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Model M A Ult Pplier

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MODEL MULTAPPLIER UNIT SERIAL NUMBER _______________________ MANUAL NUMBER: 306996-AA-E EFFECTIVE 02/2016 1330 76TH AVE SW CEDAR RAPIDS, IA 52404-7052 PHONE (319) 363-8281 | FAX (319) 286-3350 www.highwayequipment.com For Additional information, please visit (Online users direct click links): Service Videos: http://www.highwayequipment.com/customer_support/service-videosv2/ Warranty Registration and Claims Request: http://www.highwayequipment.com/dealer-portal/unit (Dealer Use Only) Copyright 2009 Highway Equipment Company, Inc. TA B L E O F C O N T E N T S NEW LEADER TABLEHEADER OF CONTENTS MULTAPPLIER Table of Contents��2 Installation Information��5 Hydraulic Requirements��5 Pump and PTO Requirements��5 Truck Requirements��7 Hydraulic Pump Installation��7 Hydraulic Hose Installation��8 General Description��11 Dimensions & Capacities - Style I��12 Dimensions & Capacities - Style II��13 Style Comparison��14 Installation Instructions��16 Feedgate Adjustment��16 Insert Installation��17 Hydraulics��20 Hillside Divider��21 Dual Conveyor Cover��22 MultApplier Removal/Endgate Installation��22 General Operating Procedures ��23 Field Testing ��24 Preventative Maintenance Pays!��25 Conveyor Chain��25 Lubrication��25 Tension��25 Lubrication and Maintenance ��25 Conveyor Belt Maintenance��26 Lubrication of Bearings��26 Clean Up��26 Fasteners��26 Grease Gun Lubricant��27 Chain Oil Mixture��27 Lubrication and Maintenance continued��27 Hydraulic Hose��28 Troubleshooting��29 Standard Torques��30 306996-AA-E Page Rev. B 2 Please Give Part No., Description & Unit Serial No. NOTES MULTAPPLIER This page is intentionally left blank. Please Give Part No., Description & Unit Serial No. 3 306996-AA-E Page Rev. B NOTES NEW LEADER Insert Current New Leader Warranty NEW LEADER MULTAPPLIER INSTALLATION HEADER INFORMATION INSTALLATION INFORMATION Recommended sequence of installation is: 1. Spreader preparation. 2. MultApplier preparation. 3. Mounting of MultApplier. 4. Connect hydraulic hoses. 5. Installation of hillside divider and conveyor cover. 6. Checking installation. 7. Checking for leaks and proper functioning. HYDRAULIC REQUIREMENTS Hydraulics L4000 MultApplier Complete L4000 High Performance L3030G4 L3220G4 Spinner & Conveyor MultApplier Spinner Conveyor MultApplier Spinner & Conveyor MultApplier Spinner and Conveyor MultApplier GPM (LPM) (Gallons/Liters per Minute) 40 (151.5) Maximum Pressure 3100 9 (34.1) 40 (151.5) 20 (76) 20 (76) 30 (113.5) 9 (34.1) 40 (151.5) 9 (34.1) 1500 3100 3400 1500 3100 1500 3100 1500 Sizing Data Required: Since optimal performance depends upon the match between pump size, pump speed (which depends upon engine speed and PTO percent), it is essential that a correct match between these factors be made. This matching is called “sizing.” 1. Correct sizing requires accurate and complete information. a. Engine governed operating speed. b. Transmission make and model. c. PTO Data 1. Make and Model of PTO. 2. PTO percentage of Engine RPM. 3. Direction of PTO Rotation (Engine Direction or Opposite of Engine Direction). NOTICE! Excessive engine speed will cause more hydraulic oil to be pumped than is required to drive spinners and conveyor and may result in overheating the oil. Too low an engine speed may not provide sufficient hydraulic oil flow to maintain spread width or to keep the conveyor running at the speed required to deliver the desired quantity of material being spread. NOTE: It may be necessary to select a higher percentage PTO or a larger pump than standard with lower speed engines, such as diesels and heavy duty gasoline engines. Consult your dealer in such cases. It is desirable to install a tachometer in order to maintain proper engine speeds. Please Give Part No., Description & Unit Serial No. 5 306996-AA-E Page Rev. B I N S TA L L AT I O N PUMP AND PTO REQUIREMENTS NEW LEADER INSTALLATION INFORMATION HEADER CONTINUED MULTAPPLIER 2. PTO Pump Selection NOTICE! Do not select a PTO % and an engine RPM resulting in more than 3000 PTO RPM. Driving the pumps (referenced below) at speeds greater than 3000 RPM will result in premature failure of the pump and other hydraulic components. L4000G4 HECO Pump Part Numbers Pump CID Theoretical Pump GPM (LPM) 100% Efficiency Pump RPM 86664 3.85 *40 (151.4) 