Western CP600 User manual

CP600 Pivot
Operation Manual
POM-EN-December 2018

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CP600 Pivot Operation Manual
POM-EN-December 2018
Section 1
Operation, Safety & Maintenance
Safety Symbols, Pictures and Denitions ................................. 3
Final Checks and Initial Operation ....................................... 5
Machine Alignment .................................................. 6
Cam and Safety Switch ............................................... 9
Maintenance Check List .............................................. 10
Power Drivetrain Maintenance ......................................... 12
Lockout/Tagout Procedures ............................................ 19
Tire Care .......................................................... 23
Winterizing ......................................................... 24
Lube & Oil Charts ................................................... 25
Service Log ........................................................ 27
Troubleshooting ..................................................... 30
Section 2
General Information
Span Tower Weights and Dimensions .................................... 2
Revolution Times and Water Application ................................. 4
Revolution Times and Water Application Charts ........................... 6
Sprinklers ......................................................... 7
End Guns- Nelson ................................................... 36
Standard Galvanized Drop Details ...................................... 37
Standard Flexible Hose Drop Detail ..................................... 38
Variable Spacing Drop Details .......................................... 39
Slurry Drops ........................................................ 40
Standard Galvanized Extended Drop Detail ............................... 41
Adjustable Drop ..................................................... 42
Section 3
Getting Started
Before Your Machine Arrives ........................................... 2
Slope Considerations ................................................ 3
Power Supply ...................................................... 6
Ground Rod Placement ............................................... 8
Pivot Pad (Concrete) ................................................. 10
Standard Pivot Pad (Concrete) ......................................... 11
6-5/8 Pivot Pad (Concrete) ............................................ 12
High Prole Pivot Pad (Concrete) ....................................... 13
Towable Pivot Pad (Concrete) .......................................... 14
Minimum Equipment for Machine Assembly/Set-up ......................... 15
Page iiiContents

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CP600 Pivot Operation Manual
Page iv Contents
Section 4
Panel Operation
Panel Identication .................................................. 2
Forward Operation ................................................... 4
Reverse Operation .................................................. 6
Auto Reverse / Auto Off Option ......................................... 8
Auto Restart Option .................................................. 10
Local/iControlremote ................................................. 11
Safety Override ..................................................... 12
Disconnect Switch ................................................... 13
Section 5
Electrical
A Word About Proper Grounding ........................................ 2
Standard Panel Span Cable Connections ................................. 3
Panel Wiring 90239-41_R4 ............................................ 4
Main Panel Parts List ................................................. 6
Standard Panel Schematic ............................................ 8
CP JB Intermediate Cam 10142-01 ...................................... 10
End Tower Junction Box w/out Auto Reverse and Booster 90017-01 ............ 12
Stall Timer Wiring 90016-01 ........................................... 13
Collector Ring Wiring ................................................. 14
Warning ........................................................... 15
Notes ............................................................. 16

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CP600 Pivot Operation Manual
Section 1
Operation, Safety & Maintenance

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CP600 Pivot Operation Manual
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Throughout the manual you will nd pictures or symbols that are inserted for your safety. Most of
these pictures and symbols are universal and are known to the reader. It is always a good idea
to review these pictures and symbols to understand the context of how they are presented in the
manual.
WARNING: COULD CAUSE SERIOUS INJURY OR POSSIBLE DEATH.
WARNING: KEEP HANDS AND OBJECTS AWAY FROM MECHANICALLY MOVING
PARTS. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR POSSIBLE
DEATH.
WARNING; HIGH VOLTAGE POTENTIAL FOR ELECTROCUTION.
WARNING: STAY CLEAR OF HEAVY MATERIAL BEING LIFTED ABOVE.
WARNING: MACHINE MAY INTERMITTENTLY START OR STOP.
WARNING: BE AWARE OF SURROUNDING POWER LINES WHEN INSTALLING
OR TROUBLESHOOTING EQUIPMENT. FAILURE TO DO SO COULD CAUSE SE-
RIOUS INJURY OR POSSIBLE DEATH.
WARNING: DO NOT CLIMB ON OR JUMP OFF MACHINE.
WARNING: FOLLOW MANUFACTURES SPECIFICATIONS FOR PROPER TIRE
INFLATION AND INSPECTION. OVER INFLATION MAY CAUSE SERIOUS INJURY
OR DEATH.
Section 1-3
Operation, Safety & Maintenance
Safety Symbols, Pictures and Definitions

