OPERATOR S MANUAL & PARTS LIST (SEE SEPARATE MANUAL FOR SEEDER CALIBRATION)

Transcription

1 OPERATOR S MANUAL & PARTS LIST (SEE SEPARATE MANUAL FOR SEEDER CALIBRATION) AERA-vator MODEL AE-60FT FIRST PRODUCTS INC. 164 Oakridge Road Tifton, Georgia U.S.A. Phone (229) Fax (229) Web: Sales@1stproducts.com Ser. 101 thru Printed in U.S.A.

2 INTRODUCTION Thank you for purchasing a Multi-tine Aera-vator. This piece of equipment has been carefully engineered and manufactured to provide years of reliable service. This machine is one of the most unique and versatile pieces of equipment on the market today. It is designed for preparing optimum seedbeds in existing and bare turf. We recommend that you carefully read the owners and operators manual prior to operation. Also ensure that all future operators read this manual and become fully trained before allowing them to use or maintain this equipment. Time spent becoming acquainted with the safe operation, performance, and maintenance of the Multi-tine will add longer life and greater satisfaction to your new purchase. This machine is designed with safety in mind. However, if the machine is handled carelessly and not as instructed it can be a dangerous piece of equipment. Observe all safety information in this manual and decals on the equipment. The illustrations and data used in the manual were current at the time of printing. The manufacturer reserves the right to make changes or add improvements to its products at any time without incurring any obligation to make such changes to products manufactured previously. REMEMBER SAFETY IS ALWAYS FIRST! ATTENTION: Read and understand the instructions and warnings carefully before using this machine. Read the warranty located on page 19. Fill in the required information on the warranty registration provided and return to the address on the front of this manual. The warranty registration must be returned to validate warranty. 1

3 TABLE OF CONTENTS SAFETY SYMBOLS...3 SAFETY DECALS...4 OPERATION SAFETY...5 OPERATOR INSTRUCTIONS - General...6 How The Swing Hitch Operates (Prior To Hitching To Tractor)...6 Roller Positions...7 Transporting The Unit...7 From Lift Position To Operating...8 From Operating To Lift Position...8 Do Not Operate In Reverse...8 Roller Scraper Usage...8 Trial Run...8 OPERATOR INSTRUCTIONS Seeder...9 Seed Flow Control...9 Emptying The Hopper...10 Unclogging Seed Tubes...10 PRE-OPERATION CHECK LIST...10 MAINTENANCE SAFETY...10 ROUTINE MAINTENANCE...10 ROTOR SHAFT SERVICE INSTRUCTIONS...12 Rotor Shaft Removal (Figure 4)...12 Rotor Shaft Disassembly (Figure 5)...12 Rotor Hub Disassembly (Figure 6)...13 Rotor Hub Re-Assembly (Figure 7)...13 Rotor Shaft Re-Assembly...15 Rotor Shaft Installation...16 Tine Shell Replacement...17 WARRANTY INFORMATION...19 AE 60MT HITCH...21 MT HITCH parts list...22 AE 60MT MAIN FRAME...23 MAIN FRAME parts list...24 AE 60MT ROTOR SHAFT...25 AE 60MT IDLER ASSEMBLY...26 AE 60MT DOFFER ROLLER...27 DRIVE LINE parts list...28 SEEDER HOPPER MOUNTING...29 WIRING HARNESS...30 SEEDER HOPPER...31 SEEDER HOPPER parts list

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

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

7 OPERATOR INSTRUCTIONS - General The Multi-tine Aera-vator is designed to attach to a tractor with a category one three point hitch, 540 PTO, and a minimum of 30 horsepower. However, the tractor must have a Lift capacity of 1950 lbs. at a distance of 24 to the rear of the lower Lift points to handle the unit loaded with 6.7 cu. MT. of 40#/cu. MT. seed. Before hitching to the unit familiarize yourself with all of the tractors control functions. Be prepared to stop the tractor movement, PTO operation, and the engine quickly in an emergency. How The Swing Hitch Operates (Prior To Hitching To Tractor) With the parking stands lowered and the swing mast rearward to disengage the swing lock, grasp the hitch pins and rotate the A frame to simulate operation in a sharp turn. Release the hitch pins and slowly pull the swing mast forward as it would be pulled by the top link during Lifting. Notice how one mast chain tightens causing the A frame and unit to realign as the compressed lock link spring engages the swing lock. Now push the swing mast rearward against the lock link tab to disengage the swing lock and loosen the chains to allow sharp turns again. This demonstrates how the top link of the tractor Lift system switches the unit between the trail and Lift modes. FORWARD SWING MAST REARWARD STORAGE TUBE FOR MANUALS TOP HOLE TOP LINK BOTTOM HOLE "A" FRAME LOWER LINKS Figure 1. Swing Hitch Operation 6