2350 86665 4.38 40 (151.4) 2100 304424 (Front Section) 4.46 40 (151.4) 304425 (Rear Section for Insert) .93 9 (34.1) 304426 (Rear Section for High Performance Hydraulics) 2.17 20 (75.7) 2075 * - Requires higher RPM to achieve GPM. L3030G4 I N S TA L L AT I O N HECO Pump Part Numbers Pump CID Theoretical Pump GPM (LPM) 100% Efficiency 304428 (Front Section) 3.19 30 (113.6) 304425 (Rear Section) .93 9 (34.1) Pump RPM 2175 * 304428 and 304425 are both required for L3030G4 operation with MultApplier. L3220G4 HECO Pump Part Numbers* 304424 (Front Section) 304425 (Rear Section) Pump CID 4.46 .93 Theoretical Pump GPM (LPM) 100% Efficiency 40 (151.4) 9 (34.1) Pump RPM 2075 * - 304424 and 304425 are both required for L3220G4 operation with MultApplier. To determine PTO (Power Take-Off) percentage: (PTO RPM ÷ OPTIMAL TRUCK ENGINE RPM) x 100 = PTO% To determine Engine RPM: PTO RPM ÷ (PTO% ÷ 100) = Engine RPM 306996-AA-E Page Rev. B 6 Please Give Part No., Description & Unit Serial No. NEW LEADER INSTALLATION INFORMATION HEADER CONTINUED MULTAPPLIER TRUCK REQUIREMENTS Before installing the MultApplier spreader, the following major questions must be considered: 1. Does the CA (Cab to Axle) dimension of the truck permit the addition of the MultApplier? 2. Is the truck’s GAWR (Gross Axle Weight Rating) and the GVWR (Gross Vehicle Weight Rating) adequate to carry the fully loaded spreaders? Refer to your New Leader dealer to find the GAWR and GVWR for most trucks, and how to calculate the weight distribution on each axle and total loaded vehicle weight. HYDRAULIC PUMP INSTALLATION HECO pumps are direct mount. See Pump Hydraulics parts list in the operator’s manual for assembly instructions. LIFTING THE SPREADER Use only lifting devices that meet or exceed OSHA standard 1910.84 or ASME B30.20-2006. Never lift equipment over people. Never lift unit with anything or anybody in the body. WARNING Loads may shift or fall if improperly supported, causing damage to unit, injury or even death. CAUTION Do not use lifting device to free unit from a chassis, storage stands or frozen ground, or to lift the chassis in any way. Shock loading is prohibited and sudden accelerations should be avoided. Lifting in such a manner could result in damage to unit or injury. Position the chassis with adequate room around the unit. Work in an environment that permits clear communication to others nearby. Keep area clear of persons when loads are to be lifted and suspended. Do not allow the lifted load to come in contact with any obstruction. Store units on a solid surface using appropriate storage stands when not installed. Figure 1 - Lifting Bar Please Give Part No., Description & Unit Serial No. 7 306996-AA-E Page Rev. B I N S TA L L AT I O N Always inspect unit lift points for signs of wear, cracking, corrosion, gouges, alterations, or distortion. Always use a sling, spreader bar, or lifting bar that attaches to the lifting points with a minimum of 60 degrees from horizontal. It is preferable to use an “H” style lifting bar that keeps the attaching chains in a near vertical orientation as shown in Figure 1. Operators of lifting devices must be qualified and knowledgeable in their use and application. NEW LEADER INSTALLATION INFORMATION HEADER CONTINUED MULTAPPLIER HYDRAULIC HOSE INSTALLATION 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. Do not use one manufacturer’s hose with another manufacturer’s fittings! Such will void WARNING any warranty and may cause premature burst or leak of hydraulic fluids! Severe injury and/ or fire could result! I N S TA L L AT I O N Determine pressure port of pump. Install pressure hose into this port as shown in Figure 7. Connect suction hose to opposite port and to tank outlet on reservoir. Use plastic tie straps as necessary to support hoses so they will not catch on field obstructions or contact hot or moving parts. Figure 7 - Hydraulic Pump Installation 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. Assemble system as shown in Hydraulics parts list in the operator’s manual. Place hose clamps as needed to keep hoses away from hot or moving parts. Do not let hoses hang so low as to be snagged. Do not stretch hoses tight. Hydraulic hoses are as follows: • Pressure Line: Four wire braided hose. High pressure hose supplied by dealer. • Suction Line: Single spiral wire reinforced to be cut to length. Fittings to be assembled with double hose clamps. • All Return Lines: Double cotton braid with crimped end fittings. 