NEERALTA EXTRACTOR OPERATOR'S MANUAL

Transcription

1 NEERALTA EXTRACTOR OPERATOR'S MANUAL

2 EXTRACTOR WARRANTY POLICY The warranty policy begins upon delivery of the unit to the original customer. Neeralta Manufacturing Inc. (hereafter referred to as NEERALTA) warrants your new NEERALTA Extractor at the time of delivery to the original purchaser, to be free from defects in material and workmanship when properly set up and operated according to the recommendations in the Owner's Manual. NEERALTA's one (1) year warranty policy covers the NEERALTA Extractor. NEERALTA's liability for any defect with respect to the NEERALTA Extractor shall be limited to repairing the NEERALTA Extractor at a NEERALTA approved location, or replacing it as NEERALTA shall choose. This warranty shall not apply to any machine or attachment which shall have been repaired or altered outside the NEERALTA factory or authorized NEERALTA location or in any way so as in NEERALTA's judgment, to affect its stability or reliability, nor which has been subject to misuse, negligence or accident, nor to any machine or attachment which shall not have been operated in accordance with NEERALTA's printed instructions or beyond the company recommended machine rated capacity. LIMITATIONS OF WARRANTY NEERALTA products are designed to provide years of dependable service when proper use and maintenance is adhered to. The potential for misuse in many applications exists, therefore a limited warranty is provided as follows: Auger wear is considered a maintenance item, and its life is dependent on the material being conveyed. Tires are warranty of the manufacturer of the tire. The tarp system is warranty of the tarp manufacturer. To receive a warranty claim, a return authorization from NEERALTA must be obtained. The failed part may then be returned in an un-tampered status. This warranty does not include freight or delivery charges incurred when returning machinery for servicing. Dealer mileage, service calls and pick~up/ delivery charges are the customer's responsibility. EXCLUSIONS OF WARRANTY Except as otherwise expressly stated herein" NEERALTA makes no representation or warranty of any kind, expressed or implied and makes no warranty, of merchantability in respect to its,machinery and/or attachments and makes no warranty that its machinery and/or attachments are fit for any particular purpose. NEERALTA shall not be liable for incidental or consequential damages for any breach of warranty, including but not limited to inconvenience, rental or replacement equipment, loss of profits or other commercial loss. Upon purchase, the buyer assumes all liability, all personal injury and property damage resulting from the handling, possession or use of the goods by the buyer. No agent, employee, or representative of NEERALTA has any authority to bind NEERALTA to any affirmation, representation or warranty concerning its machinery and/or attachments except as specifically set forth herein. WARRANTY VOID IF NOT REGISTERED

3 NEERALTA EXTRACTOR WARRANTY REGISTRATION FORM & INSPECTION REPORT WARRANTY REGISTRATION This form must be filled out by the dealer and signed by both the dealer and the customer at the time of delivery. Customer s Name Address City, State/Prov., Code Dealer Name Address City, State/Prov., Code Phone Number Serial Number Delivery Date DEALER INSPECTION REPORT Tire Pressure Checked Wheel Bolts Torqued Inspect Electrical System Check Gearbox Oil Levels Hydraulic Hoses Free and Fittings Tight Lubricate Machine Chain Drive System Tensioned and Aligned Elevator and Augers Turn Freely SAFETY Guards and Shields Installed and Secured Safety Signs Installed and Legible Reflectors and Lights Clean and Operating Review Operating and Safety Instructions I have thoroughly instructed the buyer on the above described equipment which review included the Operator s Manual content, equipment care, adjustments, safe operation and applicable warranty policy. Date Dealer s Rep. Signature Signature The above equipment and Operator s Manual have been received by me and I have been thoroughly instructed as to care, adjustments, safe operation and applicable warranty policy. Date Owner's Signature WHITE YELLOW PINK NEERALTA MFG. INC. DEALER CUSTOMER

4

5 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Neeralta Extractor when ordering parts or requesting service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference. Serial Number Production Year

6

7 TABLE OF CONTENTS SECTION DESCRIPTION PAGE 1 Introduction Safety General Safety Equipment Safety Safety Training Safety Signs Preparation Operating Safety Maintenance Safety Lock-Out Tag-Out Safety Storage Safety Transport Safety Hydraulic Safety Tire Safety Sign-Off Form Safety Signs Operation To The New Owner or Operator Machine Components Machine Break-In Pre-Operation Checklist Controls Attaching/Unhooking Extractor Entering Bag Operating Storage Transporting Service and Maintenance Service Maintenance Trouble Shooting Specifications Mechanical Bolt Torque Hydraulic Fitting Torque Index... 79

8

9 1 INTRODUCTION Congratulations on your choice of a Neeralta Extractor to complement your agricultural storage operation. This equipment has been designed and manufactured to meet the needs of the discriminating buyer for the efficient unloading of grain, pulse crops, fertilizer or any other granular material from a plastic storage bag. Safe, efficient and trouble free operation of your Extractor requires that you and anyone else who will be operating or maintaining the Extractor, read and understand the Safety, Operation, Maintenance and Trouble Shooting information contained within the Operator's Manual. This manual covers the Extractor made by Neeralta Manufacturing Inc. Use the Index or Table of Contents as a guide when searching for specific information. Keep this manual handy for frequent reference and to pass on to new operators or owners. Call your Neeralta distributor or dealer if you need assistance, information or additional copies of the manual. OPERATOR ORIENTATION - The directions left, right, front and rear, as mentioned throughout the manual, are as seen from the tractor driver's seat and facing in the direction of the travel. If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or Neeralta, Physical Address: Highway 661, Neerlandia, AB T0G 1R0, Mailing Address: Box 115, Neerlandia, AB, Canada T0G 1R0, Phone: , Toll Free: , sales@neeralta.com, Web: 1

10 2

11 2 SAFETY SAFETY ALERT SYMBOL This Safety Alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The Safety Alert symbol identifies important safety messages on your Neeralta Extractor and in the manual. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message. Why is SAFETY important to you? 3 Big Reasons Accidents Disable and Kill Accidents Cost You Money Accidents Can Be Avoided SIGNAL WORDS: Note the use of the signal words DANGER, WARNING and CAUTION with the safety messages. The appropriate signal word for each message has been selected using the following guide-lines: DANGER - WARNING - CAUTION - Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations, typically for machine components that, for functional purposes, cannot be guarded. Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury, and includes hazards that are exposed when guards are removed. It may also be used to alert against unsafe practices. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or Neeralta, Physical Address: Highway 661, Neerlandia, AB T0G 1R0, Mailing Address: Box 115, Neerlandia, AB, Canada T0G 1R0, Phone: , Toll Free: , sales@neeralta.com, Web: 3

