- RCI Engineering LLC
Transcription
- RCI Engineering LLC
Air Compressor Bundle for 7050 and 7080 SPFH Operator Manual Includes installation, operating, adjustment, maintenance, technical, repair parts and safety instructions for the air compressor bundle. Please retain this document for future reference. RCI Engineering LLC RC077081 (15 Jun 2013) www.RCIengineering.com 1 RCI Engineering LLC New Attachments for Agricultural Equipment Warranty Statement RCI Engineering LLC, hereinafter referred to as RCI, warrants new RCI attachments, to the Original Retail Purchaser to be free from defects in material and workmanship for a period of one (1) year from the date of sale. RCI warranty includes: Genuine RCI parts costs required to repair or replace equipment at the selling dealer’s business location. RCI MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESSED OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT. RCI WARRANTY DOES NOT INCLUDE: 1. Transportation to the selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call. 2. Freight costs above standard shipping costs for the replacement parts. 3. Labor to make the repair or installation of the failed component. 4. Used equipment. 5. Components covered by their own non-RCI warranties, such as tires and trade accessories. 6. Repairs or adjustments caused by: improper use; non-intended use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty. 7. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment or damage to machines to which the attachment is installed. No agent, employee, or representative of RCI has any authority to bind RCI to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply. 2 Air Compressor Bundle Intended Use: To supply air for cleaning the machine when in Park. Table of Contents Warranty Intended Use Table of Contents Safe Operation of Machine Maintenance Bolt and Screw Torque Values Repair Parts General Comments Replacement Hardware Replacement Parts Delivery Checklist Contact Info – Instruction Issue Reporting Warranty Claim Form 2 3 3 5 6 7 9 9 9 9 41 42 43 3 Product Information This Air Compressor Bundle can be installed on the 7350 thru 7750 and 7280 thru 7780 Self-Propelled Forage Harvesters to reduce time in cleaning and service of the machine. This bundle is not compatible with any machines built prior to MY2012. It will also not fit the 7250, 7180, 7950 and 7980 models. No bundle exists for these other machines. The RC077001 Air Compressor Bundle is available from RCI ENGINEERING LLC with the following specifications: Rated Flow: 13.2 CFM @ 90 psi Rated Pressure: 90-115 psi (unloader valve settings) Reservoir: 10 Gallons IMPORTANT: Machines equipped with IT4 Engines have the auxiliary drive installed from the factory. Non-IT4 engines may or may not have the auxiliary drive gears installed from the factory. File a DTAC case to confirm and to determine options for having John Deere install the auxiliary drive gears as needed. Also, a software update from John Deere is required for MY2012 machines for proper function. The air system is only enabled when the machine is in Park. During installation, make sure all controllers are updated to the latest software. Estimated Install Time: 5 to 7 hours, depending on technician experience. This does not include the time required to install the auxiliary drive gears or updating software. 4 Safe Operation of Machine Operator Authorization The machine owner must provide the operator of the machine this manual and ensure that the operator reads and understands the contents. This must be performed before the machine is put into operation. Safety Alert Symbol This safety alert symbol is used to alert the operator to the potential for personal injury. Whenever this symbol is noticed in this manual or on the machine, be alert to the situation and read the message near the symbol. Always be alert for the potential for personal injury. General Safety Precautions / Accident Prevention Before operation of the machine each time, check the entire machine for operational safety. 