SUBJECT: Increaser maintenance on all models equipped with a two-stage hydraulic pump and Brevini increaser

The Brevini increaser by nature operates under severe conditions. The increaser gearbox is under constant heavy load, in an extremely hot, dirty and abrasive environment.

 

To prevent premature increaser, coupling or hydraulic pump failure, please observe the following maintenance procedures.

 

Daily Maintenance

 

 Each day, prior to operating the harvester, inspect the sight glass (Figure 1) on the increaser.

Figure 1--View showing the increaser sight glass.

The lubricant should be visible in the sight glass. If necessary, remove the plug (Figure 2) and add gear lubricant. The recommended lubricant is synthetic 75W-140 gear lube.

Figure 2--Remove the plug to add lubricant to the increaser.

Inspect the gasket on the plug and replace if not in acceptable condition. Tighten the plug securely but do not over tighten.

50/100 Hour Service

 

On new increaser assemblies, change the gear lubricant after the initial 50 hours of operation and after each 100 hours thereafter. To change the increaser lubricant, proceed as follows:

1.  Start the tractor and engage the pto for approximately 10 minutes to ensure that the oil is warm.

2.  Place a suitable container under the increaser and remove the plug (Figure 3).

Figure 3--Increaser drain plug.

3.  Allow the oil to completely drain. Inspect the gasket on the plug and replace it if not in acceptable condition.

4.  Install and tighten the plug securely.

5.  Remove the fill plug (Figure 2).

6.  Add one quart (0.95 l) of a good quality synthetic 75W-140 gear lube.

7.  Inspect the fill plug gasket and replace it if necessary. Install the plug securely.

 

Splined coupling service

 

After each 100 hours of operation, remove the hydraulic pump from the increaser. Remove, clean and lubricate the splined coupling.

1.  Remove the two fasteners that secure the pump to the increaser. See Figure 4.

Figure 4--Remove the two fasteners shown to disconnect the hydraulic pump from the increaser.

2.  Separate the pump from the increaser and locate the splined coupling. It may remain in the increaser (Figure 5) or on the pump shaft (Figure 6). Pull the coupling out of the increaser or off the pump shaft as necessary.

Figure 5--Remove the splined coupling from the increaser as shown.

Figure 6--View showing coupler removal from the pump shaft.

3.  Thoroughly clean and inspect the coupling (Figure 7). Check closely for excessively worn outer and inner splines cracks or other damage.

Figure 7--Inspect coupling for cracks, excessive wear or other damage.

4.  Thoroughly clean and inspect the hydraulic pump shaft and internal splines in the increaser (Figure 8).

Figure 8--Inspect the pump shaft and increaser splines for excessive wear or damage.

5.  Coat the inner and outer splines of the coupling, hydraulic pump shaft and internal splines of the increaser with good quality grease. Use grease certified NLGI No. 2 that contains extreme pressure (EP) additives.

6.  With the snap ring facing outward, insert the coupling into the increaser. Make sure the coupling is fully seated inside the increaser.

7.  Align the pump shaft and coupling splines and attach the pump to the increaser. Install the two fasteners and tighten to 75 ft.-lbs. (102 N.m).

8.  Thoroughly coat the tractor pto shaft with grease certified NLGI 2 prior to installing the increaser and pump assembly.

 

 

PTO Shaft Maintenance

 

If allowed to operate without lubrication, the tractor pto shaft and the increaser shaft will be damaged. Therefore, it is extremely important to periodically lubricate the pto shaft splines and the increaser internal splines. After each 50 hours of operation, remove the increaser/hydraulic pump assembly from the tractor. Using NLGI 2 EP type grease, thoroughly lubricate the tractor pto shaft and the internal pto splines in the increaser.

Subject: Fine Tuning Magnum Counter Speed/Distance Calibration

The harvester is equipped with a remote RUN/HOLD system that is controlled by the selector valve lever that operates the rear conveyor. When the lever is OFF, the counter will be in the HOLD mode; when the lever is ON, the counter is in RUN mode. The counter is also equipped with a RUN/HOLD button that toggles between HOLD and RUN modes. The RUN/HOLD button on the counter overrides the remote RUN/HOLD function in all cases. Therefore, if the counter remains in HOLD with the rear conveyor selector valve turned on, push the RUN/HOLD button on the counter to exit HOLD mode. When in the HOLD mode, the word HOLD is shown on the display and the counter will stop accumulating roll distance, number of pieces and load count information. When the word HOLD is absent the counter is in RUN mode.