306996-AA-E Page Rev. B 8 Please Give Part No., Description & Unit Serial No. NEW LEADER INSTALLATION INFORMATION HEADER CONTINUED MULTAPPLIER Installation Guide 1. Use elbows and adapters in the installation to relieve 2. Install hose runs to avoid rubbing or abrasion. strain on the assembly, and to provide easier and Clamps are often needed to support long runs of neater installations that are accessible for inspection hose or to keep hose away from moving parts. It is and maintenance. Remember that metal end fittings important that the clamps be of the correct size. A cannot be considered as part of the flexible portion clamp that is too large will allow the hose to move of the assembly. in the clamp causing abrasion at this point. 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.) Please Give Part No., Description & Unit Serial No. 9 306996-AA-E Page Rev. B I N S TA L L AT I O N 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. NEW LEADER NOTES MULTAPPLIER NOTES This page is intentionally left blank. 306996-AA-E Page Rev. B 10 Please Give Part No., Description & Unit Serial No. NEW LEADER GENERAL HEADER DESCRIPTION MULTAPPLIER The MultApplier is a 304 stainless steel hopper-style spreader to be inserted into the L4000G4, L3220G4, L3030G4 or compatible spreader to create a 2 bin hopper. it is available in 5’ (1.52 m) and 7’ (2.13 m) lengths. When installed, the MultApplier allows for two materials to be spread simultaneously. It features a 24-inch (60.96 cm) wide belt-over-chain type conveyor having parallel strands of pintle type (#4) chain joined by cross bars every other link. The direct-driven conveyor is also controlled independently, enabling the delivery of material at variable rates through the adjustable gate at the rear of the hopper body. The hillside divider improves material placement on the spinner for a more effective spread pattern. IMPORTANT! There are currently two styles of MultApplier available: Style I and Style II. Refer to Style Comparisons page to determine differences between styles. Be sure to reference correct style when installing, operating and maintaining MultApplier, and when ordering parts. The Style II MultApplier offers increased output capabilities. This product is intended for commercial use only. GENE RS ATA L D CR IP NT I O N IO AT LS LE IN Please Give Part No., Description & Unit Serial No. 11 306996-AA-E Page Rev. B NEW LEADER MULTAPPLIER HEADER DIMENSIONS & CAPACITIES - STYLE I B 102” (259 C cm) A (INSIDE) DIMEN IN SS IO TA NL S L& AT CIA OPA N CITIES 54” (137Bcm) 69 69” (175 cm) 102” (259 C cm) A (INSIDE) MultApplier Style I Insert Unit Length Inside Length A Overall Length B 5’ (1.52m) MultApplier 7’ (2.13m) MultApplier 60” (152 cm) 84” (213 cm) 78” (198 cm) 102” (259 cm) 306996-AA-E Page Rev. B 12 Approximate Weight Struck Capacity Lbs (Kg) Cu Yd (Cu M) Cu Ft 1000 (454.5) 1200 (545.5) 4.25 (3.25) 115 5.95 (4.55) 161 Please Give Part No., Description & Unit Serial No. NEW LEADER MULTAPPLIER DIMENSIONS & HEADER CAPACITIES - STYLE II B 102” (259 C cm) A (INSIDE) 53” B (135 cm) 102” (259 C cm) A (INSIDE) MultApplier Style II Insert Unit Length Inside Length A Overall Length B ApproximateWeight Lbs (Kg) Struck Capacity Cu Yd (Cu M) Cu Ft 5’ (1.52m) MultApplier 7’ (2.13m) MultApplier 60” (152 cm) 84” (213 cm) 80” (203 cm) 104” (264 cm) 1088 (493.5) 1303 (591.0) 4.26 (3.25) 115 5.96 (4.60) 161 Please Give Part No., Description & Unit Serial No. 13 306996-AA-E Page Rev. B CA N SL& OTA IS D I M E NISN O NC I T I E S I PA L AT 69 69” (175 cm) NEW LEADER Style I Style II 4 FEEDGATE ADJUSTMENT HOLES 9 FEEDGATE ADJUSTMENT HOLES NO HANDLES ON CONVEYOR COVER S TIY NL SE TACLO LM AT PA IO RN ISON MULTAPPLIER STYLE HEADER COMPARISON CONVEYOR COVER HAS HANDLES TRAPEZOIDAL TWO-PIECE FRONT FEEDGATE STIFFENER RECTANGULAR ONE-PIECE FRONT FEEDGATE HILLSIDE DIVIDER HILLSIDE DIVIDER 306996-AA-E Page Rev. B 14 Please Give Part No., Description & Unit Serial No. NEW LEADER NOTES MULTAPPLIER This page is intentionally left blank. NOTES Please Give Part No., Description & Unit Serial No. 15 306996-AA-E Page Rev. B NEW LEADER HEADER INSTALLATION INSTRUCTIONS FEEDGATE ADJUSTMENT WARNING MULTAPPLIER INSTALLATION INSTRUCTIONS 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 before entering. Tag all controls to prohibit