Transcript
JOHN DEERE 4900 SERIES DRY SPREADER UNIT/MULTAPPLIER INSTALLATION INSTRUCTIONS EFFECTIVE 04/2012 Revision A
1330 76TH AVE SW CEDAR RAPIDS, IA 52404-7052 PHONE (319) 363-8281 | FAX (319) 286-3350
www.highwayequipment.com
Copyright 2011 Highway Equipment Company, Inc.
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Table of Contents
JD DRY SPREADER
Pump Requirements...................................................................................................................................... 3 General Installation Instructions................................................................................................................... 3 Mounting of Spreader Body.......................................................................................................................... 3 Positioning Body..................................................................................................................................... 3 Securing Spreader Body to Frame.......................................................................................................... 4 Hydraulics...................................................................................................................................................... 5 Conveyor Relief Valve Pressure Test....................................................................................................... 6 Installation Guide................................................................................................................................... 7 Electrical Harness.......................................................................................................................................... 8 Light Installation............................................................................................................................................ 8 Light Bracket........................................................................................................................................... 8 Beacon Light........................................................................................................................................... 9 Inverted V Installation................................................................................................................................. 1 0 Spinner Installation..................................................................................................................................... 1 0 Lubrication.................................................................................................................................................. 1 0 Material Divider Storage............................................................................................................................. 1 1 MULTAPPLIER Installation............................................................................................................................. 1 1 Hydraulics............................................................................................................................................. 1 3 Hillside Divider..................................................................................................................................... 1 3 Dual Conveyor Cover............................................................................................................................ 1 4 MULTAPPLIER Removal/Endgate Installation................................................................................................ 1 4 Hydraulic Drain Lines............................................................................................................................ 1 4 Checking Installation................................................................................................................................... 1 4
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installation header instructions
PUMP REQUIREMENTS Correct pump delivery for the John Deere 4900 Series G4 hydraulic system is 33 GPM (124.9 LPM). GENERAL INSTALLATION INSTRUCTIONS Recommended sequence of installation is: 1. Removing liquid system as required per John Deere instructions. 2. Mounting of spreader. 3. Installation of hydraulic hoses and electrical harness. 4. Installation of lighting and markings (i.e. SMV sign). 5. Installation of Inverted V. 6. Filling of hydraulic tanks and lubrication. 7. Checking for leaks and proper functioning. MOUNTING OF SPREADER BODY Positioning Body Use only lifting devices that meet or exceed OSHA standard 1910.184. Never lift equipment WARNING over people. Never lift unit with material in the body. Loads may shift or fall if improperly supported, causing injury or damage to unit. Position chassis with adequate room around the unit. Make sure endgate or MultApplier insert is securely installed. Lift unit with John Deere lifting device to prevent damage to the unit.
Figure 1 – Attach John Deere lifting device (see John Deere for part number and instructions) to each corner lift hook inside spreader. Assembled: With MultApplier With endgate
A 39” (99.1cm) 43” (109.2cm)
Figure 1 - Lifting
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NOTICE!
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John deere SPREADER
Securing Spreader Body to Frame (Mount kit supplied by John Deere) Figure 2 – Install rubber mounts at front of chassis.
BOLT
Position spreader with mounts located directly over chassis mounts.
WASHER RUBBER MOUNTS WASHER NUT Figure 2 – Rubber Mounts
NOTICE!
DO NOT WELD VEHICLE FRAME! Such welding can lead to fatigue cracking and must be avoided.
Figures 3, 4 & 5 – Secure unit to chassis by loosely installing mounting hardware, starting at the rear and moving forward. Add shims to rear mount between box and chassis. Tighten mounting hardware as specified under the corresponding mounts.
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SHIMS BETWEEN BOX AND CHASSIS
Figure 3 – Rear Mounts (1st) 315 ft-lb (425 nm) torque
Figure 4 – Center Mounts (2nd) 234 ft-lb (315 nm) torque
Figure 5 – Front Mounts (3rd) 330 ft-lb (450 nm) torque
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john deere SPREADER
HYDRAULICS Figure 6 – Connect unit return hose to chassis filter port.
Figure 6 – Return Hose Figure 7 & 8 - Connect dry box load sense hose to chassis load sense hose located at right-hand rear corner of chassis. If needed, reroute chassis load sense hose closer to center of chassis so it can connect to dry box load sense hose, as shown in Figure 7. Figure 8 shows chassis load sense hose connected to liquid system prior to dry box installation. DRY BOX LOAD SENSE HOSE
Figure 8 - Disconnect Chassis Load Sense Hose
Figure 9 – Connect unit pressure hose to combo valve BT port.
Figure 9 - Pressure Hose Use thread sealer on all fittings, except O-ring and JIC adapters, O-ring valves and motors, etc. When using thread sealer, do not put it on the first three threads of the fitting. Too much on the fitting or on the first three threads will force it into the oil stream where it could damage the system. CAUTION
If a threaded connection is tightened too tightly, the fitting or housing into which the fitting is placed could be distorted and an unstoppable leak could occur.