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Winterization see manufacturers specications Section 9-24.
CAUTION: Hard hat and steel toe work boots recommended when assembling equip-
ment
CAUTION: Be aware of pinch points when assembling equipment.
CAUTION: Could cause minor injury and or damage to machinery equipment, compo-
nents, product, etc.,
Note: Manufacture’s general comment, recommendation or instruction.
Lock Out / Tag Out Manufacturer recommends locking the main power disconnect
before servicing or troubleshooting electrical components. See
CAUTION or WARNING Disconnect electrical power prior to servicing or troubleshoot-
ing components.
WARNING: DO NOT ATTEMPT TO ASSEMBLE OR TROUBLESHOOT MACHIN-
ERY IF THERE IS POTENTIAL FOR A LIGHTENING STORM. COMPONENTS ARE
HIGHLY CONDUCTIVE AND SERIOUS INJURY OR POSSIBLE DEATH MAY OC-
CUR IF STRUCK BY LIGHTENING.
DANGER: DO NOT IRRIGATE NEXT TO POWER LINES. SPRAYING WATER ON
POWER LINES COULD CAUSE SERIOUS INJURY OR DEATH.
Section 1-4 Operation, Safety & Maintenance
Safety Symbols, Pictures and Definitions

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The following list of checks and operation procedures should be followed during the initial star
up of the circle. These same basic procedures can also be followed at the initial start up of each
irrigation season.
1. Bolts: Check to insure that all bolts have been properly installed and tightened.
2. Grounding: Be sure the machine is properly grounded. Refer to the Getting Started and Electri-
cal sections for proper main panel grounding.
3. Control Limit Switches: The limit switches in the tower junction boxes have been pre-set at the
factory, however, they should be checked according to the procedures out lined in maintenance
section, Control Switch Adjustment.
4. Control rods: Check that all control rods are connected to the cam arm.
5. Alignment: The machine should be in a straight line when erection is completed. Adjust the
control rod so the tower safety limit switch roller is in the middle of the “V” of the cam. Tighten the
adjusting nuts. After the machine is started, nal alignment should be performed according to the
procedure in maintenance section, alignment.
6. Voltage: Voltage at the pivot panel should be 480V on all three legs of the power lines.
Note: Voltage is dependant upon your location. Voltage should not be more than 5% higher or low-
er than the recommended voltage or damage may occur.
7. Lubrication: Check the oil level in all gearboxes and motors. Grease the two ttings on
the pivot elbow until grease is visible at the top and bottom of bearing.
8. Starting: When all the above checks have been made, the machine is ready to start.
Close the main panel inner door and turn the main disconnect switch on. Follow operation instruc-
tions outlined in Section 4 Panel Operation.
WARNING MAKE SURE POWER IS DISCONNECTED AT THE MAIN SERVICE
PANEL BEFORE PERFORMING ANY ELECTRICAL SERVICE TO THE
MACHINE OR BEFORE OPENING THE INNER DOOR OF THE MASTER CON
TROL PANEL.
Section 1-5
Operation, Safety & Maintenance
Final Checks and Initial Operation

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Your Western Center Pivot irrigation system should be run with a slight leading bow (center tow-
ers ahead of pivot and end tower) in both directions. A correctly aligned machine will have an
equal bow when operated in either direction. DO NOT let the machine run with a large leading
bow in one direction and a lagging bow in the other. To align the machine, follow these steps:
Start at the pivot end of the machine with the machine running in the forward direction and the
percent timer set to 75 percent. Stand between tower 2 and tower 3 and sight across motors No. 2
and 1 to the pivot stand pipe. Tower 1 should start when motor 1 appears to be slightly behind and
shut o󰀨 when it appears to be an equal distance ahead of the center of the standpipe.
When tower 1 is properly aligned, stand between towers 3 and 4 and sight across motors 3 and 2
to the pivot standpipe. Align tower 2 in the same manner as tower 1. As you get to the outer end
of the machine and can no longer see the pivot standpipe, pick a motor on one of the inner towers
and sight to it.
Section 1-6 Operation, Safety & Maintenance
Machine Alignment

