Number Tag. HORSCH, LLC has placed a Serial Number Tag (reference picture below) on the machine with the above mentioned information. It is located on the main frame cross member tube directly behind the front hitch, just off center towards the left hand side of each machine. Record the Model and Serial number of the machine below. Retain this page for customer use only! For future reference, the information will be used whenever the machine is being serviced, for ordering replacement parts or when requesting information for the machine such as replacement Owner s Manual or a Parts Catalog. Be sure to provide both, the model number and serial number, when contacting your dealer, for better assistance and quicker support of your machine. HORSCH, LLC Serial Number Tag Date of Purchase: Dealer Information: Name: Address: Phone: HD Series Joker Owner s Manual Version /

20 In These Operating Instructions The operating instructions distinguish between three different types of warning and safety instructions. The following graphic symbols are used: Important instructions! If there is a risk of injury! If there is a risk to life and limb! It is important that all the safety instructions contained in these operating instructions and all the warning signs on the machine are read thoroughly and understood prior to operation of the machine. Ensure that the warning signs are legible and replace any signs that are missing or damaged. These instructions must be followed in order to prevent accidents. Inform other users of the warnings and safety instructions and the location of this Owner s Operators Manual. Do not carry out any operations which may affect the safe use of the machine. Authorized Operators Only those persons who have been authorized and instructed by the operator may operate the machine. Operators must be at least 16 years of age. The operator must hold a valid driving license. They are responsible for third parties in the operating area. The person in charge must: Make the operating instructions available to the operator. Ensure that the operator has read and understood the operating instructions. The operating instructions are a key component of the machine. Protective Clothing For operation and maintenance of this machine, you will need: Snug fitting clothing; no loose articles or strings. Safety gloves and goggles to protect against dirt and sharp edged machine parts. 20 HD Series Joker Owner s Manual Version /2016

21 Information Regarding Safety The following warnings and safety instructions apply to all sections in these operating instructions. Safety Symbols on the Machine: Read and adhere to the operating instructions before starting up the machine! Stay clear of swinging area of retractable and extendible machine parts! Switch the engine off and pull out the key before starting maintenance and repair work! Never reach into areas where there is a risk of crushing, as long as parts could still be moving! Watch out for fluids spraying out under high pressure, follow the operating instructions! It is only permitted to remain in the danger zone if the safety support is in place! When hitching up the machine and when operating the hydraulic system, no persons should be between the machines! No passengers are allowed to ride on the machine! Do not climb on rotatable parts. Use mounting steps provided for this purpose! Lifting hook; attach lifting tackle (chains, ropes, etc.) here when performing loading work! HD Series Joker Owner s Manual Version /

22 Operational Safety The machine must only be put into operation after receiving instructions by employees of the authorized dealer or a HORSCH employee. The machine registration form has to be completed and returned to HORSCH. Road Traffic Safety The valid road traffic regulations are to be observed when traveling on public roads, paths and areas. Do not exceed the maximum permissible transportation widths and heights and install road lighting equipment, warnings and safety covers where necessary. Do not exceed the permissible axle loads, tire carrying capacities and total weights, in order to ensure sufficient steering and braking capabilities. Handling is affected by the implement connected. It is important to take into account the large overhang and the centrifugal mass of the implement, particularly when cornering. DO NOT EXCEED A MAXIMUM SPEED OF 20 MPH DURING TRANSPORTATION. LOSS OF VEHICLE/MACHINE CONTROL CAN RESULT IN SERIOUS PERSONAL INJURY OR DEATH! The whole machine is to be cleaned of soil that has been collected before travel on public roads. Be sure to thoroughly clean the debris from the rear Roll-Flex packer system. Do not travel on roads with the rear Roll-Flex packer system on the ground. This may cause damage to the roads and premature wear and possible malfunction of components to the machine. Passengers are strictly forbidden to ride on the machine. Hydraulic connections Do not connect hydraulic lines to the tractor before both hydraulic systems (machine and tractor) are depressurized. The hydraulic system is under high pressure. Check all lines, hoses and screwed connections regularly for leaks and any visible external damage! Only use appropriate aids when checking for leaks. Repair any damage immediately! Oil sprays can cause injuries and fire! In the case of injury, contact a doctor immediately! The control units on the tractor must be secured or locked when not in use or when the machine is in transport position, in order to prevent accidents caused by unintended hydraulic movements or movements caused by persons other than the operator (children, passengers). 22 HD Series Joker Owner s Manual Version /2016

