John Berends Implements Pty Ltd AGRICULTURAL ENGINEERS OPERATOR S MANUAL PARTS LIST TH100 - Trailing Tandem Discs PRODUCT NO. 0911/0921/0931 TH100 28 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 0912/0922/0932 TH100 32 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 0913/0923/0933 TH100 36 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 0914/0924/0934 TH100 40 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 0915/0925/0935 TH100 44 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 0916/0926/0936 TH100 48 plate with 24 x 5mm/24 x 5mm/26 x 6mm discs 130 FRANKSTON-DANDENONG RD, DANDENONG SOUTH, VIC. 3175 AUSTRALIA (ABN 79 007 035 369) PHONE (03) 9791 2494 FAX NO. (03) 9794 5568 berends@johnberendsimplements.com.au www.johnberendsimplements.com.au
TABLE OF CONTENTS Page No. SAFETY INSTRUCTIONS...3 INTRODUCTION.5 SAFETY FEATURES... 6 ASSEMBLY...7 OPERATION...10 MAINTENANCE...12 SPARE PARTS...13 2
SAFETY Farm machinery is dangerous if operated incorrectly so please read this manual in its entirety prior to operating the machine. No operator, however experienced in farm machinery operation, should attempt to use any machine they have not been competently trained to use. Your local Department of Agriculture can help you with training, as can most Occupational Health and Safety offices, Agricultural schools and colleges and farm equipment dealerships. All instructions relating to tractor safety as per the tractor operators manual should be followed. When making any machine adjustments, stop the tractor engine first and wait for all moving parts to stop. Maintain the tractor to ensure it remains safe to use. Do not operate faulty or damaged equipment. Extreme caution should be taken when fitting equipment to the tractor s three point linkage. Avoid standing between the implement and the tractor when coupling machinery. All machines should be mounted and retained correctly. All guards must be kept in place and correctly maintained. P.T.O. shafts must be correctly attached and secured to both the tractor and the machine. Decals must be visible and legible at all times. Keep well clear of all moving parts. Keep all people and animals at a safe distance from all moving parts. Children must not be allowed to operate this equipment and all passengers must have the same level of protection as the operator. Wear protective clothing where appropriate. Never operate when tired (not alert) or in poorly lit areas and stay alert for humps and other hidden hazards. Remove all timber, rocks and foreign objects prior to operation. Avoid operating the machine in wet conditions. Exercise extreme caution when changing direction on hills. Avoid sudden movement, sudden breaking, high speeds, rough terrain and steep slopes. If machine starts to vibrate, stop tractor, turn off engine and investigate. 3
After striking a foreign object or if there are doubts about the performance of the machine, stop the tractor as described and check if machine is making excessive noise. Extreme caution must be taken when working in public areas (roadsides etc). It is recommended that flaps and chains are fitted to slashers when operating in public areas. These are available as optional extras. Rear flaps are compulsory in public areas. Watch overhead clearance and beware of underground pipes and cables. Where fitted, hydraulic hoses and fittings must be maintained so as to prevent damage. Do not modify this equipment in anyway, or use it for any other purpose than it was designed to do. Never work under unsupported machines or adjust unsupported machines. Do not enter the danger zone where a load being carried by a machine could fall on you, for example a round bale from a bale fork, a log from a carryall or material from a rear end loader. These instructions should be used in conjunction with any local regulations regarding safety ie OHS. Maintenance is essential for safe operation. Ensure maintenance is carried out regularly by people qualified to do so. This is of particular importance on P.T.O. drive machines where driven parts can fly off at high speed if wearing parts are not properly maintained. FAILURE TO FOLLOW THESE INSTRUCTIONS AND PROCEDURES MAY RESULT IN EQUIPMENT MALFUNCTION, OR DAMAGE, SERIOUS INJURY OR EVEN DEATH. 4