operation. Tags should be placed, and later removed, only by person working in the body. Adjust the MultApplier’s front feedgate prior to installation. Figure 1 - 1 1/2” (3.81 cm) or 2” (5.08 cm) Opening (Style I) Figure 2 - 3” (7.62 cm) Opening (Style I) I N S TA L L AT I O N Style I - To adjust main bin’s feedgate opening on a Style I MultApplier-equipped unit: position front feedgates on MultApplier as necessary to achieve a 1-1/2 inch (3.81 cm), 2 inch (5.08 cm) (Figure 1) or 3 inch (7.62 cm) (Figure 2) opening. Position both feedgates with short side down for a 3” (7.62 cm) opening. NOTE: Both feedgates are installed for shipping. Figure 3 - 2 1/2” (3.81 cm) or 2” (5.08 cm) Opening (Style II) Figure 4 - 4” (10.16 cm) Opening (Style II) Style II - To adjust main bin’s feedgate opening on a Style II MultApplier-equipped unit: position front feedgate on MultApplier as necessary to achieve a 1 1/2 inch (3.81 cm) (Figure 3) to 4 inch (10.16 cm) (Figure 4) opening in 1/2 inch increments. NOTE: 306996-AA-E Page Rev. B Visit www.newleadervip.com and enter parameters to determine minimum and maximum application rates and feedgate openings for optimal performance of your spreader. 16 Please Give Part No., Description & Unit Serial No. NEW LEADER INSTALLATION INSTRUCTIONS HEADER CONTINUED MULTAPPLIER INSERT INSTALLATION WARNING Use only lifting devices that meet or exceed OSHA standard 1910.184. Never exceed work load limits or lift equipment over people. Empty spreader before lifting. Loads may shift or fall if improperly supported, causing injury. Before installing the MultApplier: Remove the Inverted V and Hillside Flow Divider from the spreader, if so equipped, and set hardware aside. Adjust the MultApplier’s front feedgate to the proper opening. Support endgate by attaching a hoist to the lift hooks. Remove hardware from both sides of the endgate and hoist from the spreader. Always inspect unit lift points for signs of wear, cracking, corrosion, gouges, alterations, or distortion. Always use a sling, spreader bar, or lifting bar that attaches to the lifting points with a minimum of 60 degrees from horizontal. It is preferable to use an “H” style lifting bar that keeps the attaching chains in a near vertical orientation. Parts Needed: Description MULTAPPLIER Capscrew - 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 8 Qty 1 8 16 8 8 Figure 3A Figure 3B 2. To install MultApplier: a. Figure 3A - Hoist and slide MultApplier into position between main bin’s side sheets. b. Figure 3B - Align MultApplier’s and main bin’s front and rear mount brackets. c. Make sure MultApplier is resting on inside of main bin, and not resting on tops of side sheets. d. Release tension on hoist but do not remove. Please Give Part No., Description & Unit Serial No. 17 306996-AA-E Page Rev. B I N S TA L L AT I O N 1. Make sure rubber sealer hardware is loose. If not, loosen. NEW LEADER HEADER INSTALLATION INSTRUCTIONS CONTINUED Figure 4A (uninstalled) MULTAPPLIER Figure 4B (shown installed) View from rear of unit. I N S TA L L AT I O N 3. Figures 4A-4B - Visually make sure MultApplier is centered from side to side in main bin and rear pads are resting on main bin. Figure 5 Figure 6 4. Figure 5 - There must be contact between rear pads and main unit. Check for contact by trying to slide paper between pads and main bin. If no contact, adjust MultApplier. 5. Figure 6 - Inside main unit, locate front pads by lifting rubber sealers on front endgate. Figure 7A Figure 7B 6. Figures 7A-7B - There must be contact between front pads and main unit. Check for contact by trying to slide paper between pads and main bin. If no contact, adjust MultApplier. NOTE: Pry MultApplier at mount brackets if necessary. 306996-AA-E Page Rev. B 18 Please Give Part No., Description & Unit Serial No. NEW LEADER INSTALLATION INSTRUCTIONS HEADER CONTINUED Figure 8 MULTAPPLIER Figure 9 7. Figure 8 - Once both front pads are in contact, insert hardware in front mount brackets’ lower holes. Shim between main bin and MultApplier brackets if distance is larger than 1/8” (.32cm). Tighten hardware per torque recommendations. 8. Make sure feedgate is level. 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. 9. Figure 9 - Make sure there is a complete seal covering the gap between the MultApplier and the main bin’s side sheets. Tighten all hardware on rubber sealers at front of MultApplier. 