23 Pressure Accumulator Depending on the equipment of the machine, the hydraulic system may have a pressure accumulator installed. Do not open or work (welding, drilling) on the pressure accumulator. Even after being emptied, the accumulator is still preloaded by gas pressure. Always depressurize the pressure accumulator before starting work on the hydraulic system. The pressure gauge should not indicate any pressure. The pressure gauge reading should drop to 0 psi. Only then may service be carried out on the hydraulic system. Changing Implements Secure the machine against unintended rolling! Secure lifted frame parts, under which you will be working, with suitable supports! Caution! Danger of injury caused by protruding parts (tines, discs)! Do not use the packer or other rotating parts when climbing onto the machine. These could start to rotate and you could fall and be seriously injured. In Operation Check the area around the machine (for children!) before setting off and starting operation of the machine. Ensure sufficient visibility! Stay clear of the operating range of hydraulically operated parts. Passengers are not allowed to ride on the machine during operation! Service and Maintenance Ensure that regular tests and inspections are always carried out to schedule, as specified in the operating instructions. Prior to performing maintenance and servicing work, ensure that the machine is positioned on firm, level ground and that it is properly secured against rolling away. De-pressurize the hydraulic system and lower or support the implement. After cleaning, check all hydraulic lines for leaks and loose connections. Check hoses for chafing and signs of other damage. Remedy any faults immediately! Prior to working on the electrical system, disconnect it from the electric power supply. Retighten screwed connections which had been loosened during servicing and maintenance work. Tire Information Do not wash new machines with a steam-jet or high-pressure cleaner. The paint takes approximately 3 months to cure and could thus be damaged if this time has not yet expired. Proper Tire inflation is important. Inflate tires accordingly: o HD20 64 PSI Transport / 60 PSI Gauge wheels. o HD30/40 70 PSI Transport / 60 PSI Gauge wheels. Verify tightness of all wheel lugs. Follow posted torque specs below: o HD-Series 220 ft.-lbs. Transport / 400 ft.-lbs. Gauge wheels. HD Series Joker Owner s Manual Version /

24 Transport/Installation There is higher danger of accident during initial installation. Please pay attention to the notes in the corresponding chapters. Delivery The machine with implements is normally delivered completely assembled on a low loader. If parts or modules had to be disassembled for transportation purposes, these will be assembled by our distributor. Depending on the design of the low loader the machine can be unloaded with a tractor, or needs to lift off with suitable lifting gear (forklift truck or crane). Sufficient load bearing capacity of lifting gear and lifting tackle must therefore be assured. Lifting and latching points are identified by labels. When using other lifting points pay careful attention to the center of gravity and the weight distribution. These points must, in any case, only be on the frame of the machine. Installation Instruction of the operation and initial installation of the machine will be carried out by our service representatives or distributors. Any use of the machine without dealer/distributor training is prohibited! The machine can only be released for operation after the instructional session has been conducted by our service engineer / distributor and after the operating instructions have been reviewed and read. There is higher danger of accident during installation and maintenance. Before performing any installation and maintenance work or service, make yourself familiar with the machine and read the operating instructions. Depending on scope of equipment: Take loosely delivered parts off the machine. Check all important screw connections! Lubricate all grease fittings! Check air pressure in tires! Check all hydraulic connections and hoses for correct fastening and function. Immediately rectify any occurring damage or have it corrected by an authorized dealer! 24 HD Series Joker Owner s Manual Version /2016

25 Transport Depending on country specific regulations and working width, the equipment can be transported on public roads, either attached to a tractor or on a trailer or low loader. The permissible dimensions and weights for transport must be complied with. The tractor must be big enough, so that sufficient steering and braking abilities are assured. If the machine is hitched up in two-point mode, the tractor link arms must be blocked against swinging sideways. For road transport, insert the provided yellow safety stops to front and rear hydraulic cylinders and insert wing locks pins (if available, where necessary). NOTE: Do NOT rest the machine on the safety stops. The machine has a load hold valve in the circuit to hold the cylinder when it is disconnected from the tractor. The yellow safety stops are primarily a safety device in case of a failure in the hydraulic circuit and used during service of the machine. The machine is transported on the rear tires of the transport axle. Never transport the machine on the rear Roll-Flex packer system. Be sure to turn the Road/Field selector valve to Road mode for transportation. The Road/Field valve turns on/off hydraulic pressure to the rear circuit of the machine. Shown in Field mode On a trailer or low loader, the machine must be secured with tensioning straps, chain binders, or other means. Attach lifting tackle only at the specially marked hoisting/lifting points. NOTE: The Lift circuit must be fully extended before Folding/Unfolding the machine! DO NOT EXCEED A MAXIMUM TRANSPORTATION SPEED OF 20 MPH (32 KPH) DURING TRANSPORTATION IF TOWING THE MACHINE. LOSS OF VEHICLE/MACHINE CONTROL MAY/CAN RESULT IN PROPERTY DAAMGE AND SERIOUS PERSONAL INJURY OR DEATH! HD-Series Joker Front Hitch decal HD Series Joker Owner s Manual Version /