8 Adjusting The Hitch To A Tractor (See Fig. 1 Tractor and Unit on flat, hard surface with parking stands up and roller in float position). A category 1 hitch tractor is required with the lower links stabilized. With the unit swing stand lowered connect the lower Lift links to the A Frame Hitch Pins and top link to the swing mast with the tractor end in the top hole. Push the Lift control lever on the tractor to the completely lowered position. Lengthen the adjustable top link until the swing mast closes tight against the A Frame. This causes the combined weight of the unit and the tractor hitch components to be transferred to the tines. This extended top link also causes the unit to tilt backwards when Lifting allowing gravity to assist the mast chains in aligning the unit with the tractor. Roller Positions As shown in Figure 2, the roller on the back can be pinned in three positions. It may be desirable to pin the roller up as close to the tines as possible to prevent damage during transport on and off trailers. The middle slot is used during operation. It allows the roller to float and acts as a doffer to avoid rolling turf around the rotors. The last hole is used in conjunction with the parking stands for parking the Multi-tine. Figure 2. Roller Positions Transporting The Unit As previously stated, an extended top link to tilt the unit backwards helps to align it with the tractor during Lifting. However, the backward tilt increases the potential for damage to the unit on trailer ramps. To avoid damage without having to change the length of the top link, move the tractor end of the top link from the top hole to the bottom hole. This will tilt the unit forward for more clearance when lifted. Not changing the top link length will save time at the next job site. On steep ramps it may also require the roller to be pinned in the highest position for more clearance. 7

9 From Lift Position To Operating When lowering for operation, lower slowly until the tines touch the ground. Then swiftly push the Lift control lever on the tractor to the completely lowered position to instantly unlock the hitch. This is especially true when lowering the unit in a sharp turn. Failure to do this may cause the swing hitch not to unlock, resulting in damage to the machine and/or turf damage. In the event the unit should fail to unlock for trail mode, stop the tractor and repeat the lowering procedure. From Operating To Lift Position WARNING: When operating diagonally downhill or transversely (sideways) on a hillside slope above 5 the mast chains will not swing the unit uphill to center and lock on the tractor when the unit is Lifted. Occasionally the unit will swing farther to the downhill side of the tractor creating the hazard of tractor roll over. If the tractor ever seems unstable, immediately lower the hitch and steer the tractor uphill or on a more level surface where it will center and lock when lifted. Do Not Operate In Reverse Do not back the tractor up with the unit touching the ground. Always disengage the PTO, raise the unit, back to desired location and then lower the machine and engage the PTO. Roller Scraper Usage Generally the roller scrapers are only used when the ground does not have rocks, roots, construction debris, etc that would clog and stop the rollers from turning. Trial Run The geometry of tractor Lift linkages varies, and a trial run over uneven ground is recommended. Ideally the swing lock will not engage when operating over the crown of a hill and the tractor hitch is always free to float upward at all times. The tines should clear curbs etc., when lifted. Refer to the pre-operation checklist prior to trial run. 8

10 OPERATOR INSTRUCTIONS Seeder The Gandy Seeder is equipped with an electric driven fluted rotor that feeds seed to a precision mated stainless hopper bottom and slide with adjustable holes at each of the 22 outlet spouts. CALIBRATION TROUGH SEED TUBES HOPPERBOTTOM & SLIDE HAIRPIN COTTER SEED DEFLECTOR SEED TUBE PIN Figure 3. Seeder Seed Flow Control A cam gauge that varies the size of the adjustable holes controls the flow rate. The seed flow is instantly turned off or on by closing and opening the hopper bottom holes with the control handle on the right front of the hopper. NOTE: Fragile seeds may be damaged if the electric drive continues to turn the fluted rotor for very long with the flow turned off. The flow is gradually stopped or started by stopping or starting the rotation of the fluted rotor while leaving the control handle in the open position. When the rotor is stopped, the seed contained in the fluted rotor section above the adjustable holes will flow until the section is emptied. When the rotor starts again, the seed won t flow until the next fluted rotor section with seed rotates over the adjustable holes. The flow control rotor is stopped and started with a remote control switch at the tractor seat. 9