12. Install hardware in all four mount brackets’ upper holes. Tighten hardware per torque recommendations. 13. Remove hoist. 14. Inspect unit for foreign debris around conveyor area. Please Give Part No., Description & Unit Serial No. 19 306996-AA-E Page Rev. B I N S TA L L AT I O N 10. Make sure rear pads are still in place against main bin. Install hardware in lower holes of rear mount brackets. Shim between main bin and MultApplier brackets if distance is larger than 1/8” (.32cm). Tighten hardware per torque recommendations in this manual. 11. Make sure MultApplier’s side sheets are not resting on top of main bin’s side sheets. NEW LEADER INSTALLATION INSTRUCTIONS HEADER CONTINUED MULTAPPLIER HYDRAULICS MULTAPPLIER MOTOR Figure 10 – Detach Quick Disconnects MULTAPPLIER MOTOR Figure 11 – MULTAPPLIER Operation I N S TA L L AT I O N Detach quick disconnects on the main bin and the MultApplier as shown in Figure 10. Attach MultApplier disconnects to main bin’s disconnects as shown in Figure 11. Plug in rate sensor. 306996-AA-E Page Rev. B 20 Please Give Part No., Description & Unit Serial No. NEW LEADER INSTALLATION INSTRUCTIONS HEADER CONTINUED MULTAPPLIER HILLSIDE DIVIDER NOTICE! Highway Equipment Company will not be liable for misapplied material due to an improperly adjusted divider, spreader or both. A Style I - Remove hardware from rear two chain shield holes on each side of MultApplier and set aside. Install MultApplier Hillside Divider (A) over conveyors and attach using chain shield hardware. Adjust Hillside Divider so that the middle divider is centered over both conveyors and the Material Divider (B) as shown in Figure 12. Tighten hardware to recommended torque. Figure 12 - Hillside Divider (Style I) B Style II - Loosen hardware from rear two chain shield holes on each side of MultApplier. Install MultApplier Hillside Divider (A) and fasten to Support using single bin Hillside Divider hardware removed before MultApplier installation (B). Adjust Hillside Divider so that the middle divider is centered over both conveyors and the Material Divider (C) as shown in Figure 13. Tighten all hardware to recommended torque. C A Figure 13 - Hillside Divider (Style II) Please Give Part No., Description & Unit Serial No. 21 306996-AA-E Page Rev. B I N S TA L L AT I O N B NEW LEADER INSTALLATION INSTRUCTIONS HEADER CONTINUED MULTAPPLIER DUAL CONVEYOR COVER Parts Needed: Description Cover Hold-down Hair Pin Capscrew - 3/8 x 1 Flat Washer - 3/8 Lock Washer - 3/8 Hex Nut - 3/8 D C A B (FRONT) Qty 1 1 2 6 6 6 8 Figure 14 - Dual Conveyor Cover (Style I) Style I - Remove rear plate of Material Divider. Place Cover (A) on MultApplier sills as shown in Figure 14 and insert hair pins (B) through cover pins. Position Hold-down (C) over cover and attach with supplied hardware (D). Reinstall rear plate of material divider. Parts Needed: I N S TA L L AT I O N Description Qty Cover 1 Hair Pin 2 B A C (FRONT) Figure 15 - Dual Conveyor Cover (Style II) Style II - Remove rear plate of Material Divider. Place Cover (A) on Hillside Divider Support (B) as shown in Figure 15 and insert hair pins (C) through cover pins. Reinstall rear plate of material divider. 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 and electrical are disconnected from the main bin before removal. See “Inverted V” in the New Leader Installation Instructions manual. 306996-AA-E Page Rev. B 22 Please Give Part No., Description & Unit Serial No. NEW LEADER WARNING GENERAL OPERATING HEADER PROCEDURES MULTAPPLIER Stand clear of moving machinery. NOTE: Do not load spreader with material. 1. Check entire unit to make sure all fasteners are in place and properly tightened per Standard Torques National Coarse (NC) Capscrews section in this manual. 2. Make sure no other persons are in vicinity of truck or spreader. 3. Make sure no loose parts are in unit or on conveyor or spinner. 4. Set feedgate so it is completely clear of conveyor. 5. Refer to the controller’s operation manual for the correct setting to operate the conveyor. Run conveyor until it is operating smoothly. WARNING DO NOT check for leaks adjacent to moving parts while system is operating as there may be danger of entanglement! 