12 SAFETY YOU are responsible for the SAFE operation and maintenance of your Neeralta Extractor. YOU must ensure that you and anyone else who is going to operate, maintain or work around the Extractor be familiar with the operating and maintenance procedures and related SAFETY information contained in this manual. This manual will take you step-by-step through your working day and alerts you to all good safety practices that should be adhered to while operating the Extractor. Remember, YOU are the key to safety. Good safety practices not only protect you but also the people around you. Make these practices a working part of your safety program. Be certain that EVERYONE operating this equipment is familiar with the recommended operating and maintenance procedures and follows all the safety precautions. Most accidents can be prevented. Do not risk injury or death by ignoring good safety practices. Extractor owners must give operating instructions to operators or employees before allowing them to operate the machine, and at least annually thereafter. The most important safety device on this equipment is a SAFE operator. It is the operator s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow them. Most accidents can be avoided. A person who has not read and understood all operating and safety instructions is not qualified to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. Do not modify the equipment in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. Think SAFETY! Work SAFELY! 2.1 GENERAL SAFETY 1. Read and understand the Operator s Manual and all safety signs before operating, maintaining, adjusting or unplugging the Extractor. 2. Only trained competent persons shall operate the Extractor. An untrained operator is not qualified to operate the machine. 3. Have a first-aid kit available for use should the need arise and know how to use it. 4. Provide a fire extinguisher for use in case of an accident. Store in a highly visible place. 5. Do not allow children, spectators or bystanders within hazard area of machine. 6. Wear appropriate protective gear. This list includes but is not limited to: - A hard hat - Protective shoes with slip resistant soles - Protective goggles - Heavy gloves - Hearing protection - Respirator or filter mask 7. Lower machine to ground, place all controls in neutral or off, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. 8. Review safety related items annually with all personnel who will be operating or maintaining the Extractor. 4

13 2.2 EQUIPMENT SAFETY GUIDELINES 1. Safety of the operator and bystanders is one of the main concerns in designing and developing a machine. However, every year many accidents occur which could have been avoided by a few seconds of thought and a more careful approach to handling equipment. You, the operator, can avoid many accidents by observing the following precautions in this section. To avoid personal injury or death, study the following precautions and insist those working with you, or for you, follow them. 2. In order to provide a better view, certain photographs or illustrations in this manual may show an assembly with a safety shield removed. However, equipment should never be operated in this condition. Keep all shields in place. If shield removal becomes necessary for repairs, replace the shield prior to use. 9. Do not modify the equipment in any way. Unauthorized modification result in serious injury or death and may impair the function and life of the equipment. 10. In addition to the design and configuration of this implement, including Safety Signs and Safety Equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation, transport, maintenance, and storage of the machine. Refer also to Safety Messages and operation instruction in each of the appropriate sections of the auxiliary equipment and machine Manuals. Pay close attention to the Safety Signs affixed to the auxiliary equipment and the machine. 3. Replace any safety sign or instruction sign that is not readable or is missing. Location of such safety signs is indicated in this manual. 4. Never use alcoholic beverages or drugs which can hinder alertness or coordination while operating this equipment. Consult your doctor about operating this machine while taking prescription medications. 5. Under no circumstances should young children be allowed to work with this equipment. Do not allow persons to operate or assemble this unit until they have read this manual and have developed a thorough understanding of the safety precautions and of how it works. Review the safety instructions with all users annually. 6. Use a tractor equipped with a Roll Over Protective Structure (ROPS). 7. This equipment is dangerous to children and persons unfamiliar with its operation. The operator should be a responsible, properly trained and physically able person familiar with farm machinery and trained in this equipment's operations. If the elderly are assisting with farm work, their physical limitations need to be recognized and accommodated. 8. Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so safely, is in question - DON'T TRY IT. 5

14 2.3 SAFETY TRAINING 1. Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by a single careless act of an operator or bystander. 2. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of this equipment. 3. It has been said, "The best safety feature is an informed, careful operator." We ask you to be that kind of an operator. It is the operator's responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow these. Accidents can be avoided. 4. Working with unfamiliar equipment can lead to careless injuries. Read this manual, and the manual for your auxiliary equipment, before assembly or operating, to acquaint yourself with the machines. If this machine is used by any person other than yourself. It is the machine owner's responsibility to make certain that the operator, prior to operating: a. Reads and understands the operator's manuals. b. Is instructed in safe and proper use. 5. Know your controls and how to stop augers, PTO, hydraulic system and any other auxiliary equipment quickly in an emergency. Read this manual and the one provided with your other equipment. 6. Train all new personnel and review instructions frequently with existing workers. Be certain only a properly trained and physically able person will operate the machinery. A person who has not read and understood all operating and safety instructions is not qualified to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. If the elderly are assisting with farm work, their physical limitations need to be recognized and accommodated. 2.4 SAFETY SIGNS 1. Keep safety signs clean and legible at all times. 2. Replace safety signs that are missing or have become illegible. 3. Replaced parts that displayed a safety sign should also display the current sign. 4. Safety signs displayed in Section 3 each have a part number in the lower right hand corner. Use this part number when ordering replacement parts. 5. Safety signs are available from your authorized Distributor or Dealer Parts Department or the factory. How to Install Safety Signs: Be sure that the installation area is clean and dry. Be sure temperature is above 50 F (10 C). Determine exact position before you remove the backing paper. (See Section 3). Remove the smallest portion of the split backing paper. Align the sign over the specified area and carefully press the small portion with the exposed sticky backing in place. Slowly peel back the remaining paper and carefully smooth the remaining portion of the sign in place. Small air pockets can be pierced with a pin and smoothed out using the piece of sign backing paper. 6

15 2.5 PREPARATION 1. Never operate the Extractor and auxiliary equipment until you have read and completely understand this manual, the auxiliary equipment Operator's Manual, and each of the Safety Messages found on the safety signs on the tractor, extractor and auxiliary equipment. 2. Personal protection equipment including hard hat, safety glasses, safety shoes, and gloves are recommended during assembly, installation, operation, adjustment, maintaining, repairing, removal, or moving the implement. Do not allow long hair, loose fitting clothing or jewelry to be around equipment. 3. PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARING LOSS! Motors or equipment attached can often be noisy enough to cause permanent, partial hearing loss. We recommend that you wear hearing protection on a full-time basis if the noise in the Operator's position exceeds 80 db. Noise over 85 db on a long-term basis can cause severe hearing loss. Noise over 90 db adjacent to the Operator over a long-term basis may cause permanent, total hearing loss. NOTE: Hearing loss from loud noise (from tractors, chain saws, radios, and other such sources close to the ear) is cumulative over a lifetime without hope of natural recovery. 4. Clear working area of debris, trash or hidden obstacles that might be hooked or snagged, causing injury, damage or tripping. 5. Operate only in daylight or good artificial light. 6. Be sure machine is properly pinned to the tractor, adjusted and in good operating condition. 7. Ensure that all safety shielding and safety signs are properly installed and in good condition. 8. Before starting, give the machine a "once over" for any loose bolts, worn parts, cracks, leaks, loose chains and make necessary repairs. Always follow maintenance instructions. 2.6 OPERATING SAFETY 1. Make sure that anyone who will be operating the Extractor or working on or around the unit reads and understands all the operating, maintenance and safety information in the operator's manual. Also read and follow the instructions in the manuals of other equipment in the system. 2. Keep all bystanders, especially children, away from the machine when loading or unloading is being done, or when authorized personnel are carrying out maintenance work. 3. Establish a lock-out tag-out policy for the work site. Be sure all personnel are trained in and follow all procedures. Lock-out tag-out all power sources before servicing the unit or working around loading/unloading equipment. 4. Lower machine to ground, place all controls in neutral or off, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. 5. Keep working area clean and free of debris to prevent slipping or tripping. 6. Do not enter bag or approach augers unless the hydraulic hoses have been disconnected and stowed. 7. Keep hands, feet, hair and clothing away from rotating flighting, elevator, swing auger and moving parts. Keep others away. 8. Stay 50 feet (15 m) away from power lines. Electrocution can occur without direct contact. 9. Install and secure all guards before starting. 10. Keep all hydraulic components in good condition before operating. 11. Fold unloading auger completely, rest in the support cradle and tilt frame fully forward before storing or transporting. 12. Clean all lights and reflectors before transporting. Be sure all lights are working. 13. Review safety related items annually with all personnel who will operating, using or maintaining the Extractor. 7