26 Technical Data Joker HD-20 Machine Width: 22 Working Width: Working Depth:. Up to 8 Transport Height: Transport Width: Length: 24 5 Weight:... 16,000 lbs. (approx. 4-Tongue RollFlex) 17,440 lbs. (approx. 5-Tongue RollFlex) Tires:... Firestone Destination Farm I-1 VF385/65R ply 163D Load Rating 10,700 lbs. / 70 psi. Number of Discs: Discs Number of Coulter: 26 Number of Ranks:. 2 Rank Spacing:.. 47 Center-to-Center Disc Spacing: Disc Size: Serrated Coulter Arm Length:. 17 Hydraulic control units:... 3 Depth Setting; Manual Hitching:... Drawbar CAT IV / CAT V (Optional) Finishing System:.. RollFlex Packer (Heavy Duty 5-Tongue 28 or Standard Duty 4-Tongue 24 ) Power requirements:... from HP Hydraulic requirements: Suggested PSI Joker HD-30 Machine Width: 32 6 Working Width: Working Depth:. Up to 8 Transport Height: Transport Width: Length: 24 7 Weight:... 23,000 lbs. (approx.) Tires:... Firestone Destination Farm I-1 VF385/65R ply 163D Load Rating 10,700 lbs. / 70 psi. Number of discs: Discs Number of Coulter: 36 Number of Ranks:. 2 Rank Spacing:.. 47 Center-to-Center Disc Spacing: Disc Size: Serrated Coulter Arm Length:. 17 Hydraulic control units:... 4 Depth Setting; Manual Hitching:... Drawbar CAT IV / CAT V (Optional) Finishing System:.. RollFlex Packer (Heavy Duty 5-Tongue 28 or Standard Duty 4-Tongue 24 ) Power requirements:... from HP Hydraulic requirements: Suggested PSI 26 HD Series Joker Owner s Manual Version /2016

27 Joker HD-40 Machine Width: 42 4 Working Width: Working Depth:. Up to 8 Transport Height: Transport Width: Length: 24 7 Weight:... 30,400 lbs. (approx.) Tires:... Firestone Destination Farm I-1 VF445/65R ply 174D Load Rating 14,800 lbs. / 75 psi. Number of discs: Discs Number of Coulter: 50 Number of Ranks:. 2 Rank Spacing:.. 47 Center-to-Center Disc Spacing: Disc Size: Serrated Coulter Arm Length:. 17 Hydraulic control units:... 4 Depth Setting; Manual Hitching:... Drawbar CAT IV / CAT V (Optional) Finishing System:.. RollFlex Packer (Heavy Duty 5-Tongue 28 or Standard Duty 4-Tongue 24 ) Power requirements:... from HP Hydraulic requirements: Suggested PSI HD Series Joker Owner s Manual Version /

28 Road Lighting Equipment Pin Description 1. Ground 2. Brake 3. Left Turn 4. Not Used* 5. Right Turn 6. Tail Lights 7. 12V +* Check the road lighting equipment at regular intervals to prevent any other road users from being endangered by negligence! 28 HD Series Joker Owner s Manual Version /2016

29 Setting/Operation Cultivation Discs: The serrated discs of the machine cut the harvest residues and the soil and mix the residues into the soil down to working depth. Maintenance: The bearings are oil filled and therefore, maintenance free. However a bit of penetrating lubricant may be applied to the backside of the bearing hub to lubricate the hub seal. The picture below will identify where to spray any type of sufficient penetrating oil for lubricating the seal. Check the discs regularly for clearance, leaks, tightness and unrestricted rotation. Apply penetrating oil to backside of hub to lubricate the seal. Notes on cleaning: The mechanical seals of the disc hubs are very sensitive. If water has entered them and the machine is then parked over a longer period of time, damage may occur. This can cause corrosion, and both mechanical seal rings may stick together. The mechanical seal rings will then rotate around the O-ring and damage it. Oil would run out of the hub and the bearing would be damaged after a short while with no lubrication. Bearings must therefore not be cleaned with high pressure cleaning equipment. Before longer periods of rest, the bearing locations should be sprayed with a rust dissolver/inhibitor, or similar lubricant. Before resuming operation, the discs should be turned by hand and checked for unrestricted rotation. HD Series Joker Owner s Manual Version /