11 Emptying The Hopper With the control lever and cam wide open, rotate the fluted rotor and catch the seed in the calibration trough or on a plastic sheet. Unclogging Seed Tubes Remove the hairpin cotters holding the clogged tube and the tubes on either side then feed the clogged tube up through the framework. Only remove the seed deflector for access to the four tubes beneath the gearbox mount. (Refer to routine maintenance section regarding more extensive cleaning). PRE-OPERATION CHECK LIST (With the Multi-tine Aera-vator lowered and the tractor engine switched off...) Replace any safety decals that are not legible. Be sure that the implement is hitched to the tractor properly with all pins in place. Pin the parking stand in the up position (see Fig. 1). WARNING: Be sure the driveline is correctly installed. (The end stenciled as the tractor end is connected to the tractor and not to the implement). Check to see that the end yokes are locked to the tractor PTO and gearbox shafts. Drive shields must turn freely on the driveline. See that all shields are correctly installed. Remove any items from seed hopper that would damage rotors or clog seed tubes. Remove any debris caught in the rotors. Check gearbox oil level before first operation and every 200 hours of operation thereafter. (Refer to routine maintenance section.) MAINTENANCE SAFETY Never attempt to clean, adjust, lubricate or perform any maintenance on the implement while the tractor engine is running. SAFETY BLOCKS should be used to support the Multi-tine Aera-vator when in the raised position during service. Lower the parking stand and roller when unhitching from the tractor. When installing tines, performing any rotor shaft service, or removing debris from the rotors, ensure that the rotor shaft does not rotate because a serious pinch injury could occur. ROUTINE MAINTENANCE Check gearbox oil level before first operation and every 200 hours of operation thereafter. With frame level, remove oil level plug on front left side of gearbox using 5/16 allen wrench. If required, add 90w-gear oil through level plug until it appears at level plug. Replace plug securely. 10

12 Grease drive line parts after the number hours use as shown in the above illustration. The hitch flex joints at the top of the A frame and above the gearbox (see page 21) should be lubricated before first operation and weekly thereafter. After the first two hours of operation tighten all tine shells on rotors. Use Torx Plus bit supplied with machine to torque bolts to 40 MT-lbs. When replacing damaged or worn tine shells, use the Torx Plus bit furnished with the machine (additional bits are available. Order # MT50-009). CHECK BELT TENSION after 4 hrs. of operation and every 40 hrs. thereafter. Also, tighten belts if shaft hesitation is noticed during operation. Be sure to re-install belt shield after servicing. Use the applicable parts break down illustration pp for maintenance, removal, and assembly instructions. The rotor shaft and bearings are sealed and permanently lubricated requiring no routine maintenance. Inside the hopper place a few drops of light oil weekly between the ends of the fluted roller and the plastic bearings. Do not over oil. NEVER apply oil or spray lubricant to hopper bottom or slide. Extensive cleaning of the seeder hopper bottom, slide and spout plate (Fig. 3) A. Remove the seed deflector and all of the seed tubes. B. Remove spout plate retaining clips, cam gauge, and spout plate assembly. C. Carefully note how the slide supports assemble to the hopper bottom and how they are shifted endwise to control the clearance between the slide and hopper bottom. The clearance is set at the factory and fixed with self-tapping screws into the hopper bottom. After removing the screws, nuts, and plastic washers, the slide supports shim to the left to remove the slide. D. Clean all components and wipe with a dry cloth. Do not apply oil or spray lubricants. E. Re-assemble components in reverse order. CAUTION BE SURE ALL SAFETY SHIELDS ARE INSTALLED PRIOR TO RETURNING THIS MACHINE TO SERVICE. 11

13 ROTOR SHAFT SERVICE INSTRUCTIONS (Clean the unit thoroughly with a pressure washer) Rotor Shaft Removal (Figure 4) 1. Mount Multi-tine Aera-vator (in parked position) to tractor. 2. Use Torx Plus bit to remove all tine shells from rotors. 3. Remove belt cover and belts. 4. Unbolt the three sets of flanges holding the shaft in the frame. 5. Shift rotor shaft slightly toward the drive end to allow the bolts to clear end plates. 6. Use tractor to Lift the frame as necessary to extract the rotor shaft. NOTE: Center bearing plate may need to be loosened in order to allow shaft to be removed. FLANGE NUT/BOLT HOLDING SHAFT TO CENTER BEARING PLATE MOVE SHAFT TOWARD PULLEY SIDE AND DROP OUT OF FRAME Figure 4. Rotor Shaft Removal Rotor Shaft Disassembly (Figure 5) 1. Remove the 1-1/8" hex jam nut from the shaft end nearest to the damaged component. 2. Only remove the rotors and spacers required to reach the damaged component. Wipe the shaft clean before each rotor is removed. Each rotor bearing has two separate cones with a hex bore adapter pressed in each. Each cone is held in position by an internal grease seal, which allows the cones to be moved apart slightly. When they are moved apart any dirt allowed inside the hex adapters can fall between the cones and contaminate the bearing. If the cones are forced apart the internal seals become ruined and are irreplaceable. 3. Clean and inspect parts as they are removed and set aside in their order of removal to simplify re-assembly. 12