16 2.7 MAINTENANCE SAFETY 1. Good maintenance is your responsibility. Poor maintenance is an invitation to trouble. 2. Follow good shop practices. - Keep service area clean and dry. - Be sure electrical outlets and tools are properly grounded. - Use adequate light for the job at hand. 3. Make sure there is plenty of ventilation. Never operate the engine in a closed building. The exhaust fumes may cause asphyxiation. 4. Before working on this machine, shut off the engine, and remove the ignition keys. 5. Never work under equipment unless it is blocked securely. 2.8 LOCK-OUT TAG-OUT SAFETY 1. Establish a formal Lock-Out Tag-Out program for your operation. 2. Train all operators and service personnel before allowing them to work around the unloading system. 3. Provide tags on the machine and a sign-up sheet to record tag out details. 2.9 STORAGE SAFETY 1. Store the unit in an area away from human activity. 2. Do not permit children to play on or around the stored machine. 3. Store the unit in a dry, level area. Support the frame with planks if required. 6. Always use personal protection devices such as eye, hand and hearing protectors, when performing any service or maintenance. 7. Where replacement parts are necessary for periodic maintenance and servicing, genuine factory replacement parts must be used to restore your equipment to original specifications. The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and/or accessories. 8. A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this equipment. 9. Periodically tighten all bolts, nuts and screws and check that all cotter pins are properly installed to ensure unit is in a safe condition. 10. When completing a maintenance or service function, make sure all safety shields and devices are installed before placing unit in service. 8

17 2.10 TRANSPORT SAFETY 1. Comply with state and local laws governing safety and transporting of farm machinery on public roads. 2. Check that all the lights, reflectors and other lighting requirements are installed and in good working condition. 3. Do not exceed a safe travel speed. Slow down for rough terrain and when cornering. 4. Fold unloading auger completely, rest in the support cradle and tilt frame fully forward before storing or transporting. 5. Clean all lights and reflectors before transporting. Be sure all lights are working. 6. Be sure that the machine is hitched positively to the towing vehicle and a retainer is used through the drawbar pin. Always attach a safety chain between the hitch and the towing vehicle. 7. Stay away from overhead power lines. Electrocution can occur without direct contact. 8. Plan your route to avoid heavy traffic. 9. Do not drink and drive. 10. Be a safe and courteous driver. Always yield to oncoming traffic in all situations, including narrow bridges, intersections, etc. Watch for traffic when operating near or crossing roadways. 11. Never allow riders on the hitch or frame when transporting HYDRAULIC SAFETY 1. Always place all tractor hydraulic controls in neutral before disconnecting from tractor or working on hydraulic system. 2. Make sure that all components in the hydraulic system are kept in good condition and are clean. 3. Replace any worn, cut, abraded, flattened or crimped hoses and steel lines. 4. Do not attempt any makeshift repairs to the hydraulic fittings or hoses by using tape, clamps or cements. The hydraulic system operates under extremely high-pressure. Such repairs will fail suddenly and create a hazardous and unsafe condition. 5. Wear proper hand and eye protection when searching for a high-pressure hydraulic leak. Use a piece of wood or cardboard as a backstop instead of hands to isolate and identify a leak. 6. If injured by a concentrated high-pressure stream of hydraulic fluid, seek medical attention immediately. Serious infection or toxic reaction can develop from hydraulic fluid piercing the skin surface TIRE SAFETY 1. Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. 2. Do not attempt to mount a tire unless you have the proper equipment and experience to do the job. 3. Have a qualified tire dealer or repair service perform required tire maintenance. 4. When replacing worn tires, make sure they meet the original tire specifications. Never undersize. 9

18 2.13 SIGN-OFF FORM Neeralta follows the general Safety Standards specified by the American Society of Agricultural and Biological Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining the Neeralta Extractor must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual. Do not operate or allow anyone else to operate this equipment until such information has been reviewed. Annually review this information before the season start-up. Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment. We feel that an untrained operator is unqualified to operate this machine. A sign-off sheet is provided for your record keeping to show that all personnel who will be working with the equipment have read and understand the information in the Operator s Manual and have been instructed in the operation of the equipment. SIGN-OFF FORM DATE EMPLOYEE'S SIGNATURE EMPLOYER'S SIGNATURE 10

19 3 SAFETY SIGN LOCATIONS The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. C J E A B REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 11

20 The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. A B C H J C D REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 12

21 The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. A B C H F J F E F REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 13

22 The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. G G H REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 14

23 The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. D D J K REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 15

24 The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires your SAFETY AWARENESS in the following areas: That you familiarize yourself with the various Safety Signs The type of warning and the area. Particular function related to area. D G J G REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied. New safety signs are available from your authorized dealer. 16

25 4 OPERATION OPERATING SAFETY Make sure that anyone who will be operating the Extractor or working on or around the unit reads and understands all the operating, maintenance and safety information in the operator's manual. Also read and follow the instructions in the manuals of other equipment in the system. Keep all bystanders, especially children, away from the machine when loading or unloading is being done, or when authorized personnel are carrying out maintenance work. Establish a lock-out tag-out policy for the work site. Be sure all personnel are trained in and follow all procedures. Lock-out tag-out all power sources before servicing the unit or working around loading/unloading equipment. Lower machine to ground, place all controls in neutral or off, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. Keep working area clean and free of debris to prevent slipping or tripping. Do not enter bag or approach augers unless the hydraulic hoses have been disconnected and stowed. Keep hands, feet, hair and clothing away from rotating flighting, elevator, swing auger and moving parts. Keep others away. Stay 50 feet (15 m) away from power lines. Electrocution can occur without direct contact. Install and secure all guards before starting. Keep all hydraulic components in good condition before operating. Fold unloading auger completely, rest in the support cradle and tilt frame fully forward before storing or transporting. Clean all lights and reflectors before transporting. Be sure all lights are working. Review safety related items annually with all personnel who will operating, using or maintaining the Extractor. 4.1 TO THE NEW OPERATOR OR OWNER The Neeralta Extractor is designed to efficiently remove grain, pulse crops, fertilizer or granular material from plastic storage bags. PTO and hydraulic power is provided by a tractor on the front of the machine. Be familiar with the machine before starting. It is the responsibility of the owner or operator to read this manual and to train all other operators before they start working with the machine. In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, and prudence of personnel involved in the operation, transport, maintenance and storage of equipment or in the use and maintenance of facilities. Follow all safety instructions exactly. Safety is everyone's business. By following recommended procedures, a safe working environment is provided for the operator, bystanders and the area around the worksite. Untrained operators are not qualified to operate the machine. Many features incorporated into this machine are the result of suggestions made by customers like you. Read this manual carefully to learn how to operate the machine safely and how to set it to provide maximum efficiency. By following the operating instructions in conjunction with a good maintenance program, your Extractor will provide many years of trouble-free service. 17