6. Check all connections in hydraulic system to make sure there are no leaks. Unit is now ready for field testing. Please Give Part No., Description & Unit Serial No. 23 306996-AA-E Page Rev. B DURES EN IO OC AT LR N GLP I TA INS O P E R AT WARNING DO NOT check leaks with hands while system is operating as high pressure oil leaks can be dangerous! If skin is pierced with hydraulic fluid at high pressure seek immediate medical attention as fluid injected into the skin could cause gangrene if left untreated. Relieve pressure before disconnecting hydraulic lines or working on system. Make sure all hydraulic fluid connections are tight and all hydraulic hoses and lines are in good condition before applying pressure to the system. Wear protective gloves and safety glasses or goggles when working with hydraulic system. NEW LEADER MULTAPPLIER FIELD HEADER TESTING 1. Read General Operating Procedures section of spreader manual. 2. Make sure unit has been properly serviced and is in good operating condition. Field test unit prior to first use, prior to each spreading season’s use and following overhaul or repair work, to verify that all components and systems are functioning properly. See Field Testing section in spreader manual. 3. Set rear feedgate opening to obtain yield desired. To adjust MultApplier rear feedgate: pull hair pins and move feedgate. Measure from conveyor to bottom of feedgate to determine opening—holes are at 0.529-inch (1.34cm) intervals. Replace hair pins. To adjust MultApplier front feedgate see “Front Feedgate Adjustment” under Installation Instructions. 4. 5. 6. 7. Fill hoppers with materials to be spread. Drive to location where spreading is to be done. Set controller program to desired values for each hopper in use. Engage pump drive PTO. CAUTION Drive only at speeds which permit good control of vehicle! 8. Drive at speeds that allow engine to turn at proper RPM. If necessary, shift transmission into lower gears so engine speed can be maintained to allow adequate hydraulic oil delivery from pump. F IN IE SL TA DL TL EAT S TIIO NN G *Visit www.newleadervip.com for interactive tools to calculate yield, proper feedgate opening, conveyor revolutions per minute, and mph to maximize the performance of your spreader. 306996-AA-E Page Rev. B 24 Please Give Part No., Description & Unit Serial No. NEW LEADER LUBRICATION HEADER AND MAINTENANCE MULTAPPLIER PREVENTATIVE MAINTENANCE PAYS! The handling and spreading of commercial fertilizers is a most severe operation with respect to metal corrosion. Establish a frequent, periodic preventative maintenance program to prevent rapid damage to spreading equipment. Proper cleaning, lubrication and maintenance will give you longer life, more satisfactory service and more economical use of your equipment. WARNING Shut off all power and allow all moving parts to come to rest before performing any maintenance operation. CONVEYOR CHAIN WARNING Hose down unit and remove any material build-up on sprockets and under chain. NOTICE! The conveyor will move away from the bottom panel if material accumulates under the conveyor or on the sprockets. The more material that accumulates, the closer the chain will come to the chain shields. If the conveyor should catch a chain shield, it could permanently damage the conveyor, the chain shields or the unit. Do not remove material while conveyor or spinner is running! LUBRICATION Make sure unit is clean and completely dry. Lubricate conveyor chain bi-weekly and at end of each season with Fluid Film™ or equivalent. Shut down spinner and run conveyor at 20 RPM for two full revolutions to lubricate chain. After each unit washing, allow to dry, then lubricate. TENSION Proper chain tension is also a factor in chain and sprocket life (Figure 14). Measure from rear of unit forward to achieve proper chain tension. MultApplier conveyor touches bottom of sill only at center when properly tensioned. Make sure chain is tensioned equally on both sides. This adjustment is made on each side of the unit with the extended idler take-up at the rear. REAR Proper Tension: MultApplier conveyor center Touches at Center Figure 14 - Chain Tension Please Give Part No., Description & Unit Serial No. 25 306996-AA-E Page Rev. B L U B R I C AT I O N & M A I N T E N A N C E 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 before entering. Tag all controls to prohibit operation. Tags should be placed, and later removed, only by person working in the body. NEW LEADER LUBRICATION AND MAINTENANCE HEADER CONTINUED MULTAPPLIER Conveyor chains that are too tight will tend to