14 CAUTION: TO APPLY FORCE AGAINST THE ROTORS OR TINES WHILE REMOVING ROTOR ASSEMBLIES WILL RUIN THE IRREPLACEABLE INTERNAL ROTOR BEARING SEALS. USE A BLUNT BAR AGAINST THE THICK FACE OF THE BEARING ADAPTER TO DRIVE THE ROTORS OFF THE SHAFT. Figure 5. Rotor Shaft Disassembly Rotor Hub Disassembly (Figure 6) 1. With a pry bar remove the external seals on both sides. Generally, seals are damaged and are not reused. 2. Remove the snap rings on both sides. 3. Press used bearing and adapter assembly out. EXTERNAL SEAL - STEP 1 (PART #: AE50-005) SNAP RING - STEP 2 (PART #: AE50-029) PRESS RAM PRESS TOOL AE60T007 TOOL CAP AE60T008 PRESS TABLE STEP 3 Figure 6. Rotor Hub Disassembly 13

15 Figure 7. Rotor Hub Re-Assembly Rotor Hub Re-Assembly (Figure 7) (keep all components clean to prevent bearing contamination) 1. Install internal snap ring in one side of rotor hub. Be sure snap rings expand full depth into grooves. 2. Press new bearing and adapter assembly down tight against snap ring as shown in Fig. 7. If bearing is loose in hub the rotor should be replaced. 3. Install snap ring in other end. 4. Apply a ribbon of general-purpose grease between the snap ring ID and bearing adapter OD on both ends of the rotor hub. 5. With the press tool inverted to fit the external seals, press the seals in both ends of the rotor with the lips out. Wipe off excess grease. Be sure seals are not bent or cut and are seated firmly. If the seals are not tight, use a hammer and punch to stake the hub faces at about 90 intervals. 14

16 Rotor Shaft Re-Assembly (Read this section thoroughly before beginning) CAUTION: IF THE BEARING ADAPTERS ARE NOT PRECISELY TIMED 180 DEGREES APART IN EACH ROTOR AND ALIGNED BETWEEN ROTORS, SERIOUS DAMAGE WILL RESULT. 1. Rotate the adapters in each rotor so the timing marks (See Figures 8, 9 & 10) are phased 180 degrees apart with hex bores aligned. Figure 8. Adaptor Mark TIMING MARK FOR PHASING BEARING ADAPTORS IN THE ROTOR SHAFT ASSEMBLY 2. Use marker pen to assist with aligning timing marks between rotors. Mark two rotor shaft flats 180 degrees apart next to the threaded end (See Figure 10). The marked flats would have to align with the timing marks on any rotors not removed during servicing. TIMING MARK ON BEARING ADAPTOR SPACER MARK SHAFT FLATS 180 APART TIMING MARK ON BEARING ADAPTOR Figure 9. Adaptor/Shaft Relationship 3. Install the required components in the sequence shown in Figure 10, double-checking the timing mark locations and spacer lengths (see following table) as each rotor is installed. SPACER LENGTH PART NO. A 3 51/64 AE B 7 1/4 AE C 3 9/16 AE D 3 19/64 AE

17 CAUTION: CLEAN THE ROTOR SHAFT THOROUGHLY REMOVING ANY BURRS THAT WOULD KEEP THE ROTOR ASSEMBLIES FROM SLIDING ON FREELY. IF A BEARING ADAPTER JAMS, THE INTERNAL BEARING SEAL COULD BE FORCED OUT AND IT IS NOT REPLACEABLE. NOTE: THE SPACERS MUST BE FULLY SEATED IN EACH ADAPTER COUNTERBORE BEFORE TIGHTENING. DO NOT FORGET TO PLACE THE BEARING STAMPINGS ON EACH OF THE SHAFT BEARINGS DURING REASSEMBLY. ALSO, THE 3/8" CARRIAGE BOLTS SHOULD BE PLACED IN THE BEARING STAMPINGS ON THE DRIVE END OF THE SHAFT BEFORE THE PULLEY IS REPLACED. Figure 10. Rotor Shaft Assembly 4. Replace the 1-1/8" hex jam nut and rotate each rotor occasionally as the nut is torqued to 350 MT-lbs. If any rotor locks up, the bearing adapters in the rotor are probably not phased 180 degrees apart or the spacers are not fully seated. Rotor Shaft Installation 1. Roll Rotor Shaft Assembly into position under frame bearing holes with pulley on drive end. 2. Carefully lower unit in small increments while keeping both bearing flanges on the side of the frame end plates and center bearing support as illustrated. Note that the center bearing support is loose against the frame and can be tilted for alignment. Never assemble with the bearing flanges separated around a Frame End or the Center Bearing Support. Note that as the frame ends and center bearing support are carefully lowered down beside each pair of bearing flanges it is necessary to push the 16