26 4.2 MACHINE COMPONENTS The Neeralta Extractor is designed to empty or remove the material from inside a large plastic storage bag, It consists of gathering augers for breaking up and moving the material to the center of the frame where it is lifted by the elevator to the discharge auger. The discharge auger is powered by the tractor PTO through a chain gearbox. Pressurized oil from the tractor provides hydraulic power for the discharge auger extend/fold, frame movement, bag roll up rollers, wheel drive and the gathering augers and elevator. Gathering augers on the end of the elevator move the material into the elevator where it is moved into the discharge auger. A bag cutter is located on the bottom of the elevator to cut the bag when operating. All the hydraulic controls are mounted on the left side of the frame. In addition, all machine functions except the unloading auger extend/fold and bag dump functions can be activated by a wireless remote control. The Extractor rolls up the plastic of the bag on a spool on top of the frame and propels the machine into and through the bag as it removes the material. Both wheels are driven hydraulically to move the machine into the bag. N A Transport/Storage Configuration B Working Configuration C Gathering Augers D Elevator E Discharge Auger F Bag Take-Up Spool G Bag Take Up Drive H Wheel Drive J PTO Driveline K Controls L Speed Control On/Off M Stile N Wireless Remote Control O Bag Cutter E B F G K L O D M J C FIG. 1 MACHINE COMPONENTS 18

27 F F A G G E L H M J G F F G E B K D H H C C 19

28 4.3 MACHINE BREAK-IN Although there are no operational restrictions on the Extractor when used for the first time, it is recommended that the following mechanical items be checked: A. Before starting work: 1. Read the Extractor and tractor's Operator's Manuals. B. After operating or for the first 1/2 hour: 1. Re-torque all the fasteners and hardware. 2. Check that all safety signs are installed and legible. Apply new signs if required. 3. Check the drive chain tension and alignment. Tension or align as required. 4. Check that all guards are installed and working as intended. 5. Check that the PTO and driveline shields turn freely. 6. Check condition of driveline, elevator and auger bearings. 7. Check the gathering augers and elevator for entangled material. Remove any entangled material. 8. Check oil level in gearboxes. Top up as required. 9. Lubricate all grease fittings. C. After operating for 5 hours and 10 hours: 1. Repeat items 1 through 9 above. 2. Then go to the normal servicing and maintenance schedule as defined in the Maintenance Section. 4.4 PRE-OPERATION CHECKLIST Efficient and safe operation of the Neeralta Extractor requires that each operator reads and understands the operating procedures and all related safety precautions outlined in this section. A pre-operation checklist is provided for the operator. It is important for both the personal safety and maintaining the good mechanical condition of the Extractor that this checklist is followed. Before operating the Extractor and each time thereafter, the following areas should be checked off: 1. Service the machine per the schedule outlined in Section 5 Service and Maintenance. 2. Use only a tractor that provides oil at the required pressure and flow to operate the machine. Extractor needs 2 outlets with 105 lpm (28 gpm) at 2500 psi (12,500 kpa). 3. Check that all guards are installed, secured and functioning as intended. Do not operate with missing or damaged shields. 4. Check worksite. Clean up working area to prevent slipping or tripping. 5. Check the pick-up head. Remove any twine, plastic or other material that has become entangled. 6. Check that all bearings turn freely. Replace any that are rough or seized. 7. Check for hydraulic leaks. Tighten any leaking fittings. 8. Check that the PTO and driveline shields turn freely and that the driveline can telescope easily. 9. Check oil level in gearboxes. Top up as required. 20

29 4.5 CONTROLS Before starting to operate the Extractor, all operators should review this section to familiarize themselves with the location and function of the controls. Each machine is designed with a set of hydraulic valves on the machine and a wireless remote that is functional within 100 m (305 feet) of the machine. The remote controls operational parameters but not set-up. 1. Hydraulic Control Bank: a b c d e f g a. Discharge Auger Extend/Fold: This 3 position spring-loaded to center-neutral controls the position of the discharge auger. Push the lever forward and hold to move/extend the auger into its working/ unloading position. Pull and hold the lever to retract/fold the auger into its storage or transport configuration. Release the lever and it will return to its neutral position and the auger will stop moving. This function is not available on the remote. FIG. 2 a CONTROLS b c d e f g b. Bag Wind-Up: This 3 position spring-loaded to center-neutral lever controls the bag roll-up function. Pull and hold to gather and roll-up the bag. Push and hold to unroll the bag. Release the lever and it will return to its centered neutral position and the bag roll-up components will stop moving. c. Machine Drive: This 3 position spring-loaded to centerneutral controls the operation of the machine drive wheels. Push and hold the lever to move the machine into the bag. Pull and hold to move the machine out of the bag. Release the lever and it will return to its centered neutral position and the machine will stop moving. d. Configuration: This 3 position spring-loaded to center-neutral lever controls the position/configuration of the frame. Pull and hold the lever to tilt the frame forward into its storage and transport configuration. Push and hold to tilt the frame back into its working configuration. Release the lever and it will return to its centered neutral position and the frame will stop moving. This function is not available on the remote. e. Auger Lift/Lower: This 3 position spring-loaded to center-neutral lever controls the height of the discharge auger. Pull and hold the lever to raise the discharge auger. Push and hold to lower the discharge auger. Release the lever and it will return to its centered neutral position and the discharge auger will stop moving. f. Bag Drop: This 3 position spring-loaded to center-neutral lever controls the position of the sides of the bag roll up spool. Push and hold to move the sides into their roll-up configuration. Pull and hold to move the sides out when releasing the rolled up bag. Release the lever and the sides will stop moving. This function is not available on the remote. g. Elevator Position/Height: This 3 position spring-loaded to centerneutral lever controls the height/position of the elevator and gathering auger assembly. Pull and hold the lever to raise the assembly. Push and hold to lower the assembly. Release the lever and it will return to its centered neutral position and the elevator assembly will stop moving. 21

30 2. Remote Control: a. Remote Off: This red push button switch turns the remote control off. Depress the button to turn the remote off. Always turn the remote off when not in use to conserve the batteries. b. Remote On: This green push button switch turns the remote control on. Depress the button to turn the remote on. c. Bag Winding Forward: This 2 position spring-loaded to neutral push button switch controls the bag take-up spool system in the forward direction. Depress the button and hold down to run the bag take-up system in the forward direction. Release the button and the take-up system will stop. d. Bag Winding Reverse: This 2 position spring-loaded to neutral push button switch controls the bag takeup system in the reverse direction. Depress and hold to run the bag take-up in the reverse direction. Release the button and the take-up system will stop. a c e g i k b d f h j l e. Drive Wheels Forward: This push button latching switch controls the wheel drive system for moving into the bag. Depress the button to engage the latching switch and engage the wheel drive system moving the machine into the bag. Depress the switch again to release the latch and disengage the wheel drive system moving the machine into the bag. The machine will stop moving. Always disengage the drive before starting to move in the reverse direction. f. Drive Wheel Reverse: This push button switch controls the wheel drive system for moving out of the bag. Depress the button and hold to engage the wheel drive system moving the machine out of the bag. Depress and hold the switch again to disengage the wheel drive system moving the machine out of the bag. The machine will stop moving. Always disengage the drive before starting to move in the opposite direction. fig. 3 REMOTE CONTROL 22

31 g. Elevator Raise: This 2 position spring-loaded to neutral push button switch raises the height of the elevator. Depress and hold the switch to raise the elevator. Release the switch and the elevator will stop moving. h. Elevator Lower: This 2 position spring-loaded to neutral push button switch lowers the height of the elevator. Depress and hold the switch to lower the elevator. Release the switch and the elevator will stop moving. i. Unloading Auger Raise: This 2 position spring-loaded to neutral push button switch raises the height of the discharge/unloading auger. Depress and hold the switch to raise the discharge/unloading auger. Release the switch and the discharge/unloading auger will stop moving. j. Unloading Auger Lower: This 2 position spring-loaded to neutral push button switch lowers the height of the discharge/unloading auger. Depress and hold the switch to lower the discharge/unloading auger. Release the switch and the discharge/unloading auger will stop moving. k. Spout Position Left: This 2 position spring-loaded to neutral push button switch controls the movement of the spout on the end of the unloading auger moving to the left. Depress and hold the switch to move the spout to the left. Release the switch and the spout will stop moving. NOTE The wiring harness must be plugged in and power provided to the Extractor for any remote function to work. Only the electric actuator on the spout can't be operated manually. l. Spout position Right: This 2 position spring-loaded to neutral push button switch controls the movement of the spout on the end of the unloading auger moving to the right. Depress and hold the switch to move the spout to the right. Release the switch and the spout will stop moving. 23