30 The disc hub (illustrated on the following page) is oil filled as mentioned above. If the seals or O- rings are damaged and further service is required, replace the seals and O-rings and fill the hub with 1.0 ounces high performance 75w140 synthetic industrial gear oil lubricant, based on polyalphaolefins. (See HD-Series Joker Parts Catalog Joker HD Bearing Assembly) Assembly, Bearing Blade 30 HD Series Joker Owner s Manual Version /2016

31 Roll-Flex Packer The Roll-Flex system can be attached as a rear packer on the machine. While in field use, the packer is used to lift/lower the machine. There are two options of Roll-Flex packer systems available for the HD-Series Joker. The standard option is a 4-Tongue spring 24 diameter packer configuration. (See picture below) The other option, is a Heavy Duty 5-Tongue spring 28 diameter packer configuration. While in use in the field, the machine always travels on the packer. NOTE: Never exceed a maximum operating speed of 8mph while traveling on the Roll-Flex system only during Field mode. The packer is not rated for extreme loads at high speeds, only for machine weight for short distances, such as turning around at the end of a field or traveling across a headland. Due to the weight of the machine, a high consolidation and a fine, crumbly, level surface is achieved. M16 Countersunk Bolts Torque to 170 Ft-lbs. (x4). Torque from nut side. M12 Socket Head Bolts Torque to 120 Ft-lbs. (x2). Torque first one, then second, and then first one again. Roll-Flex Packer 4 Tongue Standard With cohesive soils the packers may pick up more soil and thus become considerably heavier. This can overload components or soil the roads during transportation. Packers must therefore, always be cleaned before road transportation if they have picked up soil. HD Series Joker Owner s Manual Version /

32 Hitching/Unhitching the Machine DANGER! Crush Hazard - Nobody is to remain between the tractor and the machine when hitching up and unhitching. Hitching-up: Hitch up the machine to the trailer coupling ring on the tractor. Connect hydraulic lines. Connect the road lighting equipment plug and check the function. Lift machine. Pivot front hitch jack stand to storage location. Remove the rear cylinder yellow transport supports. Fold the side section wings in. Hydraulic Colored Markings: (Hydraulic lines are identified by symbols on the brackets additionally marked with colored caps to avoid mixing up by mistake.) 1 Lift - Green 2 Rear Axle - Blue 3 Fold - Yellow 4 Gauge Wheels - Red (HD30 & HD40 only) Hydraulic Hose End caps Front Hitch Stand Transport Axle Cyl Support Stop CAT IV/V Perfect Hitch CAT IV/V Perfect Hitch NOTICE of Extended Life decal 32 HD Series Joker Owner s Manual Version /2016

33 Folding/Unfolding Folding movements must only be performed on firm and level ground. The folding process should only be performed in the field because the coulter discs could get caught in the ground. If the folding process is performed on the road, discs and road surface layer could get damaged. Joker HD-Series Folding Manual HD: 1. Stop tractor and lower machine to set depth on packer system. 2. Raise machine completely with the transport axle (remove any excess soil buildup). The LIFT circuit MUST be fully extended prior to Folding/Unfolding. 3. Extend Hitch cylinder completely. 4. Insert yellow safety stops to front hitch (or flip-over depth stops) and rear transport axle cylinders. 5. Fold in the side wings. 6. Insert Wing Lock pins, (if equipped). 7. Turn the Selector Valve to Road mode operation. Do not transport the machine in a position higher than necessary. With the Joker, consider the transport height, especially in case of bridges or low hanging power lines. Unfolding: 1. Stop tractor and remove wing lock pins, (if equipped). 2. Turn Selector Valve to Field mode operation. 3. Unfold wings and put hydraulic remote into float position. 4. Raise machine on rear transport axle. The LIFT circuit MUST be fully extended prior to Folding/Unfolding. 5. Remove yellow safety stops from front hitch cylinder (or flip-over depth stops) and rear transport axle. 6. Lower Roll-Flex packer system. 7. Raise rear axle so implement is resting on the packer. 8. Phase the packer cylinders. See Phasing the Hydraulic Cylinders on the following pages. HD Series Joker Owner s Manual Version /

34 Phasing the Hydraulic Cylinders The machine is fitted with hydraulic rephasing cylinders on the rear packer system. The cylinders are all connected in series, and therefore operate in a lift/lower function simultaneously. Here, the hydraulic oil if forced out of the piston rod chamber of one cylinder and in to the piston chamber of the next cylinder, and so on and so forth, for however many cylinders are connected in series. The diameter of each cylinder is smaller in the series to enable the lifting distance to remain constant. In the extended position the rephasing orifices are exposed to allow the oil to flow in to the next cylinder. The cylinders are filled with oil, vented, and aligned with the end stop. HD20 Model machine shown 34 HD Series Joker Owner s Manual Version /2016