18 unit away from the pulley end. This allows the frame end to pass the carriage bolts sticking through both bearing flanges next to the pulley. 3. When the frame ends align with the carriage bolt holes and the bearing flanges, pull the unit toward the pulley end to assemble nuts on carriage bolts. 4. Install bolts and nuts in center bearing support and other end plate being careful to align carriage bolt shoulders with the square holes in bearing flanges (hand tighten). 5. Tighten all bearing flange bolts MT-Lbs. 6. Tighten 3 bolts connecting center bearing support to frame MT. Lbs. 7. Install and tighten drive belts. 8. Install Belt Cover and tighten bolts 8-12 MT. Lbs. 9. Fasten tine-shells to rotor shaft. Figure 11. Rotor Shaft Re-assembly Shell Removal: Tine Shell Replacement (Torx Plus bit required Part #: MT50-009) 1. With the Multi-tine Aera-vator in the parked position and unhitched from the tractor, wash the rotors thoroughly. Be sure to remove all debris from inside the Torx Plus bolt head. 2. Use the Torx Plus bit provided to remove the worn tine shells. 17

19 Shell Installation: 1. Starting with the bare rotor, place the first shell on the rotor and start the threads on the Torx Plus button head cap screws (Figure 12). Note the rotation the rotor will travel in relation to the shell placement. Note: To insure smooth installation, do not tighten until all shells are installed. 2. Once the first shell is on the rotor, the next can be slipped under the heads of the bolts of the first shell and then fastened as before. 3. When all shells are in place, tightening may begin, but pull the shell to the base of the slot before applying 40 MT-lbs of torque. Excessive torque will break retaining nut out of its cage. NOTE: First Products uses TORX PLUS for this application because of its superior characteristics over all other button head cap screws. Due to the abrasive action of the bolt heads on the turf, most bolts wear away and prove near impossible to remove. It is not recommended these bolts be replaced by any fastener other than 3/8 X 1 Torx Plus button head cap screw. SLIDE NEXT SHELL UNDER BOLT HEADS OF PREVIOUS SHELL DIRECTION OF TRAVEL Figure 12. Tine Shell Installation 18

20 WARRANTY INFORMATION ONE YEAR LIMITED WARRANTY FIRST PRODUCTS INC. WARRANTS THIS PRODUCT TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP FOR A PERIOD OF TWELVE MONTHS FROM THE ORIGINAL DELIVERY DATE. THIS WARRANTY DOES NOT COVER PARTS CAUSED TO BE DEFICIENT DUE TO NORMAL WEAR, MISUSE, ACCIDENTS, OR LACK OF PROPER MAINTENANCE. ANY PARTS THOUGHT TO BE DEFECTIVE MUST BE RETURNED TO THE DEALER/DISTRIBUTOR FOR WARRANTY CONSIDERATION JOINTLY WITH FACTORY REPRESENTATIVES. A RETURN AUTHORIZATION NUMBER MUST BE OBTAINED AND CLEARLY MARKED ON ALL PACKAGES OF PARTS REQUIRING RETURN TO THE FACTORY. THE OBLIGATION OF FIRST PRODUCTS INC. UNDER THIS WARRANTY SHALL BE EXCLUSIVELY LIMITED TO REPLACEMENT OF PARTS DETERMINED TO BE DEFECTIVE BY FIRST PRODUCTS INC. WITH FREIGHT PREPAID. IN NO EVENT SHALL FIRST PRODUCTS INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH THE USE OF THIS PRODUCT. FIRST PRODUCTS INC. RESERVES THE RIGHT TO MAKE CHANGES OR ADD IMPROVEMENTS TO ITS PRODUCTS AT ANY TIME WITHOUT OBLIGATION TO MAKE SUCH CHANGES OR IMPROVEMENTS ON PRODUCTS SOLD PREVIOUSLY. 19

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