32 3. Hydraulic System On/Off: The hydraulic system flow divider valve on the front handhold of the stile. This flow divider is used to turn the flow on to the elevator and set the operating speed. Move the dial to its vertical '0' position to stop the elevator. Move the pointer toward '10' to increase the operating speed to its maximum. Set the dial to provide the elevator speed appropriate for the application. fig. 4 HYDRAULIC SYSTEM ON/OFF 24

33 4.6 ATTACHING/UNHOOKING The Extractor uses a tractor for operation and at times for moving or transporting. A truck can be used for transporting from location to location TRACTOR When attaching the machine to a tractor, follow this procedure: 1. Clear the area of bystanders, especially small children. 2. Make sure there is enough room and clearance to safely back up to the machine RPM 16 INCHES (410 MM) 3. While backing up, align the hitch and drawbar. 4. Be sure the drawbar dimension is set at 16 inches (410 mm) between the end of the tractor PTO shaft and the center of the drawbar pin. 5. Stop tractor, set park brake, remove ignition key and wait for all moving parts to stop before dismounting. FIG. 5 DRAWBAR DIMENSION 6. Use a drawbar pin with provisions for a mechanical retainer. Install the retainer. Aligning FIG. 6 DRAWBAR PIN Pin/Retainer 25

34 7. Connect the wiring harness to the tractor to provide power to the machine. Be sure to secure to the hitch and provide sufficient slack for turning. FIG. 7 WIRING HARNESS 8. Connect the Hydraulic System: a. Use a clean cloth or paper towel to clean the dirt and build-up from around the couplers and male tips. NOTE Always connect the hoses to the circuit on the tractor that is equipped with a detent. The circuit must be placed in detent to continuously provide oil to the extractor. b. Insert the male tips into the couplers. Make sure they are locked in place. Circuit 1 NOTE The pressure side hose is equipped with a plastic tie. Install the pressure hose into the pressure side of the outlets. c. Route the hoses along the hitch and secure in place with clips, tape or tie wraps. Be sure they do not drop to the ground or get pinched when turning. Provide sufficient slack for turning. Circuit 2 fig. 8 HYDRAULIC HOSES 26

35 9. Attach the PTO Driveline: a. Release the tie-down strap over the yoke and remove yoke from storage bolt. b. Check the driveline telescopes easily and the shield rotates freely. Stowed c. Attach the driveline to the tractor by depressing the lock pin, slide the yoke over the shaft and push on the yoke until the lock pin clicks into position. Pull on the yoke to be sure it is locked in position. d. Attach the guard anchor chain to an adjacent frame component. 10. Unpin, rotate and re-pin jack. 11. Attach the safety chain around the drawbar cage to prevent unexpected separation. Attached FIG. 9 DRIVELINE 12. Reverse the above procedure when unhooking from tractor. fig. 10 ATTACHED 27

36 4.6.2 TRUCK When attaching the machine to a truck, follow this procedure: 1. Clear the area of bystanders, especially small children. 2. Make sure there is enough room and clearance to safely back up to the machine. 3. Slowly back the truck until the hitch is aligned. IMPORTANT Only use a 1 ton truck or larger to transport the machine on a public road. fig. 11 Aligned a. Install the drawbar pin through the hitch. b. Install the retainer through the drawbar pin. fig. 12 drawbar PIN/reTAINer 4 Retract the jack. 6. Pull anchor pin on jack and rotate to its storage position. Re-pin. fig. 13 jack 28

37 7. Cross the safety chains under the hitch when attaching to support the hitch in the event of failure and to prevent unexpected separation. fig. 14 SAFETY CHAIN 10. Connect the wiring harness to the tractor if transporting on a public road. Be sure to secure to the hitch and provide sufficient slack when turning. Adaptor Installed fig. 15 WIRING HARNESS 12. Reverse the above procedure when unhooking from tractor. 29

38 4.7 EXTRACTOR ENTERING BAG The most important aspect of operating the Extractor is preparing the machine and starting it into the bag. When properly set, the Extractor removes the material from the bag with minimal problems. Follow this procedure when entering the bag: 1. Clear the area of bystanders, especially small children. 2. Move tractor and extractor up to the bag. 3. Align the elevator with the center of the bag. fig. 16 ALIGNING 30

39 4. Convert machine into its working configuration: a. Tilt frame back until elevator is about 300 mm (12 inches) above the ground. b. Set the length of the frame support chain to carry the frame weight when in working configuration (frame vertical). c. Adjust the chain link position to keep the chain tight. Transport Elevator Down d. Extend the unloading auger. IMPORTANT Stay away from overhead power lines when extending auger to prevent electrocution. Discharge Extending fig. 17 CONVERTING Extended 31

40 5. Move bag cutting knife into its working position and secure with anchor pin and retainer. fig. 18 KNIFE 6. Open the bag: a. Remove all the snow and ice from the top of the bag. Snow Removal b. Roll out the 2 X 4's used to close the end of the bag. 2 x 4's Positioned FIG. 19 PREPARING BAG 32

41 c. Cut along the 'bag side' of the 2 X 4's and lay to the side out of the way so they do not interfere with the operation. Cutting d. Cut the top center of the bag about 1/3rd of the way up to the top of the bag. e. Pull each side of the bag to the side to expose the grain. Top Center Cut f. Cut the bottom of the bag in the center to allow for the bag to be gathered into 2 bundles. Bottom Center Cut g. Separate each side. fig. 20 CUTTING BAG Folding Back 33

42 7. Move Extractor into bag: a. Pull each side of the bag away from the center line. b. Start the tractor and place the hydraulic circuit into its detent position. Opening Bag c. Use the valve on the control bank to move the machine into the bag. Machine Position d. Raise or lower the elevator as required to clear the bag. Into Bag Forward FIG. 21 POSITIONING THE MACHINE 34

43 e. Lower the elevator when in the grain until it is 200 mm (8 inches) above the bottom of the bag. Into Grain f. Pull the sides of the bag out and around the gathering augers and elevator. Under Bag fig. 22 MOVING EXTRACTOR INTO BAG 35

44 8. Attach bag to roll-up rope: a. Cut a 6.5 m (20 foot) piece of 9 mm (3/8 inch) rope or (a multi-strand piece of baling twine) will work. Rope b. Lay rope over the elevator with equal lengths on each side. c. Gather the outer edges of the bag into a roll. Bag End d. Route the end of the rope around the end of the rolled up bag. Left Side e. Tie a tight knot around the end of the bag on both sides of the elevator. Right Side FIG. 23 ROPE TO BAG ENDS 36

45 9. Attach rope to Extractor spool: a. Lift the center of the rope up to the spool. Pull Rope Up b. Loop the rope over the spool anchor rod to hold it in place. Rope Anchored c. Run the bag rolling system to slowly pull the bag up as the grain is removed from the bag. Run the elevator and gathering augers. Starting to Wind 10. The machine has now been attached to the bag and the grain removal process has been started. Refer to Section 4.8 for operational information. Winding FIG. 24 ATTACHING ROPE 37