stretch, causing excess sprocket wear and eventually breakage. Excess slack presents the possibility of chain catching on sub-frame parts. Bent or distorted chain bars will cause damage as well. Straighten or replace bent or distorted chain bars immediately. CONVEYOR BELT MAINTENANCE Standard belt for the #4 chain is moderate oil resistant that is impervious to moisture, weathering, or normal action which can be used with chemical impregnated fertilizer or oil based additives. Inspect belt fastener occasionally for wear or “raveling” of belt grip area. LUBRICATION OF BEARINGS L U B R I C AT I O N & M A I N T E N A N C E Grease in a bearing acts to prevent excessive wear of parts, protects ball races and balls from corrosion, and aids in preventing excessive heat within the bearing. It is very important the grease maintain its proper consistency during operation. It must not be fluid and it must not channel. Make sure all fittings are thoroughly cleaned before grease is injected. Points to be lubricated by means of a grease gun have standard grease fittings. Lubricate bearings by pumping grease slowly until it forms a slight bead around the seals. This bead indicates adequate lubrication and also provides additional protection against the entrance of dirt. CLEAN UP NOTICE! High pressure wash can inject water and/or fertilizer into control components, causing damage. Use caution when cleaning these areas. Thoroughly wash unit every two to three days during the operating season to maintain minimal maintenance operation. Hose unit down under pressure to free all sticky and frozen material. It is important the unit be thoroughly cleaned at the end of each operating season. All lubrication and maintenance instructions should be closely followed. Repaint worn spots to prevent formation of rust. FASTENERS Tighten all screws fasteners to recommended torque’s after first week of operation and annually thereafter. If loose fasteners are found at anytime, tighten to recommended torque. Replace any lost or damaged fasteners or other parts immediately. Check MultApplier’s mounting hardware every week. 306996-AA-E Page Rev. B 26 Please Give Part No., Description & Unit Serial No. NEW LEADER LUBRICATION AND MAINTENANCE HEADER CONTINUED WARNING MULTAPPLIER Shut off all power and allow all moving parts to come to rest before performing any maintenance operation. The spreader should be regularly lubricated with the lubricants recommended in this manual in accordance with the following chart: CONVEYOR Driveshaft Bearings Idler Shaft Bearings Take-Up Screws Chain PLACES 2 2 2 2 Strands METHOD Grease Gun Grease Gun Hand Grease Fluid Film™ FREQUENCY Weekly Weekly Weekly Bi-Weekly NOTE: Unusual conditions, such as excessive dust, temperature extremes or excessive moisture may require more frequent lubrication of specific parts. GREASE GUN LUBRICANT Use a waterproof ball and roller bearing lithium base lubricant with a minimum melting point of 300°F (148.8° C). This lubricant should have a viscosity which assures easy handling in the pressure gun at prevailing atmospheric temperatures. The grease should conform to NLGI No. 2 consistency. CHAIN OIL MIXTURE Use Fluid Film™ or equivalent. Please Give Part No., Description & Unit Serial No. 27 306996-AA-E Page Rev. B L U B R I C AT I O N & M A I N T E N A N C E NOTICE! The lubricant distributor and/or supplier is to be held responsible for results obtained from their products. Procure lubricants from distributors and/or suppliers of unquestionable integrity, supplying known and tested products. Do not jeopardize your equipment with inferior lubricants. No specific brands of oil are recommended. Use only products qualified under the following oil viscosity specifications and classification recommended by reputable oil companies. NEW LEADER LUBRICATION AND MAINTENANCE HEADER CONTINUED MULTAPPLIER HYDRAULIC HOSE Hose assemblies in operation should be inspected frequently for leakage, kinking, abrasion, corrosion or other signs of wear or damage. Worn or damaged hose assemblies should be replaced immediately. WARNING Testing should be conducted in approved test stands with adequate guards to protect the operator. L U B R IO CP AT ER IO . & N & MA MIA NITN ET NEANNACNEC E Clean Clean assembly by blowing out with clean compressed air. Assemblies may be rinsed out with mineral spirits if the tube stock is compatible with