INTRODUCTION: This manual was developed specifically for the machine you have purchased. The information within is to assist you in preparing, operating and maintaining your machine. Please read and understand the contents of the manual completely before attempting to operate your machine, paying special attention to all safety details. With our policy of continuous improvement, products and specifications may change without notice and without incurring the obligation to install such changes on any unit previously delivered. TH100 Trailing Tandem Disc Ploughs The TH100 Wheeled Tandem Disc plough introduces an implement that is built in Australia to suit Australian conditions. In designing this machine with its many innovative features, primary consideration was given to the user and the varying conditions he/she would encounter when operating the TH100. With emphasis in design strongly stressed, a machine of a heavy weight with a strong, robust main frame, a disc gang assembly incorporating a heavy axle and heavy castings and finally complete with every wanted feature to enable the machine to leave a high class finish wherever used, has certainly been accomplished. Notably, the TH100 will track straight and not present problems with side draught. The setting of gang axles is easy and quick by means of manual ratchets or hydraulic rams. MACHINE SPECIFICATIONS 28 Plate 32 Plate 36 Plate 40 Plate 44 Plate 48 Plate Approx. weight 2450kg 2660kg 2840kg 2990kg 3310kg 3460kg No. Bearings 8 12 16 16 16 16 Cutting Width 3.2m (10 6 ) 3.6m (12 ) 4.11m (13 6 ) 4.57m (15 ) 5.03m (16 6 ) 5.48m (18 ) No. Axles 4 4 8 8 8 8 WARRANTY John Berends Implements P/L warrants each new product sold to be free from defects in material and workmanship, under normal use and service, as outlined in the operators manual, for a period of 12 months. This warranty is void if any damage to the machine has been caused by misuse or non-genuine parts have been used or any repairs have been made by any persons other than authorised dealer service personnel. The manufacturer/dealer is not obligated to any transportation charges incurred in the repair or replacement of parts. This warranty does not exclude any condition or warranty implied by the Trade Practices Act 1974 or any other legislation which implies any condition which cannot be excluded. Copyright 1998 This Safety Manual is copyright and no part may be reproduced without the written permission of John Berends Implements. 5
Safety Features 1. SERIAL NUMBER (Decal inside frame) 2. WARNING DECAL 3. GIBBINS RAWLINGS DECAL (Top of frame) 2 3 1 6
MACHINE ASSEMBLY When setting up the TH.100 it is suggested that it be hitched to a tractor and not left on the jack. The main frame is to be set up first before gang frames are attached. The object is to set the main frame parallel to the ground and the following order of instructions will do this: Steps for setting main frame (refer Figure 1): 1. Connect to tractor. 2. Adjust the parallel link lift arm (B) giving a maximum of 6 (E) from the centre of the 5 x ¾ upright support to the centre of the attaching pin in the link arm. 3. Adjust pressure springs (A) to an even amount of thread top and bottom (X). The springs should have enough tension to hold the machine firm without over-tensioning the springs. 4. If at this stage, the frame is not parallel, adjust the pull bar hitch tongue (F) up or down and finally finish the setting up procedure with adjusting pressure spring (A) giving ½ - ¾ clearance (C) between the under side of pull bar and top of bolts(d). It may be found that this final adjustment (refer step.3.) where it has equal amounts of thread top and bottom, is no longer achievable. Minimal adjustment maybe required to the extended top link (refer step.2.) until the frame is parallel with the ground. Figure 1. Main Frame Set-up 7
