Comby | Super Comby | Super Comby EX Instruction Manual

Comby | Super Comby | Super Comby EX

Feedout Wagon Original Instruction

IMPORTANT Read this manual before operation HUSTLER EQUIPMENT INTERNATIONAL LIMITED

CONTENTS

Introduction................................................................................. 2 Important..................................................................................... 2 Warranty ...................................................................................... 3 Warnings...................................................................................... 4 Operational Instructions....................................................... 4-5 Adjustments..........................................................................6-10 Hydraulic Hosing............................................................... 11-17 Wiring Diagram................................................................... 18-23 Greasing Chart................................................................... 24-34 Trouble Shooting............................................................... 35-36

1

INTRODUCTION We take this opportunity of welcoming you as the owner of a Hustler Equipment Machine.

We want your machine to be the most efficient and productive piece of equipment you have. This small manual will help you to achieve this objective The correct parts and maintenance of your machine is very important to prevent downtime and equipment damage.

Please take special note of the warnings on page 4 and troubleshooting on page 35-36.

Correctly maintained and operated this machine will give many years of service. If you have any questions please contact the dealer who supplied you this machine. They have trained technicians who will be able to help you.

IMPORTANT • Please ensure this booklet is read and understood by every operator of this machine.

• Also ensure that this booklet goes with the machine if it is resold and is read and understood by owner.

• This manual is based on the Super Comby EX, included in this manual are the parts that differ to the Comby and Super Comby machines. Where Super Comby EX is stated in this manual it is most likely that the instruction/part applies to the Comby and Super Comby also. If there is any doubt in the information you are looking for in this manual, please contact Hustler Equipment Int (0800 487 853).

2

WARRANTY Hustler warrants new products sold by us to be free from defects in material and workmanship twenty four months after delivery to the initial user. This warranty is for the replacement or repair of any part found to be defective during the warranty period. This warranty excludes any freight cost incurred by the dealer in giving effect to the warranty and specifically excludes all normal maintenance costs.

Replacement parts provided under the terms of this warranty are covered for the remainder of the warranty period applicable to the product in which they are installed as if such parts were original components of that product.

Tools Required For Maintaining Operation • • • • • •

1 1/2 Ring Spanner x 2 30mm Ring Spanner x 2 24mm Ring Spanner x 2 19mm Ring Spanner 18mm Ring Spanner 13mm Ring Spanner

• Flexi Tube Grease Gun

3

WARNINGS To operate this machine on the open road it must comply with the LTSA regulations. To operate this machine in other off road operations it must comply with farm safety regulations. Do not operate while standing in or close to the machine or moving parts.

Do not make any adjustments while the machine is operating.

Beware of surroundings when operating the machine to prevent injury to personnel & prevent damage to the machine.

OPERATION INSTRUCTIONS Connection of the machine • Connect Super Comby EX to tractor via drawbar, quick hitch or Euro hitch connection. Connect towing safety chains when required ( public road use) • Clean hydraulic connectors and couple in to tractor in correct hydraulic banks. If your tractor has a priority system couple the Tilt/Fork hoses into hydraulic bank 1 and machine in to hydraulic bank 2.

• Connect electrics.

• Adjust tractor hydraulic oil flow rate to 60-80 litres per minute.

• Check direction of elevator rotation prior to feeding.

• Load feed material in to machine. Note when feeding silage material load the Cross Feed Chamber and Bed Storage Chamber separate to minimize knitting together of long material across the compartments .This decreases the pressure on the drives to separate the load when feeding out with the cross feed chamber.

Operating tip and tricks: • When loading bales with the fork assembly. Use an electric fence dropper mounted into a bale a few back to see where to line the bales up with the machine.

• If bales don’t roll on to the bed chamber properly off the forks and become stuck in the gap, reverse the bed storage floor back carefully, this will straighten up the bale in to position.

4

OPERATING INSTRUCTIONS CONT. Do not: • Operate the X-Floor or the Bed Storage Floor in the backward direction with material in the machine.

• Actuate the control levers backward and forwards to ‘free’ the load if the floor or elevator chains become jammed. As this can cause damage to drives and hydraulics.

• Apply excessive pressure with fork/bin assembly when rising, while storage floor is fully loaded.

• Overload the machine with material. 10 tonne the maximum capacity.

• Use the elevator in the traveling position to feed out. Always extend the elevator out to feed. Note if the bed storage chain fails to move, extend the elevator fully so the rear flaps are out of the machine then retract into feeding position.

• Ride on the drawbar • Water blast the load cell head unit or load cells or junction box.

• Apply excessive material pressure on to elevator with XFloor load.