35 Procedure 1. Set the tractor at a medium RPM rating, or about half throttle. 2. Activate the lift control device and maintain the pressure (hold the SCV) for approximately 30 seconds. (This will lift the machine and apply pressure to the first series cylinder. Once they have full extended and reached maximum pressure, the relief, or rephasing port of the cylinder, will send the pressure to the next series cylinder. The process is then repeated. When the final series cylinder has phased, the relief port sends the pressure back to the tractor and completes the series rephase of the cylinder circuit.) 3. Reposition the cylinders and repeat the procedure several times. (The system should NOT need to be bled out during phasing, unless the circuit has recently been repaired or a cylinder replaced. Otherwise, bleeding is done at the factory.) 4. Once phased, continue with machine set up for wing pressure and verify depth setting. 5. Begin tillage. Remember to verify proper phasing of the series circuit throughout the work day to guarantee proper operation of the machine and obtain a nice field finish. Troubleshooting If several rephasing hydraulic cylinders are connected in series and one cylinder has an internal leak, it is possible to locate the defective cylinder using a shut-off valve. A shut-off valve (Cylinder Test Kit) is available for purchase for further troubleshooting and diagnostics, PN NOTE: Multiple test kits may be necessary to successfully troubleshoot the series circuit. See diagram below. 1. Install the shut-off valve between the first and second cylinder. 2. Open the shut-off valve and level off the cylinder (align and vent). 3. Fully extend the cylinder and disconnect the hydraulics. 4. If the cylinder continues to fall, depressurize the system and mount a shut-off valve between the second and third cylinders. Realign and vent the cylinders. 5. Repeat the procedure until the rear packer is no longer lowered. 6. The defective cylinder in the series will be the one that has been disconnected from the circuit. 7. Remove the cylinder. Repair the cylinder with a new seal kit or replace the cylinder as needed. (Kits available are listed for the model specific machine in the parts catalog. There is no seal kit available for the 5 x 8 or 4.75 x 8 Electronic version rephasing cylinders.) Helpful Hint In some cases it may be possible to successfully diagnose the cylinder simply by putting the tractor in to continuous flow, then check each cylinder to see if they are warm or hot to the touch. This would identify a defective cylinder with an internal leak. Another method, while in continuous flow, is to listen for blow-by internally to the cylinder. This would identify a defective cylinder as well. HD Series Joker Owner s Manual Version /

36 HD20 Model shown 36 HD Series Joker Owner s Manual Version /2016

37 Parking the Machine Only park the machine on a firm and level surface. The Joker can be parked folded in transport position. 1. Lift the machine to its highest level. 2. Insert the rear transport axle cylinder yellow safety stops and front cylinder stop(s). 3. Pull the pin of the front hitch jack stand out to lower the stand to the ground. 4. Insert the pin to the frame securing the stand vertically with the machine. 5. Lower the machine to the ground, resting it on the stand. 6. Unhitch the drawbar pin from the tractor and machine. 7. Disconnect hydraulic lines, road lighting equipment, and depth control wire. WARNING! Keep hands clear. Put a block under the front hitch jack stand as there is excessive amount of weight from front hitch and machine. Be sure to install any yellow transport stops into position on the front and rear cylinders as needed. Front Cylinder Transport Stop (Manual) Front Hitch Jack Stand Front Cylinder & Flip-over Stops (Manual) Front Hitch Jack Stand Front Cylinder & Flip-Over Stops (Manual Machine Only) Rear Transport Stop & Holder Rear Cylinder Rear Lift Cylinder & Transport Stop HD Series Joker Owner s Manual Version /

38 Setting Wing Pressure The wing pressure is adjustable to keep the wings of the implement level with the rest of the machine when it is in operation. 1. Set the wing pressure by pushing the wings down with the hydraulic remote to the desired pressure between psi. DO NOT EXCEED 500 PSI! Adjust pressure until the machine is level. The pressure gauge will indicate the level of pressure (psi). Gauge showing wing pressure. 38 HD Series Joker Owner s Manual Version /2016