1/ Read Operator's Manual completely before transporting unit. 2/ Do not use air system unless machine is in Park and all harvesting components have stopped moving. 3/ Do not use the air system to clean the engine compartment unless the engine has been turned off. 4/ Inspect safety valve regularly and replace or repair if defective. 5 Maintenance Check for water in air tank every 100 hours of machine use. Drain as necessary. Replace the air tank per the recommendation specified on the tank. 6 Bolt and Screw Torque Values 7 8 Repair Parts General Comments The following pages include information regarding parts for the Air Compressor Bundle. Right or left hand parts are determined by sitting in the operator’s seat facing forward. The abbreviation “A.R.” in the “USED” column indicates “As Required.” This is because a different number of the specific component may be needed for proper assembly depending on the tolerance of the individual machine. Replacement Hardware All bolts, cap screws, washers and machine screws are grade 8.8 and zinc plated unless markings on the part indicate otherwise. Flange bolts and flange nuts are metric grade 8.8 and zinc plated unless markings on the part indicate otherwise. The use of improper hardware in any location can result in the failure of the component fastened with the hardware or related structures, and can cause personal injury, further damage to the product, or loss of property. Replacement Parts Replacement parts may have occasional differences to the parts being replaced. This difference is typically providing the benefit of a design change made after the release of this publication. 9 Part Listing 10 Component C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Fitting F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 Description ENGINE – REFERENCE ONLY COMPRESSOR, 13.2 CFM TANK, AIR VALVE, SOLENOID REEL, HOSE GUN, BLOW AIR INTAKE TUBE – REFERENCE ONLY VALVE, 3/8 NPT X BARB RELIEF, SAFETY VALVE, DRAIN Part Number N.A. RC077002 RC077044 RC077042 RC077047 RC077049 N.A. RC077069 RC077045 RC077046 QTY. 1 1 1 1 1 1 1 1 1 1 Description COUPLER, 3/4 NPT ANCHOR ELBOW, 3/4 NPT X NPTF 90DEG BARB, 3/4 NPT X HOSE CLAMP, #20 SS HOSE CONNECTOR, 1/2 NPTM X #8 ORFS O-RING FITTING, ADAPTER FITTING, ADAPTER ELBOW, 1/8 NPT X 1/4 PTC 90DEG CONNECTOR, 1/2 NPT X FNPSM STRAIGHT SWIVEL ELBOW, 1/2 NPT X NPT 90DEG FITTING, ELBOW FITTING, ADAPTER O-RING FITTING, ELBOW TEE, 1/2 NPT MALE RUN BUSHING, 1/2 NPT X 3/8 NPTF ELBOW, 1/4 NPT X PTC 90DEG TEE, 1/4 NPT MFF REDUCER, 3/8 NPTF X 1/4 NPT BUSHING, 3/4 NPT X 1/2 NPTF TEE, 3/4 NPT MFF ELBOW, 1/2 NPT X PTC 90DEG CONNECTOR, 3/8 NPT X 1/2 PTC STRAIGHT ELBOW, 3/8 NPT X 1/2 PTC 90DEG COUPLER, 3/8 NPTF X 1/4 QUICK COUPLER, 1/4 NPT X 1/4 HOSE Part Number RC077065 RC077066 RC077067 RC077041 RC077076 RC077033 RC077040 RC077020 RC077060 RC077070 RC077071 RC077010 RC077007 RC077008 RC077006 RC077068 RC077056 RC077059 RC077057 RC077058 RC077054 RC077053 RC077055 RC077061 RC077064 RC077062 RC077063 QTY. 1 1 1 2 1 4 1 2 1 1 1 1 2 2 1 1 2 1 1 1 3 1 1 2 1 1 1 11 Line 1 2 3 4 5 6 7 8 9 10 Description HOSE, 3/8 ID, 1/2 NPSMF X 1/2 NPT SS BRAIDED, 8" LINE LINE LINE LINE, 1/4" AIR, 51" HOSE, 1/2 ID, 1/2NPSMF X 1/2 NPT SS BRAIDED, 51" HOSE HOSE, 1" I.D. RUBBER LINE, 1/2" AIR, 40" LINE, 1/2" AIR, 144" 12 Part Number RC077080 RC077028 RC077024 RC077039 RC077072 RC077079 RC077009 RC077073 RC077074 RC077075 QTY. 1 1 1 1 1 1 1 1 1 1 Installation Instructions 1.0 Mount Compressor 1.1 Drain cooling system as needed. Note: This is to install the coolant lines to the air compressor. 