46 4.8 OPERATING Make sure that anyone who will be operating the Extractor or working on or around the unit reads and understands all the operating, maintenance and safety information in the operator's manual. Also read and follow the instructions in the manuals of other equipment in the system. OPERATING SAFETY Do not enter bag or approach augers unless the hydraulic hoses have been disconnected and stowed. Keep hands, feet, hair and clothing away from rotating flighting, elevator, swing auger and moving parts. Keep others away. Keep all bystanders, especially children, away from the machine when loading or unloading is being done, or when authorized personnel are carrying out maintenance work. Establish a lock-out tag-out policy for the work site. Be sure all personnel are trained in and follow all procedures. Lock-out tag-out all power sources before servicing the unit or working around loading/unloading equipment. Lower machine to ground, place all controls in neutral or off, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. Keep working area clean and free of debris to prevent slipping or tripping. Stay 50 feet (15 m) away from power lines. Electrocution can occur without direct contact. Install and secure all guards before starting. Keep all hydraulic components in good condition before operating. Fold unloading auger completely, rest in the support cradle and tilt frame fully forward before storing or transporting. Clean all lights and reflectors before transporting. Be sure all lights are working. Review safety related items annually with all personnel who will operating, using or maintaining the Extractor. When using the Extractor, follow this procedure: 1. Clear the area of bystanders, especially small children, before starting. 2. Review the Pre-Operation Checklist (Section 4.4) before starting. 3. Keep all spectators and bystanders out of the working and machine area. Should anyone enter this area, stop immediately. 4. Prepare the machine per Section Check that the machine is positioned per Section 4.7 and the bag ends have been tied up and attached to the wind-up spool on the Extractor. FIG. 25 BAG ENDS 38

47 6. Drive truck under auger discharge and set brakes. FIG. 26 TRUCK 7. Starting: a. Start the tractor and run at low idle. b. Place the hydraulic circuit in detent. Engage the PTO. IMPORTANT Do not set park brake on tractor or leave the transmission in gear. The Extractor must be able to move both the machine and the tractor into the bag during operation. Setting the park brake on the tractor will prevent this. c. Increase the engine RPM to mid-range. d. Move the flow control on the front stand to its on (10) position. e. Use the flow control to set the speed of the elevator and gathering augers. Do not exceed the loading capacity of the system FIG. 27 FLOW CONTROL 39

48 f. Use the bank of hydraulic valves or the remote to operate the machine. IMPORTANT It is recommended that 2 people be involved when operating the Extractor. One person at the controls or remote to operate machine and the truck driver in the tractor cab to monitor the operation. The truck driver is then available to shut everything down if required. Valve Bank Remote fig. 28 MACHINE CONTROLS 40

49 9. Stopping: a. Stop the drive wheels. b. Run until the pick-up assembly is empty. c. Run until the discharge auger is empty. d. Slow engine RPM to low idle. e. Move the flow control into its OFF or '0' position to turn elevator OFF. f. Place hydraulic circuit and PTO in neutral and stop engine. FIG. 29 STOPPING 10. Emergency Stopping: Although all the augers and elevator should be emptied before shutting down, in an emergency situation shut down all power and power units immediately. Correct the emergency before resuming work. 11. Restarting (Unit Full): When the machine is shut down inadvertently or for an emergency, the augers and pick-up assembly will still be full of grain or material. When restarting, the starting loads will be higher than normal. When restarting, follow this procedure: a. Start the tractor and place the hydraulic lever in detent. b. Set the engine RPM to low idle. c. Engage the PTO to start the unloading auger and empty the unloading system. d. Increase engine speed to 3/4 throttle position and completely empty the augers. e. Use the flow control valve to start the elevator and gathering augers. NOTE Reverse the elevator if required to expel some of the grain out of the intake components to reduce the starting loads. 41

50 12. Starting Bag: The most critical part of bag extracting operation is the starting phase. The Extractor must move into the bag and remove the grain while pulling the bag up and winding it around the take-up spool on the top of the frame. Monitor the following items when starting the bag: a. Be sure both sides of the bag are being evenly pulled on to top winding spool. b. Push on bottom of bag if required to push grain into augers and elevator for removal. Bag Ends Bottom of Bag c. Stop winding bag if there is too much grain in bottom of bag and a chance of bag to tear. Bag Winding d. Keep bag tight to move grain into gathering augers and elevator. 13. Operator Responsibility: It is the operator's responsibility to monitor the operation of the Extractor and set it to provide maximum performance: Operating Wind up the bag to move grain into the elevator and gathering augers. Move the machine into the bag as required to keep the elevator and gathering augers covered and full of grain. FIG. 30 STARTING BAG Bag 42

51 14. Operating Speed: The operating speed is determined by the PTO speed and the flow divider setting. a. PTO Speed: It is recommended that the PTO be operated at a speed of about 300 RPM or mid-range engine speed. This speed will provide adequate power for the unloading auger and sufficient flow for the hydraulic system. Loading b. Flow Divider: The flow divider on the front of the frame sets the amount of oil flowing through the elevator/gathering augers hydraulic motor. Set it to keep the unloading auger intake hopper full at all times. This will provide maximum capacity for the system. Hopper Full fig. 31 OPERATING SPEED 15. Unloading Auger Height: The unloading auger is designed with a cylinder for raising and lowering it to set the height. This feature is used to assist in positioning the discharge in the center of the truck box. Place in a low position when it is windy to minimize the chance of grain being blown away. High Low fig. 32 AUGER POSITION 43

52 16. Discharge Spout: The spout on the end of the unloading auger is equipped with an electric actuator for moving it from side-to-side to assist in distributing the grain in the truck box. NOTE The wiring harness must be plugged into the tractor for the spout to have power and move. Left Right fig. 33 DISCHARGE SPOUT 17. Bag Wrapper Spool: The Extractor is designed with a take-up spool on the top of the frame. It is large enough to accept the largest bags in use today. FIG. 34 SPOOL 18. Bag Cutter: The Extractor is equipped with a knife on the bottom of the elevator to cut the bag as it is emptied of grain and gathered on the spool. The knife must be sharp to cut the bag as it moves up on the spool. FIG. 35 KNIFE 44

53 19. End Of Bag: Move the elevator and gathering augers into the end of the bag to pick-up most of the material. Lift the last portion of the bag to move the grain into the elevator. A bag with a square end works best. 20. Bag Position Sensor: Some extractor models are designed with a system that senses the position of the bag in relationship to the elevator. If the unit is equipped with a sensor system, it is designed to set the control system where the machine will move into the bag automatically or where it is moved manually by the operator. The position arm senses the position of the bag and through the linkage, moves the selector valve for manual or automatic operation. Select the mode of operation best suited for your application. a. Manual operation. FIG. 36 END OF BAG d a c Automatic Operation b. Automatic operation. c. Selector valve. b c d Manual Operation d. Position arm. d Position Arm FIG. 37 POSITION SENSOR SYSTEM 45

54 21. Unplugging: Although the Extractor is designed with a large capacity, in unusual circumstances, it can plug. Follow this procedure when unplugging: a. Stop moving into bag and let machine clear itself. If the plug doesn't clear itself? b. Stop moving into the bag and reverse the elevator to expel the plug. Then set for normal operation. If the plug doesn't clear? Elevator c. Raise the elevator slightly to allow the gathering augers to clear the bottom of the bag. Reverse the elevator to clear plug. If plug doesn't clear? d. Open the sliding access door on the bottom of the unloading auger tube (for unloading auger plugging only). If the plug doesn't clear? Sliding Access Door e. Stop Extractor and tractor. Cut a vertical slit in the bag and use a shovel to move grain away from the intake. FIG. 38 UNPLUGGING Shovel 46