• Weld on the machine with a load cell assembly, without first contacting Hustler Equipment Technical staff.

5

ADJUSTMENTS Bed Storage Floor Chains

It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components.

Follow the short instruction below to correctly adjust the bed floor storage chain assemblies.

• Check to see if the chains need to be adjusted • Tighten up Nut 1 whilst holding Nut 2 with a 24mm ring spanner until the floor slats are just sitting on the rear chain guides or contacting the chain guide 20 mm down on the front side (see drawing). Adjust Nut 1 at small intervals.

6

ADJUSTMENT

Elevator Chains

It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components.

Follow the short instruction below to correctly adjust the bed floor storage chain assemblies.

• Check to see if the chains need to be adjusted • Loosen off the bolts that clamp the elevator shaft cover to the elevator screen • Loosen off the 4 x M12 locking bolts on the Drive Shaft Idler Bearing • Loosen off Adjuster Lock Nuts 1 & 3 • Adjust the chain tension adjuster Nuts 2 & 4 until the chain/slat is at the desired tension of 75mm total travel. Check that the drive shaft is close to parallel.

• Tighten up Adjuster Lock Nuts 1 & 3. Tighten up the 4 x M12 locking bolts on the Drive Shaft Idler Bearing • Recheck elevator tension is still correct • Re-clamp elevator shaft cover so there is a minimum 5mm gap between the elevator slat and the elevator shaft cover.

Refer to drawings on next page for part locations

DO NOT OVER TENSION THE ELEVATOR & FLOOR CHAINS. DAMAGE & EXTENSIVE WEAR WILL OCCUR

7

8

ADJUSTMENT ADJUSTMENT OF THE X-FLOOR CHAINS It is important to keep this machine adjusted correctly to get the best performance out of this machine and to reduce wear and tear on components resulting in less down time and broken components.

Follow the short instruction below to correctly adjust the bed floor storage chain assemblies.

• Check to see if the chains need to be adjusted.

• Loosen off the large Nut 1 locking nut.

• Tighten up the large Nut 2 until the X-Floor slats are just sitting on the lower panel returns (see drawing). Adjust Nut 2 at small intervals and adjust both nuts at the same time to get an even chain tension on both sides.

• Tighten up large Nut 1 to lock up the shaft idler shaft assembly.

• Recheck chain tension is still correct.

Nut 1

Slat Just Touching

9

Nut 2

LOADED MACHINE BALE LAYOUT

10

HOSING MACHINE MANUAL Port 1

Port 2

DETAIL A

A

B

C

Port 1

Port 2

Port 1

Port 2

DETAIL B 11

DETAIL C

HOSING MACHINE MANUAL Comby standard machine

Fork Ram

Elevator Motor c

c 5

8

c 3

c

Valve Top Upwards

4

c

7

Power Beyond Valve 6 Port Valve c 6

X-Floor Motor

12

c

2

c 1

To Tractor Remotes

c 9

HOSING MACHINE MANUAL Standard machine Elevator Motor SCEX

5 SCEX

3 SCEX

9 SCEX

Valve Top Upwards

4

Bed Motor

SCEX

8 SCEX

7

Power Beyond Valve 6 Port Valve SCEX

6

X-Floor Motor

SCEX

SCEX

2

1

To Tractor Remotes

To increase system pressure, loosen the lock nut, then screw in relief valve on Power Beyond Valve. This increases pressure to all motors, except the cross floor.

Apply same logic to increase cross floor pressure on the 6 Port Valve, however the pressure is unable to exceed pressure set on Power Beyond Valve.

WARNING! Standard pressure is set at 1800PSI, and can safely be upgraded to 2200PSI. However any higher than this exceeds hydraulic motor specifications.

Adjustment tools require a ring spanner set and allen keys.