1.2 Remove access cover of auxiliary drive. 1.3 Assemble Air Compressor and adapter as shown in Figure 2. Install Air Compressor and Gasket. Install two mounting cap screws and tighten to specifications. Reuse mounting cap screws from cover plate. Specification: Air Compressor Mounting Cap Screw Torque 102 Nm (75 lb-ft) Install mounting support block and hardware (Key 34 in Figure 2). Tighten properly. 1.4 Install oil supply line and fittings. Secure oil lines as shown with P-Clamps and supplied hardware. 1.5 Install coolant lines to air compressor. 1.6 Fill cooling system. Note: The Air Compressor on the 13.5L Engine, depending on vintage of engine, may interfere with one of the tabs of the block of the engine as shown in Figure 1. Use a cutoff wheel / grinder to remove half of the ear prior to compressor installation if interference occurs. This compressor system and installation are common to John Deere 12.5/13.5 L engines. See the “Remove and Install Air Compressor” section of the technical manual for the 6135 Engine for any further details needed. Figure 1. Location of Interference Key 1 – Tab Location (Behind Hoses) 13 Figure 2. Air Compressor Component Diagram 14 Figure 3. Parts Listing of Compressor Components Key Part Number Part Name Qty Comments 1 T74412 Clamp 4 2 19M7783 Screw 1 3 RE534610 Bracket 1 4 RE540044 Line 1 5 RE547994 Line 1 6 T77857 O-Ring 5 7 38H1005 Elbow Fitting 1 8 R26375 O-Ring 1 9 38H5036 Elbow Fitting 1 10 51M7042 O-Ring 1 11 RE540045 Line 1 12 38H5011 Adapter Fitting 1 13 51M7041 O-Ring 1 14 T77814 O-Ring 1 15 T11899 O-Ring 1 16 T80937 Adapter Fitting 1 17 T12938 Elbow Fitting 1 18 42M7069 Stud 2 19 R531534 Gasket 1 20 14H1083 Nut 1 21 R70268 Washer 1 22 R526621 Gear 1 23 T70176 O-Ring 1 24 R526646 Housing 1 25 RE530365 Screw 2 26 19M7784 Screw 1 M10 X 20 27 14M7299 Flange Nut 2 M12 28 51M7047 O-Ring 1 23.600 X 2.900 mm 29 38H5245 Elbow Fitting 1 30 RE546711 Compressor 1 31 19M7865 Screw 1 M8 X 16 32 19M7786 Screw 2 M10 X 30 33 19H3411 Screw 1 3/8" X 1-1/8" 34 R532992 Bracket 1 35 RE547925 Line 1 M10 X 16 (INCLUDES T77857) 13.300 X 2.200 mm 11.300 X 2.200 mm 5/8" 15 Figure 4. Compressor Installation Completed Note: Air Intake and Exhaust lines are shown installed but will be installed in the next few stages. Note that tab at intake manifold is modified. Figure 5. Coolant Return Line Installation at Back Side of Engine For line mounting, see Figure 6. Key F21 – Bushing, ¾ NPT x ½ NPT Key F5 – Connector, ½ NPT x -8 ORFS 16 Note: Line 1 is short braided hose that is 8” Long and has an ½” NPT end. The main coolant return line is the original John Deere tube line that passes alongside the engine. Key 1 – Oil Cooler Figure 6. Coolant Line Mounting Key 2 – Clamp Mounting Key 3 – Coolant Line Figure 7. Coolant Line Mounting Key 1 – 8” Adapter Line Key 2 – Bushing at Water Pump Key 3 – John Deere Coolant Line 17 Figure 8. Coolant Line Routing Key 1 – Coolant Line Reference: Location above flywheel housing 18 Figure 9. Hanger Bracket Installation above Flywheel Housing Key 1 – Coolant Line Key 2 – Hanger Bracket Key 1 – Coolant Line Figure 8. Coolant Line Install Key 2 – Oil Line (ref) Key 3 – T-Fitting an Elbow 19 Figure 10. Coolant Line Component Identification Key C8 – Valve, 3/8” NPT x BARB Key F6 – O-Ring Key F8 – Fitting, Adapter Key F16 – Tee, ½ NPT Male Run Key F17 - Bushing 2.0 Install Intake Line 2.1 Drill hole in air intake boot of engine. Remove elbow from air intake. See Repair manual for 6135 Engine for information. more Locate and Drill a 32 mm (1.25”) diameter hole approximately 75 mm (3”) from the inside edge of the contact with the filter housing when installed (First Bend) as shown in Figure 10 or 11, depending on emissions level of the engine. 