55 22. Shear Bolts: The Extractor is designed with a shear pin in the input and tractor yokes to prevent overloading any drive components. Always correct the problem after the shear pin is replaced and before resuming work. Input Yoke fig. 39 SHEAR BOLTS Tractor Yoke 47

56 23. Bag Spool Removal: When the bag has been emptied and it has been wound on the spool, it must be removed. Follow this procedure when removing bag: a. Clear the area of bystanders, especially small children. b. Move machine into an open area where a truck or trailer can be positioned under the elevator for hauling away. c. Tie up the bag on the spool. Cut a 6 to 12 m (20 to 40 foot) piece of rope or heavy twine to secure bag. End of Bag Use a knife to poke a hole in the tail of the bag on the spool. Hole Tie the end of the rope/twine through the hole. Rope Attached Turn the spool to wrap the rope/twine around the bag. Wrapping FIG. 40 BAG SPOOL REMOVAL 48

57 Tie the end of the rope to another rope on bag to secure. More Wrapping fig. 41 TIE UP BAG Tied 49

58 d. Prepare to release bag: Pull the pins on the bag guide rails and lower them on each side. Rails Rails Released Raise the elevator to its highest position. Elevator Raised Release the wedge locks on each side of the spool. Use a hammer to drive them upward and release the sides. Wedge - Left Wedge - Right FIG. 42 PREPARING TO RELEASE 50

59 e. Releasing bag: Raise the elevator as high as it can go. Raised Elevator Retract the spool drivers to release the rolled up bag. Retract Drivers (Typical) Lower the elevator. Lower Elevator Let the bag roll down the elevator. NOTE A truck or other transport vehicle can be positioned at the end of the elevator to allow the bag to roll on the vehicle. Released Bail Flip the rails up and pin in position. Rails Up and Pinned FIG. 43 RELEASING BAG 51

60 24. Operating hints: a. Use the flow control on the front frame to turn the oil on to the elevator drive system. Move to '0' to stop and '10' for maximum speed. FIG. 44 FLOW CONTROL b. Center the truck under the spout when loading for the best results. FIG. 45 TRUCK c. Stay away from overhead power lines when extending or folding the unloading auger to prevent electrocution. Extend unloading auger when machine is in working configuration only. FIG. 46 UNLOADING AUGER 52

61 d. Raise the elevator and use it as a guide to roll the bag out of the wrapping spool assembly. Do not allow unauthorized bystanders in the area when removing the roll. FIG. 47 RAISED ELEVATOR e. Always attach frame anchor chain to support frame in its operating configuration and relieve the load on the hydraulic cylinder. FIG. 48 FRAME ANCHOR CHAIN f. Extend and fold the discharge auger ONLY when the frame is in the working configuration to prevent interference with other frame components. FIG. 49 EXTENDING/FOLDING 53

62 4.9 STORAGE STORAGE SAFETY Store the unit in an area away from human activity. Do not permit children to play on or around the stored machine. Store the unit in a dry, level area. Support the frame with planks if required. After the season's use, the machine should be thoroughly inspected and prepared for storage. Repair or replace any worn or damaged components to prevent any unnecessary down time at the start of next season. To insure a long, trouble free life, this procedure should be followed when preparing the unit for storage: 1. Clear the area of bystanders, especially small children. 2. Remove all residual material from the elevator, gathering augers and the unloading auger. 3. Thoroughly wash the entire machine using a pressure washer to remove all dirt, mud, debris or residue. 4. Inspect all moving or rotating parts to see if anything has become entangled in them. Remove the entangled material. 5. Lubricate all grease fittings to remove any moisture in the bearings. 6. Run the machine slowly for 1 minute to distribute lubricant to all surfaces. 7. Fully fold the frame into its transport/storage configuration. 8. Touch up all paint nicks and scratches to prevent rusting. 9. Select an area that is dry, level and free of debris. FIG. 50 STORAGE 10. Store machine inside if possible. 11. Do not allow children to play on or around the stored machine. 12. Unhook from tractor or truck (See sections or respectively). 54

63 4.10 TRANSPORTING TRANSPORT SAFETY 1. Comply with state and local laws governing safety and transporting of farm machinery on public roads. 2. Check that all the lights, reflectors and other lighting requirements are installed and in good working condition. 3. Do not exceed a safe travel speed. Slow down for rough terrain and when cornering. 6. Be sure that the machine is hitched positively to the towing vehicle and a retainer is used through the drawbar pin. Always attach a safety chain between the hitch and the towing vehicle. 7. Stay away from overhead power lines. Electrocution can occur without direct contact. 8. Plan your route to avoid heavy traffic. 4. Fold unloading auger completely, rest in the support cradle and tilt frame fully forward before storing or transporting. 5. Clean all lights and reflectors before transporting. Be sure all lights are working. 9. Do not drink and drive. 10. Be a safe and courteous driver. Always yield to oncoming traffic in all situations, including narrow bridges, intersections, etc. Watch for traffic when operating near or crossing roadways. 11. Never allow riders on the hitch or frame when transporting. Neeralta Extractors are designed to be easily and conveniently moved from location to location. When transporting, follow this procedure: 1. Clear the area of bystanders, especially small children before starting. 2. Be sure the Extractor is hitched securely to the tractor or truck. Always use a safety chain between the machine and the tow vehicle and a retainer on the drawbar pin. 3. Keep to the right and yield the right-of-way to allow faster traffic to pass. Drive on the shoulder if permitted by law. Folding 4. Make sure all the lights and reflectors required by local highway and transport authorities are in place, clean, in good working order and clearly visible to all overtaking and on-coming traffic. 5. Fold the discharge auger and rest into its transport/storage bracket when the frame is in its working configuration. FIG. 50 Transport TRANSPORT CONFIGURATION 55

64 6. Do not allow riders on the machine or tractor. 7. Always use a 3/4 ton or larger truck to provide sufficient control when transporting. Truck Tractor FIG. 52 TRANSPORTING 56

65 5 SERVICE AND MAINTENANCE MAINTENANCE SAFETY Good maintenance is your responsibility. Poor maintenance is an invitation to trouble. Follow good shop practices. - Keep service area clean and dry. - Be sure electrical outlets and tools are properly grounded. - Use adequate light for the job at hand. Make sure there is plenty of ventilation. Never operate the engine in a closed building. The exhaust fumes may cause asphyxiation. Before working on this machine, shut off the engine, and remove the ignition keys. Never work under equipment unless it is blocked securely. Always use personal protection devices such as eye, hand and hearing protectors, when performing any service or maintenance. Where replacement parts are necessary for periodic maintenance and servicing, genuine factory replacement parts must be used to restore your equipment to original specifications. The manufacturer will not be responsible for injuries or damages caused by use of unapproved parts and/or accessories. A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this equipment. Periodically tighten all bolts, nuts and screws and check that all cotter pins are properly installed to ensure unit is in a safe condition. 5.1 SERVICE FLUIDS AND LUBRICANTS 1. Grease: Use an SAE multi-purpose high temperature grease with extreme pressure (EP) performance. Also acceptable is an SAE multi-purpose lithium based grease. 2. Gearbox Oil: Use an SAE 85W90 multi-viscosity oil meeting the American Petroleum Institute (API) classification of SF, SG, SH or SJ for normal operating temperatures. Gear Box Capacity: 1 US qt (1 litre). 3. Storing Lubricants: Your machine can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants GREASING Use the Maintenance Checklist provided to keep a record of all scheduled maintenance. 1. Use a hand-held grease gun for all greasing. 2. Wipe grease fitting with a clean cloth before greasing, to avoid injecting dirt and grit. 3. Replace and repair broken fittings immediately. 4. If fittings will not take grease, remove and clean thoroughly. Also clean lubricant passageway. Replace fitting if necessary. When completing a maintenance or service function, make sure all safety shields and devices are installed before placing unit in service. 57