39 Depth Setting Manual Depth Control The depth of the machine is set by the packer and drawbar. The positions of the cylinders are controlled by the manual depth control linkage on the machine. Setting: 1. Raise outside Gauge Wheels of the machine off the ground to their highest set points. (Gauge wheels need to be lifted so they do not interfere with correctly setting the depth control.) For further information see Gauge Wheels in the next section 2. For shallower working depth of the machine, turn the handle clockwise. 3. For deeper working depth of the machine, turn the handle counterclockwise. NOTE: The machine will also need to be leveled for proper operation. The machine can be leveled by either adding, or removing stops to the front hydraulic cylinder. Leveling: 1. For shallower working depth of the machine, add stops. 2. For deeper working depth of the machine, remove stops. Manual Depth Control adjustment HD Series Joker Owner s Manual Version /

40 Tracking Manual Depth Control Machine may not track straight after initial setting. To change tracking of the implement add or remove stops from the front cylinder. To Adjust: 1. If machine is tracking to the right, add more stops to the front cylinder. 2. If machine is still tracking to the right, repeat Step If machine is tracking to the left, remove stops from the front cylinder. 4. Add or remove stops from the front cylinder until the machine tracks straight. Front Hitch Cylinder Manual Flip-over Depth Stops 40 HD Series Joker Owner s Manual Version /2016

41 Gauge Wheels The gauge wheels keep the machine steady and maintain the working depth in the ground. The wheels only have a sensing and supporting function. They are not designed as load bearing transport wheels. The gauge wheel can be set, but not until after the depth setting has been completed. When starting work the gauge wheel should be in its highest position. The gauge wheel is lifted with the machine when it is taken out of the ground at the headland. Setting Gauge Wheels: 1. Before setting the depth of the implement, raise the gauge wheel to its highest position by turning the turnbuckle. 2. Set the desired machine depth. (See procedure in previous section). 3. Lower the implement to the predetermined set depth into the ground and start tilling the field. 4. Stop in the field with the machine still in the ground. DO NOT LIFT MACHINE OUT OF THE GROUND! 5. Turn the turnbuckle to lower the gauge wheel to the ground. NOTE: HD30 & HD40 Joker machines use a hydraulic cylinder for depth control assistance on the gauge wheels. See picture below. Set desired depth using hydraulic pressure. 1. Start with the machine gauge wheels set at a setting of 20. (Each count of 10 equals 2.) 2. Set the Wing pressure at about 250 PSI. 3. Adjust the front hitch cylinder so there is about shims unused to start out. Machine should be set roughly at about working depth. Continue working field. Adjust depth control and front hitch as necessary for level and tracking and desired working depth. NOTE: The tires should only support the machine on the ground in case of obstructions and following the contour of the field. The frame must always rest on the stop screws. The wheels should not lift up the side wings when in operation. Gauge Wheel indicator decal HD20 HD20 with Turnbuckle. HD30/40 with Hydraulic Cylinder. HD Series Joker Owner s Manual Version /

42 Maintenance and Servicing Observe the safety instructions for maintenance and servicing. Your machine has been designed and constructed for maximum power, efficiency and userfriendliness according to a multitude of operating conditions. Your machine has been checked at the factory and by your appointed authorized dealer prior to delivery in order to determine that the machine is in perfect condition. The recommended maintenance and servicing schedule should be carried out at regular intervals in order to maintain failure-free operation. Cleaning The recommended cleaning and maintenance schedule should be carried out at regular intervals in order to maintain operational availability and guarantee optimum performance. The hydraulic cylinders and bearings should not be cleaned with a highpressure cleaner or direct water jet. The seals and bearings are not waterproof under high pressure. Maintenance Periods The maintenance intervals are determined by various different factors. Various operating, weather and soil conditions, as well as working speeds, affect the maintenance intervals, but also the quality of the lubricants and cleaning agents used, determines the time interval required until the next period for scheduled maintenance. The specified maintenance intervals can therefore only be regarded as an indication. The intervals of maintenance work affected have to be adjusted to suit the conditions, should there be any deviations from normal operating conditions. Regular maintenance forms the basis for a serviceable machine. Serviced machines lower the risk of malfunctions and guarantee the efficient application and operation of machines. Before working on or crawling under machine, insert transport stops and follow all noted safety guidelines. See Maintenance Schedule on the following page. Storage Should the machine not be used for a longer period of time, follow these steps: If possible, store the machine under a roofed area. Protect the machine against rust. Only spray with biologically degradable oils, i.e. rapeseed oil. 42 HD Series Joker Owner s Manual Version /2016