Assemble system as shown in “Hydraulics” parts list. Use plastic tie straps as needed to support hoses so they will not snag field debris or contact moving parts. Do not stretch hoses tight.
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Figure 7 - Connect Load Sense Hoses
CHASSIS LOAD SENSE HOSE
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John deere SPREADER
Conveyor Relief Valve Pressure Test 1. 2. 3. 4. 5. 6. 7.
Install pressure gauge in relief valve test port (#3). Install in-line gate valve after relief valve (#3.1). Make sure gate valve is fully open. Turn off spinners. Start engine and engage hydraulics. Slowly run engine speed up to governed RPM. Set up controller for manual speed and turn on conveyor switch.
CAUTION
Stay out of body when conveyor is running. Stay clear of all moving parts. Entanglement of clothes, any part of your body or anything you have in your hands can cause serious injury. Do not use a bar, rod or hammer on conveyor while it is moving—if it gets caught it could cause injury!
8. Slowly close gate valve while watching pressure gauge. 9. When gate valve is fully closed, pressure gauge should read 2050 PSI; if not, slowly open gate valve until there is ‘0’ PSI on the gauge. 10. Turn lock nut counterclockwise (#3.2) to loosen adjustment screw (#3.3). 11. Turn adjustment screw (#3.3) by 1/4 turn increments, clockwise to increase pressure, counterclockwise to decrease pressure. After each turn, slowly close gate valve to verify new pressure setting. 12. When recommended 2050 PSI setting reached, hold adjustment screw and tighten lock nut.
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#3.3
#3
Figure 10 - Conveyor Relief Valve
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#3.1
#3.2
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Installation Guide
WRONG WRONG
RIGHT
RIGHT
1. Use elbows and adapters in the installation to 2. Install hose runs to avoid rubbing or abrasion. relieve strain on the assembly, and to provide Clamps are often needed to support long runs of easier and neater installations that are accessible hose or to keep hose away from moving parts. It is for inspection and maintenance. Remember that important that the clamps be of the correct size. A metal end fittings cannot be considered as part of clamp that is too large will allow the hose to move in the flexible portion of the assembly. the clamp causing abrasion at this point.
WRONG WRONG
RIGHT
3. In straight hose installations allow enough slack in 4. Do not twist hose during installation. This can be the hose line to provide for changes in length that determined by the printed layline on the hose. will occur when pressure is applied. This change in Pressure applied to a twisted hose can cause hose length can be from +2% to -4%. failure or loosening of the connections.
WRONG RIGHT
WRONG
RIGHT
5. Keep hose away from hot parts. High ambient 6. Keep the bend radii of the hose as large as possible temperature will shorten hose life. If you cannot to avoid hose collapsing and restriction of flow. route it away from the heat source, insulate it. Follow catalog specs on minimum bend radii. (Used with the permission of The Weatherhead Company.)
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John deere SPREADER
ELECTRICAL HARNESS Figure 11 - Locate electrical harness on unit right side near controller box and position closer to chassis connection. Figure 12 - Attach electrical harness to connection on chassis right side.
Figure 11 - Electrical Harness
Figure 12 - Electrical Harness Chassis Connection
LIGHT INSTALLATION Light Bracket Lights and brackets are factory installed in tilted position. End user must adjust both brackets so perpendicular to unit.
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Figure 13 – Remove bolts and adjust bracket to correct position. Secure bracket with bolts.
Figure 13 - Adjust Light Bracket Position
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Beacon Light Kit PN 308896 (optional) Figure 14 - Remove existing right hand light bracket bolts. Attach and secure beacon light bracket to existing bracket with bolts.
Figure 14 - Attach Beacon Light Bracket Figure 15 - Attach electrical harness to bracket top: 1. Thread electrical wire through bottom of hole on bracket top. 2. Connect electrical wire to connector and secure. Screw connector into top of hole on bracket top. 3. Secure ground wire to bracket top. Figure 16 - Attach beacon light to connector at bracket top and secure. CONNECTOR
GROUND WIRE
Figure 15 - Attach Electrical Harness
Figure 16 - Attach Beacon Light
Figure 17 - Route electrical harness down bracket and secure. Connect to main light harness. SECURE HARNESS
CONNECT TO MAIN HARNESS Figure 17 - Secure and Connect Harness
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John deere SPREADER
INVERTED V INSTALLATION 1/2” HARDWARE
5/8” HARDWARE
ADJUSTING BAR
HANGER CHANNELS
INVERTED V 5/16” HARDWARE Standard Installation
5/8” HARDWARE
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1/2” HARDWARE ADJUSTING BAR
HANGER CHANNELS
INVERTED V
5/16” HARDWARE High-Yield Installation Figure 18 – Inverted V Installation Slide Adjusting Bars through Inverted V as shown in Figure 18 and attach with 5/16” hardware. Set Inverted V inside unit with shorter Adjusting Bar at front. Attach Hanger Channels to sides of unit with flanges facing rearward using 1/2” hardware. Position Inverted V at desired level and attach Adjusting Bars to Hanger Channels using 5/8” hardware. Tighten hardware to recommended torque. SPINNER INSTALLATION See “G4 Spread Pattern” tabbed section in operator’s manual for instructions. LUBRICATION Lubricate all points requiring lubrication per Lubrication Chart in operator’s manual.