Steps for fitting gangs (refer Figure 2) 5. Sling both front gang beams (A) under the main frame (always do front gangs before rear), support gang in near correct position and bolt outside gang retaining plates (B) in position. Do this on both sides, remembering to include spacer tubes (C). 6. Manoeuvre each gang to its respective location to the centre beam and position the top gang angling plate (Pt 3416 in spare parts section). Have the ram lug on top and on the edge away from the front of the machine. Attach gang pivot pins (Pt 3418) and locate in matching holes with gang beam. Lift the lower gang angling plate (D) into position and hold up with lower pivot pin castle nuts (Pt 3419), position spacers (Pt 3415) between plates and tension bolts (Pt 3413). Finally tension pivot pin castle nuts and fix with cotter pins. Attach ratchet link (or optional hydraulic ram) and open gang out to check that there is not any restriction in achieving full gang angle. It is suggested that some form of lubrication be used on the threads of the ratchet link and sliding area on centre frame beam. 7. Rear gang (E) assembly is a repeat of step.6. Have the top gang angling plate (F) in the reverse position to the front gang with the ram lug on top and to the front of the machine. CAUTION: Don t put rear gang on first. This will put extreme pressure on frame when front outside gang retaining plates are removed. When fitting hydraulic rams check clevis clearance at both ends for possible fouling at attaching points. It should be explained that the transport pin (G) is positive and should be removed before ram is operated. Pressure Springs Don t tension up pressure springs so that they become ineffective by being rigid (you will find when one spring takes all the weight, the other will be loose, this is only natural). Pull Bar Don t allow the pull bar to rest on either of the two bolts (Figure 1, D) beneath it when in a transport position. This will remove the effect of the pressure spring acting as shock absorbers when in transit. Parallel Lift Toggle Link Don t allow the toggle link (Figure 2, H) to come through and touch the pressure springs when wheels are up. The result will eventually be a bent pressure rod. 8
F G E B & C H D A Figure 2. Gang Set-up 9
OPERATION Jack Prior to moving the machine, retract jack well clear of the ground, and if the implement is to cross very rough terrain, consider removing the jack completely. Buster Tine The buster tine should be placed as far forward as possible without interfering with the ram or ram lug fittings. Set the tine with the machine lifted in a transport position. Transit When the machine is in a transport position, use the transport bar to support the ratchet or hydraulic ram. A recommended maximum travelling speed is 25km/hr however due consideration must be given to varying surface conditions. Always secure transport bar with linch pins provided. CAUTION: Always be mindful of the furrow filler disc adding extra width to implement when approaching gates etc. Gang Setting This machine is capable of up to 26 gang angle or 311/2 ram lug hole centres and for general cultivating with gang angles of 18 on the front gang and 15 on the rear. Second passes require approximately 3 degree less - as a rule 5/8 or 16mm is approximately one degree. Setting gang angles is entirely related to conditions as they are presented. Observe the closeness of the two P.594 end castings in the centre when setting the front gangs. Minimum clearance of 1 1/2 (40mm) will avoid contact of these parts when operating. Don t be afraid to experiment with gang angles or ever moving gangs or discs, as the machine must be set to achieve the ultimate result and this will vary because of soil, moisture content, tractor speed etc. 1) Ridging Don t accept ridging, as this is the result of any one of the following reasons, if you understand the reason you can solve the problem. a) Speed too fast - possibly reducing the back gang angle will be the solution. b) Gang angles too great for speed travelled - close gangs up or reduce speed. c) Back gang (particularly) set too close to each other in the centre on gang frames - follow steps in note on moving disc gang and move gang away from the centre of machine. NOTE: It is considered as a general rule, the earth that the front gangs throw out the rear gang must throw back, otherwise unevenness will occur. 2) Harrow Finish Should you be faced with a hollow depression left in the centre of the harrowed area - this can be rectified by reversing the ridging solution instructions. 10