 

This procedure is designed to verify and fine tune the speed/distance calibration of the system. Perform each step as precisely as possible to ensure the best results. Note that a hard-packed surface such as a road will result in a different distance reading than actual field conditions.

 

 

CALC-AN-ACRE AND MAGNUM I

 

1.  Set up a measured course with a clearly marked beginning and end.

Figure 1--View showing early Magnum counter.

A. RUN/HOLD button

B. CAL button

C. RESET and minus (-) button

D. Plus (+) button

E. Rotary switch

 

2.  Power up the counter. Place the counter in HOLD by pushing the

RUN/HOLD button (Figure1) or place the selector valve that controls the rear conveyor in the OFF position. The display will read HOLD.

3.  Turn the rotary switch to the DISTANCE position and note the display reading. If the reading is not zero, press and hold the reset button until the distance value resets to zero.

4.  Identify a suitable point on the tractor or harvester to use as a reference when passing the beginning and ending markers on the measured course. The 

tractor platform step or the center of the rear wheel will work well.

5.  Begin driving the tractor forward well ahead of the beginning marker. Maintain a consistent tractor speed.

6.  Place the counter in the RUN mode at the exact time the reference point (Step 4) passes the beginning field marker. The counter should start counting upon exiting the RUN/HOLD mode.

7.  Drive through the measured course at a consistent speed. Place the counter in HOLD as the reference point passes the ending field marker.

8.  Stop the tractor in a safe area.

9.  Make sure the rotary switch is still pointing toward DISTANCE. Next, push and hold the CAL button for approximately three seconds. When in CAL mode, the red LED on the face of the counter will glow.

10.  The display will alternate between the circumference valve and the distance measured in three-second intervals. When the display shows CAL and HOLD and 1234, the counter is showing the circumference value (CIRC). When only HOLD and 1234 are shown the counter is showing the distance value. Verify that the distance indicated is the same as the actual distance traveled (within 2 percent). If not, use the + or - buttons to match the distance reading to the actual distance traveled. When the values match, as close as possible, press the CAL button to exit the calibration mode and the circumference factor is now set. Repeat the procedure to verify the correct CIRC factor is correct. Record the number so it can simply be re-entered if necessary.

 

Magnum II

 

1.  Lay out a measured course with beginning and end markers.

2.  Place the counter in the HOLD mode. Either push the rear conveyor selector valve in the OFF position or push the RUN/HOLD button on the counter. See Figure 2.

Figure 2--RUN/HOLD button on Magnum II counter.

3.  Turn the rotary switch to the TOTAL DISTANCE position (Figure 4). Press and hold the reset button (DEC) for approximately one second.

Figure 4--Rotary switch in the TOTAL DISTANCE position.

4.  Identify a suitable point on the tractor or harvester to use as a reference when passing the beginning and ending markers on the measured course. The tractor platform step or the center of the rear wheel will work well.  

5.  Begin driving the tractor forward well ahead of the beginning marker. Maintain a consistent tractor speed.

6.  Place the counter in the RUN mode at the exact time the reference point (Step 4) passes the beginning field marker. The counter should start counting upon exiting the RUN/HOLD mode.

7.  Drive through the measured course at a consistent speed. Place the counter in HOLD mode as the reference point passes the ending field marker.

8.  Stop the tractor in a safe area.

9.  Press and hold the CAL button for approximately one second. The display should read CAL HOLD,

10.  Next, turn the rotary switch to SPEED CAL (Figure 5). The current calibration factor will be displayed.

Figure 5--Rotary switch in SPEED

CAL position.

11.  Press and release the CAL button and the total distance traveled will be displayed. Pushing and releasing the CAL button will toggle between the total distance and calibration values. The CAL icon will be on solid when displaying the calibration value and it will flash with displaying the total distance value.

12.  When reading the total distance value, use the plus (+) or minus (-) keys as required to match the total distance value with the actual distance traveled. When the values match, the calibration factor automatically set at the correct value.

13.  Press and release the CAL button to toggle to the calibration factor and record this number for future reference.

14.  Press and hold the CAL button to exit calibration mode.

15.  Repeat this procedure to ensure an accurate result.

AFFECTED MODELS: BR, SR, SRA AND AR SERIES HARVESTERS

Excessive cutter head blade speed can cause damage to the heads, undercarriage, bearings or other components. This is especially true when harvesting in dry, hard soil. Running the head(s) wide open in dry, hard soil causes excessive vibration which can damage the head frame, undercarriage and related bearings and shafts. Excessive vibration will be more evident on machines without timed heads.