20 Figure 10. Hole Location at Boot. Key 1 – Location Key 2 – Boot Figure 11. IT4 Engine – Hole Location Key 1 – Location Key 2 - Boot 21 Figure 12. Hole Location and Diameter 2.2 Install fitting in air intake boot of engine. See Figure 13 for components used. (Washers with bulkhead fitting not shown) Figure 13. Fittings at Intake Boot Key F1 – Bulkhead Fitting Key F2 – 90 Degree elbow, ¾” NPT Key C7 – Boot (for reference) Key F3 – ¾” NPT to 1” Hose Barb Key F4 – Hose Clamp Key 8 – Intake Hose 22 Install the bulkhead fitting from the inside out, with only a washer and no retaining ring on the inside. See Figure 14. Figure 14. Bulkhead Fitting Note: Install washer against boot, threads to outside. At the outside of the boot, install the washer, retaining ring, and nut. The washer is installed under the retaining ring, against the boot. Use a thin layer of high temperature silicone sealant around the base before installing the nut. See Figure 15. Figure 15. Bulkhead Fitting Installation Note: Install Washer against boot, under retaining ring. Tighten nut properly. Scar the threads directly above the nut to prevent inadvertent loosening. Reinstall boot on engine. Install elbow fitting, hose barb and hose with hose clamp. See Figure 16. 23 Figure 16. Bulkhead Fitting Installation Completion Key 1 – Hose Key 2 – Elbow (brass) Key 3 – Point of thread scarring (important) Key 4 – Washer Key 5 – Retaining Ring Route air hose over the engine to the compressor. Secure with tie bands as necessary. Do not secure the air line to any coolant lines, fuel lines, or near any exhaust or other components that may become hot during operation. Cut off excess hose and discard. Figure 17. Air Intake Line Assembly Completion Key 1 – Air Line Key 2 – Hose Clamp 24 3.0 Install Air Tank 3.1 Install Tank Brackets Install tank brackets over left frame rail, in engine compartment. Assemble with provided hardware, but leave hardware loose until the tank is fully installed. It is recommended to leave the self-threading screws until all components are installed fully. Figure 18. Tank Frame Component Identification Key 1 – Plate Key 2 – Hanger Bracket Key 3 – Base Plate Key 4 – SPFH Frame for Reference Only 25 Figure 19. Bracket Installation Figure 1. Self-Threading Screw Installation Locations (3/8” x 1” Thread Rolling Screws) Note: Pilot hole size of 11/32” (8.5mm) is needed for proper installation of screws. Figure 20. Bracket Installation Key 1 – Location of Mounting Hardware (M10 x 25 Flange, with Flange Nut) 26 Figure 21. Bracket Location Key 1 – Flush with Existing Bracket Key 2 – Filler Plate (for reference) 3.2 Install Tank Mount tank to bracket with tank tag facing to the outside. Use M10 x 45 Flange Bolts and Lock Nuts to secure tank to frame. See Figure 22. Figure 22. Tank Installation Key 1 – Tank Key 2 – Mounting Hardware (4X) Key 3 – Tank Tag Key 4 – Space to frame – For Reference of Install Only Ensure that the tank is not in contact with the rear axle support bracket or other structural components before tightening all hardware. 27 4.0 Install Hose Reel 4.1 Locate and Drill Holes Locate the hose reel and select a location at the front of the right cab platform that is clear of any other accessories and the cab side window in the open position. Mark four holes and drill to 11mm (7/16”) diameter. 4.2 Install Hose Reel Install hose reel using four M10 x 25 Flange Bolts and M10 Flange Nuts. See Figure 23. Figure 23. Installation of Hose Reel Key 1 – Hose Reel Key 2 – Bolt Locations (2 hidden) 5.0 Install Shut-Off Valve 4.1 Locate valve and drill holes. Assemble the shut-off valve and Push-To-Connect Fittings as shown in Figure 24. 