Moving Disc Gangs (refer Figure 3) It is possible that gangs may need to be moved along the gang beam as they are not pre-set. Loosen the eight hanger nuts on each gang and tap axle either way with a hammer. This will work better if the discs are initially raised off the ground. Front gangs the distance between pivot point and the centre of the first disc spacer should be approximately 4 ¾ for each front gang. When the front gangs are closed up there should only be ½ gap between the two axles. Rear gangs the distance between the pivot point and the centre of the first disc spacer is approximately 9 for each rear gang. This should stop the rear disc running in the groove cut by the front disc. When resetting gang of discs after being moved to the required position, tighten four bolts on hanger closet to centre of frame and work outwards making sure the top plate of the hanger bracket lies parallel to the gang frame when bolts are being tensioned up. Figure 3. Moving Disc Gangs Scrapers Set scrapers when discs are revolving, don t have scrapers touching (otherwise the scallop in the disc may pick up the blade). Turning Do not turn sharp and fast at corners. Should this be unavoidable lift disc clear of the ground. Discs This machine has been designed to perform in the most adverse conditions, but we as manufacturers are aware that someone will require big gang angles to plough extremely tight soil conditions, therefore we recommend that a backing disc be used as support to the opening discs, this can be achieved economically by using a worn disc of smaller diameter behind the opening discs. Hydraulics Should the gang be operated by hydraulics don t use a small size ram. Larger rams will absorb the strain of pressure which would be transferred back to the pumping equipment. Contact Berends or your dealer for details on the correct size ram to use. CAUTION: 11
Don t alter the design, or attempt to add weight to implement s frame. MAINTENANCE Bolts, Pivot Pins and Bronze Bushes Keep all bolts tight, in particular gang bolts, and replace pivot pins when showing signs of wear. All bronze bushes should be checked each season as they are a wearing part and may need replacing. Gang Bolts Don t forget to keep the gang bolts tight with regular checks, particularly when the machine is new (when the machine is new friction will cause the disc and spacers to wear in). The gang bolt is vulnerable to damage or breakage if not in tension and damage caused because of loose gang bolts would void warranty. Furrow Fillers & Furrows Operators will observe as the discs wear the furrow filler disc will start to leave a furrow (mainly because it is not a cutting disc and should only flick surface dirt back into the furrow) Its diameter will not wear at the same rate as other discs so it should be replaced with a smaller disc from time to time to give maximum benefit, a discarded worn out disc can readily be employed to suit this need. Cast Axle Bearings Don t lubricate cast axle bearing blocks (this will cause a type of graphite abrasive paste which will cause expensive wear to the high tensile axle. NOTE: Bearing blocks (Pt 3405) are in matching halves and can be turned over or replaced if wear occurs. Lubrication Lubrication plays a very important part in extending the life of wearing parts. 1) Threaded rod - should be kept covered with a smear of grease to keep nuts and thread corrosion FREE. 2) Gang slide - regularly lubricated with oil will produce very easy gang adjustment. 3) Grease nipples - have been provided on heavily worked parts and are to be greased regularly. 4) Wheel hubs - are pre-packed with grease and should only need attention at the end of each season, unless dusty conditions cause seals to break down. Force wheel bearing grease between rollers cone and cage, using hand method or grease packing equipment. Add grease in wheel hub between hub between caps and fill hub cap. Wheel Bearing Adjustment Tighten adjusting nut while rotating or oscillating wheel until the wheel binds slightly. Back off castellated type nuts between 1/6 to ¼ turn. Wheel should now turn freely, having between.001 and.010 end play. Lock with split pin securely at this position. Disc Bearings These are of the pre-lubricated type and will not require attention through their long life. Although protector plates will prevent most material from getting into the bearing, objects such as grass and wire wrapping around the bearing should be removed regularly to prevent early bearing failure. 12
SPARE PARTS ORDER SPARE PARTS THROUGH YOUR ORIGINAL SUPPLIER OR YOUR LOCAL JOHN BERENDS IMPLEMENTS DEALER. Always quote the machine serial No. or product No., spare part number and its part name as stated in the operator s manual. Glossary of terms c/w = Complete with sw = Spring Washer n.s.s. = Not serviced separately a.r. = As required fw = Flat Washer 13