 

Even when cutting in soft, damp soil, it is a good practice to operate the heads no faster than necessary to obtain clean efficient sod harvesting.

 

On all models except AR and SRA, set the blade speed using the flow control located on the right side of the control panel. On AR and SRA models, adjust blade speed using the five-position rotary switch located on the right side of the control panel inside the tractor cab.

AFFECTED MODELS: SR, SRA AND AR SERIES HARVESTERS

On some models, especially models with worn undercarriage bearings, the cutter head shields can contact the chop system mounting fasteners. Contact with the chop system mounting fasteners will result in excessive wear of the head shields.

 

Cutter head spacers are available to prevent interference between the head shields and chop fasteners. See Figure 1.

Figure 1--Cutter Head Spacers

The spacers are designed to move the cutter heads upward and back away from the chop system. The spacers and longer cutter head mounting bolts are required to perform this update.

Contact Bucyrus Equipment Company Inc. (800-330-0857) for the necessary parts to perform this update.

 

1.  Remove the cutter head shields (Figure 2).

  Figure 2--Cutter Head Shields

2.  On the right cutter head, loosen the bolt that secures the belt idler pulley

(Figure 3) and slide the idler away from the belt.

Figure 3--Idler Pulley

NOTE:

If the belts do not slip in the toothed pulleys during this procedure, it will not be necessary to time the cutter heads. If the belts slip, however, time the heads as described later in this procedure.

 

3.  Remove the cutter head mounting bolts. See Figure 4 and Figure 5. Maintain some tension on the cutter head belts as necessary to prevent the belts from slipping on the pulleys.

Figure 4--Right Side Cutter Head

Figure 5--Left Side Cutter Head

4.  Lift one head sufficiently to slide the spacers between the head mounting plate and head frame on each side of the head. Repeat for the other cutter head.

5.  Install the mounting bolts. On the left side the bolts are 5/8-11 X 2-1/2 in. On the right side, the bolts are 5/8-11 X 3-1/2 in.

6.  On the right side, pry the head forward to tension the belt. The belt should have approximately ¼ in. (6.4 mm) of deflection in the center of the belt. Make sure the head is mounted evenly in the frame and securely tighten the mounting bolts.

7.  On the left side, slide the head forward to obtain 1-1/2 in. (38.1) mm measured as shown in Figure 6. Make sure the head is positioned evenly in the frame and securely tighten the mounting bolts.

8.  Slide the idler pulley upward until the belt will deflect approximately ¼ in. 6/4 mm) in the center, then securely tighten the idler mounting bolt.

Figure 6--Distance Shown Should Be 1-1/2 (38.1 mm)

9.  Check head timing by carefully rotating the heads by hand. The heads are properly timed if the blades move in opposite directions. If necessary, loosen one belt and reposition the pulleys to obtain the correct timing.

 

AFFECTED MODELS: SR, SRA AND AR SERIES HARVESTERS

On some models, the chop mechanism may not return to the up position after chopping. This may occur only intermittently and operate normally most of the time or the chop may stay in the down position..

 

The cooling fan motor case drain (Figure 1) on models prior to serial No. 208 (SR), 109 (SRA) and 108 (AR) is connected to a return-to-tank circuit that is attached to the manual chop valve. See Figure 2. Because the fan motor case drain is connected to the chop valve return circuit, it can create enough pressure to cause the chop system to remain in the down position. Routing the fan motor case drain directly to tank eliminates this problem.

Figure 1--Cooling Fan Motor Case Drain

To determine if the fan motor case drain is causing the chop mechanism to not return to the up position, disconnect the case drain from the fan motor (Figure 1). Plug the hose using a No. 6 JIC plug and cap the motor fitting using a No. 6 JIC cap. Operate the harvester and chop system. If the chop system now operates normally, the fan motor case drain is causing excessive pressure in the return-to-tank circuit.

 

1.  Disconnect the fan motor case drain hose from the T-fitting at the manual chop valve. Using a No. 6 JIC cap, cap the Tee-fitting as shown in Figure 2.

Figure 2--Disconnect Fan Motor Case Drain Hose and Cap the Fitting

2.  Disconnect the case drain hose from the cooling fan motor Figure 1).

3.  Disconnect the two return hoses and remove the swivel nut run Tee fitting at the hydraulic reservoir. Install a No. 6 swivel union and a No. 6 union cross as shown in Figure 3.

Figure 3--Install a Swivel Union and Union Cross to the Reservoir as Shown.