43 Lubricating Machine The machine should be lubricated regularly and after every pressure wash. This ensures operational reliability and reduces the costs of repair work and down time. See Maintenance Schedule below. Hygiene When used according to regulations, lubricants and mineral oil products present no danger to health. You should, however, avoid longer contact to the skin and not breathe in any fumes. Exposure to Lubricants CAUTION: Avoid direct contact with oils by wearing gloves or protective creams. Thoroughly wash off traces of oil on the skin with warm water and soap. Do not clean your skin with petrol, diesel fuel or other solvents. Oil is poisonous. You should immediately visit your doctor if you have swallowed oil. Ensure that lubricants are kept out of reach of children. Never store lubricants in open or unlabeled containers. Avoid skin contact with oily clothes. Change dirty clothing. Never keep oily cloths in your pockets. Dispose of oily shoes as hazardous waste. Rinse oil that has splashed into your eyes with clean water and visit your doctor, if necessary. Absorb spilled oil with suitable bonding agents and dispose of properly. Never extinguish oil fires with water. Only use permissible and suitable extinguishing agents and wear breathing apparatus. Oily waste and waste oil have to be disposed of according to the legal regulations. Check with your local Hazardous Waste Material Management facility. Service HORSCH, LLC hopes you are completely satisfied with your machine and the HORSCH company itself. Please contact your distribution partner or authorized dealer in the event of a problem. The customer service employees of our distribution partners and customer service employees of the company HORSCH are available for your support. Please help us solve any technical faults as soon as possible. Provide the customer service staff with the following details in order to prevent unnecessary queries. Customer No. Name of customer service advisor Name and address Machine model and serial number Purchase date and operating hours Type of problem HD Series Joker Owner s Manual Version /

44 Maintenance Schedule Machine Item Checklist Hardware, Connections, Plug-ins Maintenance Schedule Preventative Maintenance Check Tension Bushings of Main Frame, Front Hitch, Wings, Gauge Wheels & Hydraulic Cylinders. Check for tightness, and proper connection. Torque hardware to specifications. Prior to Use X X Daily X X Service Time Lubrication Grease Wing Pivot Pins X Grease Transport Axle Pivot Pins X Grease Front Hitch Pivot Pins X Grease Front Hitch Cylinder pin X Grease Manual Depth rod X Lubricate packer shaft nylon bushings X Wheel / Hub Bearings Check condition, tightness and fit. X X Lubricate wheel hub bearings (Transport & Gauge wheels) X Packer System Check condition, tightness and fit. X X Check bearings for leaks and tightness. X X Check bearing grease/oil level. X X Check Tension Bushings on frame. X X Inspect packer tongue springs. X X Cultivation Discs / Coulters Check condition of discs, tightness and fit. X X Check bearings for leaks and tightness. X X Check bearing grease/oil level. X X Inspect rubber cords. X Hydraulic Components Verify function & operation X X Inspect hoses, fittings, accumulators, valves & cylinders. X X Electrical Components Verify function & operation X X Inspect wiring harnesses & road lighting. X X End of Season Carry out inspections noted above. Spray piston rods of hydraulic cylinders X X with anti-corrosion agent. NOTE: If Tension Bushings are worn, replace immediately! Weekly - 40hrs Bi-Weekly Monthly Quarterly Yearly 44 HD Series Joker Owner s Manual Version /2016

45 Preventative Maintenance A quick, simple walk-around of the entire machine is highly encouraged before operation of the machine each time of intended use. Inspect all moving and wear items such as cultivating discs, hub bearings, and rear Roll-Flex packer springs. Cultivating discs should be tight to the hub. Also check that there are no cracked or broken discs. If so, replace immediately. In the sense of the discs being a wear type item, it is recommended to replace the discs once they have worn considerably and are noticeably requiring more depth control of the machine for proper soil cultivation. Disc hubs are oil filled as mentioned earlier in this manual and require no maintenance, unless there is noticeable oil seepage from the housing. If so, replace the hub or repair the failed seal and fill the hub with the correct recommended oil, 1.0 ounces 75w140 synthetic gear oil. Roll-Flex packer springs are also a wear item to the Joker machine. As spring steel is allowed to flex, keep in mind that given their intended use, the spring, as any other, does have a life span. Its life expectancy is shortened each time it flexes. Flexing will cause weakened steel and eventually fail, or break. The maximum amount of flex allowed for a packer spring is 1. Inspect each packer spring for cracks/fractures or breakage, flattened springs, and extended flexing. If any of these conditions are apparent, replace immediately. Also, if the spring is outside the allowed flex amount it should be replaced immediately. An aftermarket kit is available as well for an added option in preserving packer tongue springs, HORSCH PN Roll-Flex Spring Support, available from your local authorized dealer. New Roll-Flex packer springs Used Roll-Flex packer springs at max. flex allowed Spring Support HD Series Joker Owner s Manual Version /