66 5.1.3 SERVICING INTERVALS The period recommended is based on normal operating conditions. Severe or unusual conditions may require more frequent lubrication or oil changes. 30 Hours 1. Grease PTO drivelines. a. PTO Driveline (Primary). b. Input Driveline. Schematic b a FIG. 53 DRIVELINES Machine 58

67 60 Hours 1. Grease the telescoping section of the PTO and secondary shafts. FIG. 54 TELESCOPING SECTION (TYPICAL) 2. Grease bearings with one shot of grease. a. Input jackshaft. FIG. 55 INPUT JACKSHAFT b. Grease input shaft. FIG. 57 INPUT SHAFT FIG. 58 PTO DRIVELINE LUBRICATION 59

68 c. Chain gearbox bearings. Top Bottom FIG. 59 CHAIN GEARBOX BEARINGS 60

69 d. Unloading auger. Bottom. Bottom Center. Center Top. Top FIG. 60 UNLOADING AUGER 61

70 e. Top elevator bearings. Left Right FIG. 61 TOP ELEVATOR BEARINGS f. Bottom elevator bearings. FIG. 62 BOTTOM ELEVATOR BEARINGS 3. Check drive chain tension. 4. Lubricate drive chain. FIG. 63 DRIVE CHAIN TENSION 62

71 100 Hours 1. Lubricate winder roller bushings with 1 shot of grease. Left Right FIG. 64 WINDER ROLLER BUSHINGS (TYPICAL) 2. Lubricate unloading auger hinge bushing with 1 shot of grease. FIG. 65 AUGER HINGE BUSHING 3. Lubricate frame pivot bushings with 1 shot of grease. FIG. 66 FRAME PIVOTS 63

72 4. Check oil level in speed reducer gearboxes. Wheel Drive Winder Roller Drive FIG. 67 SPEED REDUCER GEARBOXES (TYPICAL) 64

73 Annually 1. Lubricate cylinder pins and bushings with 1 shot of grease at the beginning and end of the season. a. Elevator height. b. Auger height. c. Auger fold/extend. d. Frame position. Elevator Right Side FIG. 68 CYLINDER ENDS 65

74 2. Lubricate roller chain in gearbox on drive couplers. Gearbox Elevator Drive FIG. 69 ROLLER CHAIN Unloading Auger Drive 3. Clean machine annually. FIG. 70 MACHINE 66

75 Every Two Years 1. Change oil in speed reducer gearboxes. NOTE Oil in gearboxes is treated with Power Up. Wheel Drives Winder Roller Drive FIG. 71 GEARBOXES (TYPICAL) 67

76 5.1.4 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE LU GREASE CL CLEAN CK CHECK CH CHANGE Hours Serviced by 30 Hours LU PTO Drivelines 60 Hours LU PTO Telescoping Section and Secondary Shafts LU Bearings CK Drive Chain Tension LU Drive Chain 100 Hours LU Winder Roller Bushings LU Unloading Auger Hinge Bushing LU Frame Pivot Bushings CK Oil Level Speed Reducer Gearbox Annually LU Cylinder Pins and Bushings LU Roller Chain in Gearbox Drive Couplers CL Machine Every Two Years CH Speed Reducer Gearboxes 68

77 5.2 MAINTENANCE By following a careful service and maintenance program for your machine, you will enjoy many years and trouble-free operation DRIVELINE MAINTENANCE The PTO driveline is designed to telescope to allow for dimensional changes as the machine goes through its operational range. A tubular guard encloses the driving components and is designed to turn relative to the driving components. The driveline should telescope easily and the guard turn freely on the shaft at all times. Annual disassembly, cleaning and lubrication is recommended to insure that all components function as intended. To maintain the driveline, follow this procedure: Anchor Screws 1. Stop engine, lower machine to ground, place all controls in neutral, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 2. Remove the driveline(s) from the machine. 3. Pull driveline(s) apart. Disassembled 4. Use a screwdriver to remove 3 tabs holding tube to bell. 5. Pull the shaft out of the plastic tubular guard. 6. Use a solvent to clean the male and female portions of the telescoping ends. 7. Apply a light coat of grease to each end. 8. Use a solvent to wash the grooves on each end where the tabs are located. Clean each end also. 9. Apply a light coat of grease to each groove. PTO Driveline (Typical) FIG. 72 DRIVELINES (TYPICAL) 10. Insert the shaft into its respective guard and align. 11. Install and engage the anchor tabs. 12. Check that each guard turns freely on bearings and its shaft. 13. Reassemble the driveline. 14. Check that the driveline telescopes easily. 15. Replace any components that are damaged or worn. 16. Reinstall the driveline on the machine. 69

78 5.2.2 SHEAR BOLT Shear bolts are provided at the yoke to the tractor and the chain gearbox to protect the drive system during an overload. To change the shear bolts, follow this procedure: 1. Clear the area of bystanders, especially small children. 2. Place all controls in neutral or off, stop engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing, or unplugging. Input Yoke 3. Disconnect driveline if the shaft can't be turned by hand. 4. Turn PTO shaft by hand to locate and align the shear bolt holes. 5. Carefully remove remaining shear bolts using hammer and drift if necessary. Be careful not to enlarge the hole. NOTE Inspect shear bolt mounting components to verify that the holes are not enlarged. If deformed in any way, replace yoke. Tractor Yoke fig. 73 SHEAR BOLTS (TYPICAL) 6. Install the new shear bolts and tighten to their specified torque. Do not over-tighten. IMPORTANT All shear bolts must be 3/8" x 1 1/2" Grade 5 to provide the required protection. Always use a locknut or double nut on the bolts to insure the required clamping force is maintained across the shear plane in the yoke. Always check the integrity of the shear bolt holes when replacing bolts. When holes are enlarged, replace yoke. 7. Reconnect driveline. 70

79 5.2.3 DRIVE CHAIN TENSION AND ALIGNMENT A chain in the gearbox transmits rotational power to the unloading auger It must be kept properly tensioned and the sprockets aligned to obtain the expected performance and life. To check the tension and alignment, follow this procedure: 1. Clear the area of bystanders, especially small children. 2. Turn machine off, stop engine, remove ignition key and place in pocket and wait for all moving parts to stop. 3. Open access door on gearbox. Idler 4. The chain should have +/- 1/8 inch (3 mm) of play to be properly tensioned. 5. To adjust chain tension: a. Loosen idler mounting bolts. b. Move the idler to the required position to set chain tension. c. Set sprocket alignment. d. Tighten mounting bolt to its specified torque. 6. To replace chain: a. Move idler to its loosest position. b. Replace chain. c. Set sprocket alignment. d. Tighten idler mounting bolt to its specified torque. e. Check frequently during the first ten hours and set chain tension as required. 7. Sight across the sprocket faces to check alignment. Adjust alignment if sprocket faces vary more than 1/32 inch (.7 mm). fig. 74 Alignment CHAIN DRIVE SYSTEM 71