28 Figure 24. Shut-Off Valve Assembly Key C4 – Valve Key F24 – ½” Hose PTC Fitting At the firewall support along the right frame rail, select a location to mount the solenoid valve assembly as shown in Figure 25. Keep the valve centered on the part. Place the ubolts over the assembly and mark four holes to be drilled. Drill the locations to 8mm (5/16”) diameter. Install the valve and use red thread retaining compound to secure the nuts on the back side of the u-bolt. Figure 25. Shut-Off Valve Installation Key 1 – Valve Key 2 – U-Bolts Key 3 – PTC Fittings Key 4 – Harness Installation Key 5 – Main Frame Harness Connection 29 Locate the wire harness supplied and attach the two wires to the wires at the coil using the supplied crimp connectors. Install the conduit over the wires from the Deutsch connector to the coil. Tape ends with black electrical tape. Locate the 2-pin Deutsch connector at the main SPFH harness as shown in Figure 25. Remove cap and plug connector into the main harness. 5.0 Install Air Governor 5.1 Locate valve and assemble components. Assemble the governor and plugs as shown in Figure 26 and 27. Figure 26. Air Governor Assembly Figure 27. Air Governor Assembly 30 5.2 Install Air Governor Install air governor to compressor as shown in Figure 28. Install gasket between governor and compressor. Assemble with two M8 x 80 mm long bolts and 8mm washers through the governor. Tighten hardware properly. Install 1/4” 90 Deg PTC Fitting at governor as indicated by Figure 28. Figure 28. Air Governor Installation Key 1 – Air Governor Key 2 – 1/4” 90 Deg PTC Fitting Key 3 – 1/4” Air Line 6.0 Install Remaining Fittings and Hoses 6.1 Install Fittings and Safety Valve at Tank Install fittings and safety valve at tank. See Figure 29 for component description and Figures 30 through 32 for images of installation. Tighten all fittings properly. Install plugs in remaining ports on tank. Use thread sealing tape or compound when installing. 31 Figure 29. Fitting and Safety Valve Installation Key C9 – Safety Valve Key F20 – Adapter Key F19 – T-Fitting Key F18 – 1/4” 90 deg PTC Fitting Key F21 – Bushing Key F22 – T-Fitting Key F23 – ½” 90 Deg PTC Fitting Key F17 – Bushing Key C10 – Drain Valve Figure 30. Safety Valve Installation 32 Figure 31. Tank Fitting Installation Figure 32. Fitting Installation at Bottom Tank Ports 33 6.2 Install Air Lines 6.2.1 Install Pressure Line Install ½” Braided Pressure Line from Compressor to Tank Fitting as shown in Figures 33 and 34. Figure 33. Pressure Line Install Key C3 – Tank Key F10 - CONNECTOR, 1/2 NPT X FNPSM STRAIGHT SWIVEL Key F11 - ELBOW, 1/2 NPT X NPT 90DEG Key 6 – Braided Air Line Figure 34. Pressure Line Installation at Compressor Key 1 – Elbow Fitting Key 2 – Braided Line 34 Secure Pressure Line with P-Clamp at Connector Support Plate as shown in Figure 35. Figure 35. Location of Support for Pressure Line Key 1 – P-Clamp 6.2.2 Install Feedback Hose Install 1/4” diameter hose from PTC fitting at the T-Fitting by the safety valve on the tank to the PTC fitting at the Air Governor. Use hose wrap to protect the hose at any areas of rubbing with other components. Cut off excess hose and discard. Figure 36. Feedback Hose Installation Key 5 – ¼” Hose (PTC) Key F9 – ¼” 90 Deg PTC Fitting Key F18 – ¼” 90 Deg PTC Fitting 35 6.2.3 Install Hose to Valve Install ½ PTC hose from PTC fitting at tank to inlet of shut-off valve (lower hole). Cut hose to length as needed. Wrap hose at any contact points to frame with hose wrap provided. Figure 37. Hose Installation to Valve Key F23 – PTC Fitting Key 9 – ½” PTC Hose Key F24 – PTC Fitting Key C4 – Valve Figure 38. Hose Installation at Valve Key 1 – Hose Key 2 – Hose Wrap 36 6.2.4 Install Hose to Hose Reel Install ½” PTC hose from Shut-Off Valve to hose reel. Secure with tie bands as needed. Route hose along bottom of fuel tank. Figure 39. Hose to Hose Reel Key 1 – ½” PTC Hose Figure 40. Hose