oil, otherwise hot water at 150°F (65.55° C) maximum may be used. Inspect Examine hose assembly internally for cut or bulged tube, obstructions, and cleanliness. For segment style fittings, be sure that the hose butts up against the nipple shoulder; band and retaining ring are properly set and tight, and segments are properly spaced. Check for proper gap between nut and socket or hex and socket. Nuts should swivel freely. Check the layline of the hose to be sure the assembly is not twisted. Cap the ends of the hose with plastic covers to keep clean. Test The hose assembly should be hydrostatically tested at twice the recommended working pressure of the hose. Test pressure should be held for not more than one minute and not less than 30 seconds. When test pressure is reached, visually inspect hose assembly for: 1. Any leaks or signs of weakness. 2. Any movement of the hose fitting in relation to the hose. Any of these defects are cause for rejection. Storage and Handling Hose should be stored in a dark, dry atmosphere away from electrical equipment, and the temperature should not exceed 90° F (32.22° C). 306996-AA-E Page Rev. B 28 Please Give Part No., Description & Unit Serial No. NEW LEADER TROUBLESHOOTING HEADER MULTAPPLIER Spinners turn but conveyor and/or meter wheel does not run in manual mode. See reasons 1, 2, 3, 4, 9 & 10. • Symptom: Console in operation mode, but the conveyor and/or meter wheel does not move when the machine moves. See reasons 1, 2, 3, 4, 9 & 10. • Symptom: Conveyor and/or meter wheel does not run with cab control “On”, PTO engaged and vehicle driving forward. See reasons 7, 9 & 10. • Symptom: Conveyor and/or meter wheel runs when control switch in cab is in “Off” position. See reasons 5, 6, 8, & 10. • Symptom: Conveyor starts to run when PTO is engaged. See reasons 5, 7, 9, 10 & 12. • Symptom: Peak conveyor revolutions cannot be achieved. See reasons 10 & 11. • Symptom: Controller application or programming. Refer to the control manual’s Troubleshooting section. • Symptom: Undesirable spread pattern. See G4 Spread Pattern section at the back of the spreader manual. Reason 1. MultApplier conveyor relief valve open to return line. Correction Using relief valve testing adapter and flow meter, test valve for opening pressure. If not 1500 PSI (103.4 b), replace relief valve. Free up conveyor. Replace motor. 2. Jammed or frozen conveyor. 3. Jammed or frozen conveyor/meter wheel hydraulic motor. 4. Conveyor hydraulic motor shaft key sheared. Replace key. 5. Excessive oil is being pumped. 1. PTO percentage too high. Change PTO to smaller percentage or use smaller pump. 2. Pump is too large. Do not exceed 9 GPM (34 LPM) pumping rate. Change to smaller pump or use smaller percentage PTO. 3. Pressure drop in control valve is sufficient to run lightly loaded conveyor motor. Shut off pump drive by disengaging PTO shaft. 6. Conveyor valve not set properly. Consult New Leader dealer for adjustments. 7. Defective radar. Check speed on console. Repair or replace radar as required. 8. Control processor’s power is in “Off” posiTurn on control processor. tion. 9. Involves the controller. Refer to control manual. 10. MultApplier hydraulic circuit is not routed Route hydraulic circuit per instructions specific to spreader. correctly. 11. MultApplier runs by using excess hydraulic Increase feedgate opening or slow driving speed. flow from spreader. Please Give Part No., Description & Unit Serial No. 29 306996-AA-E Page Rev. B NANCE EG TN TI IN AO MO SH L E& BN IO OU AT CR L U B R IT • Symptom: NEW LEADER MULTAPPLIER STANDARD TORQUES HEADER NATIONAL COARSE (NC) CAPSCREWS CAP SCREW GRADE IDENTIFICATION - MARKINGS ON HEAD SAE GRADE 2 NO MARKINGS SAE GRADE 5 THREE MARKS - 120 DEGREES APART SAE GRADE 8 SIX MARKS - 60 DEGREES APART USE GRADE 2 TORQUES FOR STAINLESS STEEL FASTENERS AND CARRIAGE BOLTS. LUBO RI PC EAT R . I& ON MA &I M NT AE INT AE NN CA EN C E TORQUE - FOOT-POUNDS CAP SCREW SIZE 1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 3/4” 7/8” 1” 306996-AA-E Page Rev. B GRADE 2 DRY 5 11 20 30 50 65 90 100 140 220 GRADE 5 LUBE 4 8 15 24 35 50 70 120 110 160 DRY 8 17 30 50 75 110 150 260 400 580 30 GRADE 8 LUBE 6 13 23 35 55 80 110 200 300 440 DRY 12 25 45 70 110 150 220 380 600 900 LUBE 9 18 35 55 80 110 170 280 460 650 Please Give Part No., Description & Unit Serial No.

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