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john deere SPREADER
MATERIAL DIVIDER STORAGE
Figure 19 - The material divider can be stored on the provided bracket when not in use.
Figure 19 – Material Divider Storage MULTAPPLIER INSTALLATION Stay out of the spreader. If it’s necessary to enter the spreader, return to the shop, empty body, turn off all power, set vehicle brakes, lock engine starting switch and remove keys WARNING before entering. Tag all controls to prohibit operation. Tags should be placed, and later removed, only by person working in the body. Use only lifting devices that meet or exceed OSHA standard 1910.184. Never exceed work WARNING load limits or lift equipment over people. Empty spreader before lifting. Loads may shift or fall if improperly supported, causing injury.
FRONT FEEDGATE
HARDWARE
FRONT FEEDGATE
Figure 20 – 1 1/2” or 2” Opening
Figure 21 – 3” Opening
To adjust main bin’s feedgate opening when a MultApplier will be installed: position front feedgates on MultApplier as necessary to achieve a 1-1/2 inch (38 mm), 2 inch (51 mm) (Figure 20) or 3 inch (76 mm) (Figure 21) opening. Position both feedgates with short side down for a 3” (76 mm) opening. NOTE: Both feedgates are installed for shipping.
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NOTICE!
Before placing the insert in the hopper spray a light silicone film on the hopper side sheets where the insert seals will set.
Parts Needed: Description MULTAPPLIER Cap Screw – 1/2 x 1 1/4 Grade 8 Flat Washer – 1/2 Grade 8 Lock Washer – 1/2 Grade 8 Hex Nut – 1/2 Grade
Figure 22 - Four-Point Lift
John deere SPREADER
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Fasten a 4-point lifting device to lift hooks. Hoist empty MULTAPPLIER into spreader as shown in Figure 22. Use a large drift punch or equivalent to align slots and attach hardware. Tighten to recommended torque. Make sure there is a complete seal covering the gap between the MULTAPPLIER and the side sheets of the spreader as shown in Figure 23. Tighten hardware.
SEALER BELT
Figure 23 – Front Sealer Belts
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NOTICE!
Leakage of material may occur if the sealer belts are not set properly on the front of the MULTAPPLIER. Highway Equipment Company is not liable for lost material due to improperly installed sealer belts.
See General Operating Procedures in operator’s manual for feedgate adjustment instructions.
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Hydraulics
MULTAPPLIER MOTOR
Figure 24 – Detach Quick Disconnects
MULTAPPLIER MOTOR
Figure 25 – MULTAPPLIER Operation Detach quick disconnects on the spreader and the MULTAPPLIER as shown in Figure 24. Attach MULTAPPLIER disconnects to spreader disconnects as shown in Figure 25. Plug in rate sensor.
NOTICE!
Highway Equipment Company will not be liable for misapplied material due to an improperly adjusted divider, spreader or both. Remove hardware from rear two holes of chain shield on both sides and set aside. Install MULTAPPLIER Hillside Divider over conveyors and attach using chain shield hardware. Adjust Hillside Divider so that the middle divider is centered over both conveyors and the spinner Material Divider as shown in Figure 26. Tighten hardware to recommended torque. Remove rear plate of material divider.
Hillside Divider Material Divider Figure 26 – Hillside Divider
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Dual Conveyor Cover Parts needed: Description Cover Hold-down Hair Pin Cap Screw – 3/8 x 1 Flat Washer – 3/8 Lock Washer – 3/8 Hex Nut – 3/8
HARDWARE HOLDDOWN
HAIRPIN (FRONT)
COVER
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Figure 27 – Dual Conveyor Cover Place Cover on MULTAPPLIER sills as shown in Figure 27 and insert Hair pins through cover pins. Position Hold-down over cover and attach with hardware. MULTAPPLIER REMOVAL / ENDGATE INSTALLATION Remove MULTAPPLIER and reinstall endgate, Inverted V, single conveyor Hillside Divider, etc. by following installation instructions in reverse order. Make sure the MULTAPPLIER hydraulics are disconnected from the spreader before removal. See “Inverted V” under Installation Instructions.
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Hydraulic Drain Lines See Gear Case Drain Lines, Reservoir Hydraulics, and Pump Hydraulics parts lists in operator’s manual for illustrations. CHECKING INSTALLATION See Initial Start-Up procedure in operator’s manual.
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