46 Lubrication Points Lubrication Points: Wing Fold Pivot Pins (x4) Lubrication Points: Front Hitch & Rear Axle Pivot Pins (x2/ea.) Lubrication Point: Manual Depth Control Rod (x1) Lubrication Points: Gauge Wheel Turnbuckle (x2) Lubrication Point: Rear Packer Pivot Pins (x2/ea) Lubrication Point: Gauge Wheel Pivot Pin (x1/ea) 46 HD Series Joker Owner s Manual Version /2016

47 Lubrication Point: Front Hitch Cylinder Pivot Pins (x2) Lubrication Point: Rotating Axle HYD Cylinder (x1/ea) Lubrication Point: Rear Lift HYD Cylinder (x1/ea) Lubrication Points: Transport Wheel Axle Hubs (x2) Lubrication Points: Gauge Wheel Axle Hubs (x2) HD Series Joker Owner s Manual Version /

48 Troubleshooting Problem Cause Solution Machine does not track straight. Machine does not stop at desired depth. (Electronic versions) Machine acts erratically, does not maintain consistent depth. Machine stops then continues past desired set depth. Entire machine plugs when running. Machine is not level front to back. Cylinders not reaching set points before hydraulic flow stops. SCV lever is being operated multiple times per lift/lower cycle. SCV is still active after all cylinder movement has stopped. Ground speed too slow; working depth too deep. Adjust hitch tilt cylinder. Adjust SCV timer setting so valve returns to neutral within 5 seconds of all cylinder movement stopping. Only activate timer function once per cycle. Refer to tractor operator s manual. Rephase packer cylinders. Reduce timer setting (if used). Return SCV to neutral within 5 seconds of all cylinders stopping. Increase ground speed up to 10 mph. Reduce tillage depth. Rephase packer cylinders. Wings plug when running. Wings not running level. Reduce wing pressure so wings are level. Machine lifts slow. Tractor SCV not set to 100%; excessive soil buildup on machine. Set SCV to 100%. Remove soil from machine frame. Tilt cylinder will not move when discs are out of ground. Depth controller prevents tilt cylinder movement when Actual Depth is 0. Turn depth controller off. Adjust tilt cylinder. 48 HD Series Joker Owner s Manual Version /2016

49 Bolt Tightening Torques Metric Bolts Bolt tightening Torques - Metric bolts (Ft. Lbs) Bolt Diameter Grade 4.8 Grade 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Wheel Nuts/ Bolts Size Pitch Dry Lubed Dry Lubed Dry Lubed Dry Lubed Dry Lubed Dry * 8* 13* 10* 20* 15* 30* 22* 35* 26* * 14* 24* 18* 28* 20* 52* 38* 62* 48* * 28* 39* 35* 58* 54* 86* 78* 102* 92* * 43* 60* 54* 94* 86* * 65* 120* 102* * 80* * 88* NOTE: Items with (*) indicate torque in Inch/Pounds. All others in Foot/Pounds. HD Series Joker Owner s Manual Version /

50 Bolt Tightening Torques Imperial Bolts Bolt tightening Torques - Imperial bolts (Ft. Lbs) Bolt Diameter SAE Grade 2 SAE Grade 5 SAE Grade 8 L9 Size Thread Dry Lubed Dry Lubed Dry Lubed Lubed 1/ * 49* 8 75* / * 56* 10 86* / / / / / / / / / / / / / / / / / / / / / / / / NOTE: Items with (*) indicate torque in Inch/Pounds. All others in Foot/Pounds. 50 HD Series Joker Owner s Manual Version /2016

51 Notes: HD Series Joker Owner s Manual Version /

52 52 HD Series Joker Owner s Manual Version /2016

53 Index B bearing...24, 29, 41, 44 C cleaning... 23, 29, 42 Cultivation Discs D Delivery Form Depth Setting... 26, 27, 39 F Folding G Gauge Wheels Guidelines... 8 H Hitching... 26, 27, 32 L Leveling Lubrication Points M Machine Registration... 8, 11, 13, 15 Maintenance Schedule Manual Depth Control... 39, 40, 46 P Parking Phasing... 33, 34 Pressure Accumulator Preventative Maintenance Product Specification R Road Lighting Road Traffic Roll-Flex S Safety Symbols Serial Number Storage T Technical Data Torque... 44, 49, 50 Tracking Transport Troubleshooting U Unfolding Unhitching W Warranty Guidelines... 9 Wing Pressure Go to Top HD Series Joker Owner s Manual Version /

54 PN Knutson St. Mapleton, ND 58059, USA (T) 855-4HORSCH (F) (E) HD-Series Joker Owner s Manual Ver /2016