13

HOSING MACHINE MANUAL STANDARD MACHINE WITH TILTING ELEVATOR OPTION

Supply

1

Supply

2

TILT

3

TILT

2 TILT

1

TILT

6

TILT

4

TILT

5

Tilt Ram Front

14

Tilt Ram Rear

To Tractor Remotes

HOSING MACHINE MANUAL STANDARD WITH FORK OPTION

Supply Fork

2

2

To Tractor Remotes

Supply

1

Fork Ram

Fork

1

15

HOSING MACHINE MANUAL STANDARD WITH TILTING ELEVATOR, FORK & DIVERTER OPTION Fork Ram

Fork

Fork

2

1

To Tractor Remote

Diverter Valve

Supply

1

Supply

2

TILT

3

TILT

2 TILT

1

TILT

6

TILT

5

TILT

4

Tilt Ram Front 16

Tilt Ram Rear

HOSING MACHINE MANUAL

STANDARD MACHINE WITH COMBY SPREAD/GRAIN OPTION Elevator Motor SCEX

4

SCEX

6 Port Power Beyond Valve

3 SCEX

9

Bed Motor

Valves Top Upwards

SCEX

4

SCEX

8 CS

1/2 Nipple

1

6 Port Valve CS

2

SCEX SCEX

6

2 SCEX

SCEX

7 CS3

X-Floor Motor

To Tractor Remotes

1

CS4

Comby Spread Motor

17

1

Comby Spread/ Grain Bin Valve

WIRING DETAILS MANUAL PARTS LIST Brown Black Purple Jumper 1

Yellow

Black Bed Forward Front Coil Brings oil out front port

Bed Back Rear Coil Brings oil out rear port

7 Core WIre Grey Red

Purple Jumper 1

White Green

Diverter Valve Plug

18

Colour

Operation

Trailer Plug Pin Number

7 Core Black

Earth Return

Pin 5

7 Core White

Earth Return

Pin 3

7 Core Yellow

Direction bed forward

Pin 1

7 Core Brown

Direction bed backwards

Pin 7

7 Core Red

Direction X floor backwards

Pin 6

7 Core Green

Direction X floor feed

Pin 4

7 Core Blue

Dirverter Switch Control

Pin 2

WIRING DETAILS MANUAL PARTS LIST

19

Colour

Operation

Trailer Plug Pin Number

7 Core Black

Earth Return

Pin 5

7 Core White

Earth Return

Pin 3

7 Core Yellow

Direction bed forward

Pin 1

7 Core Brown

Direction bed backwards

Pin 7

7 Core Red

Direction X floor backwards

Pin 6

7 Core Green

Direction X floor feed

Pin 4

7 Core Blue

Dirverter Switch Control

Pin 2

WIRING DETAILS MANUAL PARTS LIST

Wire 3. Green

Wire 3. Brown Wire 3. Blue Wire 7. Yellow

Wire 2. Red

20

Wire 7. Green Wire 7. Red

WIRING DETAILS MANUAL PARTS LIST

Wire J5

Wire 1 Red

Wire J3

Wire J2 Wire J1 Wire J4 Wire J7 Wire 3. Green

21

WIRING DETAILS MANUAL PARTS LIST

Wire 1 Red

Wire 1 Black Wire 2 Black Wire 7 White

Wire 2 Red

Wire 7 Black

Wire 7 Brown 7 Core Cable

Wire 7 Green Wire 7 Yellow Wire 3 Blue 2 Core Cable Wire 3 Brown

3 Core Cable

22

WIRING DETAILS MANUAL PARTS LIST

Wire ID

From component ID

From Compnent Terminal

Wire 1 Black

Earth Joiner Heat Shrink

1

Center Light Contact

1c

Wire 1 Red

Panel Mount Fuse

2

Joystick Contact Switch

3a

Wire J1

Joystick contact Switch

2a

Joystick contact Switch

4c

Wire J2

Joystick contact Switch

2c

Joystick contact Switch

1c

Wire J3

Joystick contact Switch

1a

Joystick contact Switch

3c

Wire J4

SPST Normally Closed

1a

Joystick contact Switch

4a

Wire J5

Center Light Contact

2b

SPST Normally Closed

2b

Wire J6

Contact P9B10VN

4a

Center Light Contact

1c

Wire J7

Center Light Contact

1c

Center Light Contact

1c

Wire J8

Joystick contact Switch

1b

Contact P9B10VN

3c

Wire 2 Black

6mm Crimp Eyelet

1

Earth Joiner Heat Shrink

a

Wire 2 Red

6mm Crimp Eyelet

1

Panel Mount Fuse

1

Wire 3 Blue

Duraplug 3 pin Female

N

SPST Normally Closed

2a

Wire 3 Brown

Duraplug 3 pin Female

L

SPST Normally Closed

2c

Wire 3 Green

Duraplug 3 pin Female

Earth

Center Light Contact

1b

Wire 7 Black

Earth Joiner Heat Shrink

b

Female 7 Pin Trailer Plug

5

Wire 7 Blue

Contact P9B10VN

4c

Female 7 Pin Trailer Plug

2

Wire 7 Brown

Joystick contact Switch

3b

Female 7 Pin Trailer Plug

7

Wire 7 green

Joystick contact Switch

2b

Female 7 Pin Trailer Plug

4

Wire 7 Red

Joystick contact Switch

4b

Female 7 Pin Trailer Plug