Routing Key 1 – ½” PTC Hose Key 2 – Hose Routing at Cutout Key 3 – Tie Band Locations 37 Install 90 Deg PTC Fitting at Hose Reel. Route hose to hose reel as indicated in Figure 41. Cut off excess hose. Figure 41. Hose Routing Key 1 – ½” PTC 90 Deg Fitting Key 2 – ½” PTC Hose Connect Quick Coupler to end of hose. Install male adapter to end of blow gun. Note: Blow gun can be stored in the side compartment at the ladder on the left side of the machine. Adjust the hose stop such that the end of the hose can be reached from ground level, yet the hose exposed is short enough to not interfere with the wheel or other components. See Figure 42. Figure 42. Hose Reel Mounting 38 7.0 Install and Configure Electrical System 7.1 Install Fuse Install a 7.5 Amp fuse in location 1F26 at the electrical cabinet. 7.2 Install Relay Install relay at position 1K22. 7.3 Switch Connector Switch connector at 1X14.1 on the relay board. There are two connectors in this location. One is used for the air compressor, the other is used for a spare harness. The correct connector has wires 209, 153, 002FF, and 310AY. See Figure 43. Figure 43. Connector Switching Key 1 – Connector Location 7.4 Software Configuration Prior to configuration, ensure that the latest software is installed on all controllers on the machine. Navigate through the diagnostic addresses in technician mode to address SIG 104. The seventh digit indicates the Air Compressor Option. Change the seventh digit from a 0 to a 1 to enable the air compressor functionality. 39 Product Installation Review Checklist: Product has been setup according to the instructions included with the unit. Safety shut-off valve is in proper working order. and operate correctly I acknowledge that the pre-delivery service was preformed and the unit is ready for delivery to the customer. ________________________ Dealership’s Name _________________________ Representative ___________________ Date _______________________ Model Number __________________________ Serial Number ___________________ Date Sold Owner’s Name and Address Name_______________________________________________ Address_____________________________________________ City, State, Zip _______________________________________ 40 Delivery Checklist The following items must be preformed when delivering the attachment to the customer. Check off each item as it is preformed. Provide the customer with the operating manual and instruct the customer to read prior to operating the unit. Review and explain all maintenance and operation information. Review and explain maintenance schedule that is required to ensure proper operation and long life. Make it be known that the customer can visit or call to discuss any questions or problems may be encountered. Complete the Owner’s registration with the customer, ensure it is completely filled out, and return a copy to RCI Engineering LLC. _________________________________ Date Delivered _________________________________ Signature 41 Contact Info – Instruction Issue Reporting 970 Metalcraft Drive Mayville, WI 53050 Phone: 920-387-9804 Fax 920-387-9806 Website: www.rciengineering.com Email: [email protected] Please help us to help you! We can’t fix what we don’t know about! Please note and report any installation issues here and fax or email to the number above: 42 Warranty Claim Form 43 General Information Model Number: ______________________________ Serial Number: _______________________________ Date of Purchase: _____________________________ Dealer: ______________________________________ Notes:_________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ ______________________________________________________________ 44 970 Metalcraft Drive ● Mayville, WI 53050 ● 920-387-9804 ● Fax 920-387-9806 Info at: www.rciengineering.com 45