TH 100 Top Frame Key No Part No Quantity Description 1 3397 1 Drawbar tongue 2 1 Drawbar 3 3398 2 Bolt/nyloc nut 4 3399 1 Jack 5 3406 2 Bolt/nut 6 3407 1 Special bolt and locknuts 7 3361 1 Pin 8 1940 1 Linch pin 9 3396 1 Tension rod 10 1640 2 Spring 11 3346 1 Flat washer 12 3345 2 Locknut 13 3408 1 Parallel lift toggle link 14 3379 1 Pin 15 3409 1 Parallel lift link arm 16 3410 1 Bolt 17 1 Frame 18 3210 2 Ratchet arm 19 Pin n.s.s. 20 Clip n.s.s. 21 3411 2 Clamp plate - straight 22 3412 16 Pipe spacer 23 3413 16 Bolt/nut/sw 24 3414 2 Clamp plate - corner 25 3415 8 Pipe spacer 26 3416 2 Gang adjustment top plate 27 3417 2 Gang adjustment bottom clamp plate 28 3418 4 Gang pivot pin 29 3419 8 Castle nut 30 3420 8 Split pin 31 3421 1 Spanner 14
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TH 100 Wheel kit There have been many different wheel/hub/stub configurations used over the years. To enable accurate identification, provide as much detail as possible for these components. These include Serial No., purchase date, stud pattern, hole centre diameters (on rim) etc. This will enable us to identify the correct components. Key No Part No Quantity Description 1 1 Axle 2 3377 1 Bronze bush 3 3362 2 Seal suit FAD hub 4 3363 2 Inner bearing & cup suit FAD hub 5 3365 2 Hub, FAD 6 3364 6 Stud suit FAD hub 7 3366 2 Outer bearing & cup suit FAD hub 8 3367 2 Flat washer 9 3369 2 Castellated nut 10 3368 2 Split pin 11 3370 2 Hub cap 12 3374 12 Wheel nut 13 3371 2 6 stud rim 14 3373 2 Tyre 15 3372 2 Tube 16 3409 1 Parallel lift link arm 17 3379 1 Pin 18 1940 1 Linch pin 19 3422 1 Transport bar 20 1577 1 Hydraulic ram 21 1 Hydraulic pin 22 1 Clip suit hydraulic pin 23 1 Hydraulic elbow 24 3925 1 Hydraulic hose 25 3405 6 Bearing block 26 3423 6 U bolt 16
TH 100 Buster Tine Key No Part No Quantity Description 1 3433 2 T bolt 2 3310 2 Cap 3 1640 ar Chisel plough spring 1959 ar Pipe for centre of c/plough spring 4 3434 1 Clamp plate 5 3435 4 Special bolt 6 3436 1 Spacer box (specify 24 or 26 disc machine) 7 3437 1 Lower clamp plate buster tine 8 3438 1 T piece 9 1653 1 Chisel plough shank 10 3313 1 Bolt/nut/fw/sw hold T piece to shank 11 1648 1 10 Duckfoot 12 1646 2 Plough bolt/nut suit points 17
TH 100 Gang Assembly Key No Part No Quantity Description 1 Gang Frame 2 3332 ar C.163-3 disc gang bolt axle 3333 ar C.164-4 disc gang bolt axle 3334 ar C.165-5 disc gang bolt axle 3335 ar C.166-6 disc gang bolt axle 3336 ar C.167-7 disc gang bolt axle 3337 ar C.168-8 disc gang bolt axle 3338 ar C.169-9 disc gang bolt axle 3339 ar C.170-10 disc gang bolt axle 3 0576 ar P.594 Head washer 4 3424 ar Clamp plate, scraper to gang frame 5 3425 ar Hanger bracket clamp plate 6 3426 ar Bolt/nut/sw 7 3427 ar Scraper clamp bent bracket 8 3428 ar Scraper clamp plate 9 3428 ar Bolt/nut/sw 10 ar Scraper bracket 11 3429 ar Formed scraper R/H 3430 ar Formed scraper L/H 12 3431 ar Bolt/nut/sw 13 3432 ar Hanger bracket 14 0568 ar P.592 Disc spacer spool 15 ar Disc - refer disc list 16 0572 ar P.591 Bearing spacer spool 17 3344 ar P014A Bearing housing 4 I.D. 3391 ar PO14B Bearing housing 100mm I.D. 2314 ar Front (large) bearing guard not shown 2315 ar Rear ) small) bearing guard not shown 18 0594 ar C60A sealed ball race bearing 4 O.D. 0581 ar C60B sealed ball race bearing 100mm O.D. 19 3439 ar C.61 Circlip 20 3343 ar Bolt/locknut, trunnion retaining 21 0570 ar P.590 Bearing spacer spool 22 0574 ar P.593 End washer (nut end) 23 3345 2 per axle Lock nut (hexagon) 3346 1 per axle Plain washer 24 0585 ar Flanged disc bearing complete 25 3924 ar Flanged disc bearing bolt/nut/sw 18
The set-up below shows the two different bearings arrangements used. The main drawing shows triple sealed bearings pressed into a cast housing and contained by a circlip. There were two different sizes bearings available 100mm (early models) and 4 (later models). The easiest way to identify these bearings is to measure the outside diameter. Another distinguishable feature is the width of the bearing. The 100mm bearing is a parallel flat bearing whilst the 4 bearing has a raised inner section. The housings for both these bearings are designed to match. The bottom photo shows the current flanged disc greaseable bearing set-up which was introduced in 2002 25 2 19