6

Wire 7 White

Earth Joiner Heat Shrink

c

Female 7 Pin Trailer Plug

3

Wire 7 yellow

Joystick contact Switch

1b

Female 7 Pin Trailer Plug

1

23

To Component ID

To

GREASING CHART MANUAL

24

4 3 23 2 1

24

GREASING CHART MANUAL

27

25

25

5

6

7 26

8

9

28

GREASING CHART MANUAL

29 12

11 10

26

GREASING CHART MANUAL

15

13

27

14

GREASING CHART MANUAL

16

28

GREASING CHART MANUAL

17

29

GREASING CHART MANUAL

32

31

30

GREASING CHART MANUAL

18 19 20 21

31

GREASING CHART MANUAL

22

32

GREASING CHART PARTS LIST

Nipple Number

Greasing Duration

Manual Section

1

8 Hours

A-1

2

4 Hours

A-8-1

3

4 Hours

A-8-1

4

8 Hours

A-1

5

4 Hours

A-18-8-1

6

4 Hours

A-14

7

4 Hours

A-4-3

8

4 Hours

A-18-8-1

9

4 Hours

A-9

10

8 Hours

A-18-1

11

4 Hours

A-10-4

12

8 Hours

A-18-4

13

4 Hours

A-10-4

14

8 Hours

A-18-3

15

8 Hours

A-10-1-1

16

4 Hours

A-18-7-1

17

4 Hours

A-4-2

18

8 Hours

C-1

19

8 Hours

C-1

20

8 Hours

C-1

21

8 Hours

C-1

22

8 Hours

A-2-2

23

20 Hours

A-7

Waste Oil Chains

24

20 Hours

A-7

Waste Oil Chains

25

20 Hours

A-18-6

Waste Oil Chains

26

20 Hours

A-18-6

Waste Oil Chains

27

8 Hours

A-5

Waste Oil Chains

28

8 Hours

A-9-2

Waste Oil Chains

33

Comments

Remote Grease Nipple

Access Underside of Gearbox

Servicing Wheel Bearings: Wheel bearings have to be checked as part of the general maintenance of the machine, and be serviced when required. The time frame for this varies greatly depending on what conditions they are exposed to. Under normal circumstances once a year is adequate, but if the wheel bearings are exposed to water while in operation or other adverse conditions, the bearings will have to be serviced more frequently to avoid damage and down time. If damage has occurred due to lack of maintenance, warranty claims will de declined.

34

TROUBLE SHOOTING Super Comby EX Trouble Shooting Common Check Procedures • Condition Of Tractor Hydraulics And Electrics • Wiring On Drawbar Not Broken • Is There Power To The System?

• Condition Of Plug-Socket Electrical Connection (Flare Contacts In Plug Socket With Small Screwdriver) • Objects Jammed In Chains Or Chain Thrown Off Sprockets Including Reduction Boxes • Is The Machine Plugged Into The Correct Electrical Plug On Tractor • Is The Fuse Working?

Electrical Vs Hydraulic Failure • Before Undertaking Testing Make Sure That The Tractor Is Running At The Following Specifications • Dead Head Pressure 2500psi – 3000psi • Oil Flow 60-80 Litres Per Min Quick Diagnose 1. Do Hoses Move When Joystick Activated? (No, Electrical Failure (Yes, Hydraulic) 2. Swap Coils On Valve Block Banks (Yes, But Controls Backwards, Hydraulic Failure) 3. Pressing Overriding Buttons On Valve Spool Ends (Yes, Electrical) (No, Hydraulic)

Checking The Condition Of Hydraulic Motor 1. Remove Motor Tank Hose (Motor Low Pressure Side) 2. Supply Oil To Motor Result Large Oil Flow Without Tractor Working Hard To Supply Oil, Motor Damaged.

Minimal Oil Flow While Tractor Working Hard. Motors Good, Look For Jam Up Of Drive.

35

Load Cell Fault Finding • • • • • • • • •

Check For Mechanical Damage To Cells Check For Objects Jamming Cells Check For Loose Bolts Check To See If Machine Has Had Welding Repairs Check Wiring Check For Water Damage In Junction Box Check For Water Damage In Plugs Check Head Unit Calibration (See Manual) Check To See That Battery Hasn’t Been Charged With Power Supply To Head Unit Attached • For More Information On Checking Load Cells Contact Hustler Equipment

36

Comby | Super Comby | Super Comby EX Feedout Wagon

Hustler Equipment LTD PO Box 2127, 1416 Omahu Road Hastings, 4153, New Zealand.

Phone +64 6 879 7926 www.hustlerequipment.co.nz