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Figure 1-7.
Section 1-7
Operation, Safety & Maintenance
Machine Alignment

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GOOD BAD BAD BAD
Rotation Forward = Clockwise
Desired
Bow
Too Much
Leading Bow
Trailing
Bow
Crooked
Total Bow For
System is About
One Tire Width
Figure 1-8.
Section 1-8 Operation, Safety & Maintenance
Machine Alignment

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Overhead View of Cam and Safety Switch
Safety Switch
Section 1-9
Operation, Safety & Maintenance
Cam and Safety Switch

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• PIVOT: At start of irrigation season, grease pivot bearings. Repeat every 400 hours of
operation.
• GEARBOXES: At start of irrigation season, drain all gearboxes and rell with
recommended oil. See Power Drivetrain Maintenance section for detailed information.
• MOTOR GEARBOXES: At start of irrigation season drain any water that may have
accumulated during the irrigation season and ll to the proper level with the proper lubricant.
• TIRES: Check tire ination (use low pressure tire gauge). Western Corporation inates all
new tires to a higher pressure for truck loading requirements. Set tire pressure so side wall
has slight ex. If tire creases increase pressure. If tire pressure too low tires will lose bead and
damage the tube.
CAUTION: Operating tires below the manufacturers recommended pressure can
result in damage to the tire sidewall in addition to voiding your warranty.
• WHEEL BOLTS: Check to ensure they are tight.
Note: Wheel bolts can loosen after initial installation. They should be checked after 100
hours of operation.
• STRUCTURE: Routinely check pivot, span and tower structures for loose or missing bolts.
• CONNECTORS: Check for leaking gaskets, boots, drains, and malfunctioning sprinklers or
pressure regulators.
Section 1-10 Operation, Safety & Maintenance
Maintenance Check List

CP600 Pivot Operation Manual
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Lock Out / Tag Out: lock the main power disconnect before servicing or troubleshooting
electrical components.
• ELECTRICAL: Check pivot and junction box starters for burned or pitted contacts.
• ELECTRICAL: Check all wire connections, particularly on starters, to ensure they are tight.
• ELECTRICAL: Check safety limit switches in tower junction boxes.
• ELECTRICAL: Check function of automatic switching devices such as Auto Reverse, Auto
Stop and End Gun (lube as required).
• CONTROL: Check junction box cam and bushings. Turn cam back and forth several
times to ensure there is no binding.
Section 1-11
Operation, Safety & Maintenance
Maintenance Check List

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Note: The following maintenance procedures must be performed or the drivetrain warranty
will be void.
The nal drive wheel gearbox, center drive gear motor and the worm gear center drive require
pre-season maintenance. Please refer to the following service information for the above items.
If you should have any questions, please call your Western Dealer or Customer Service Represen-
tative.
FINAL DRIVE GEARBOX MAINTENANCE PROCEDURES
A. The nal drive gearbox must be serviced as follows after each crop cycle:
1. Inspect input and output shaft seals for leakage. Should either the input or out put shaft
show excessive leakage, the seals should be replaced. All replaced seals must be installed
with generous amounts of #2 Barium/Lithium based grease or use equivalent quality #2 wa
ter-resistant grease.
2. External (dust exclusion) seals should be used to keep dirt and water out of internal seal lo
cations. If the external seals are damaged or worn, replace with new seals.
3. The seal drain hole located on both input caps must be kept clear of dirt. Clear the hole with
a 12-gauge wire, nail or punch. Rotate the tool to loosen and remove dirt. Make sure the
vent hole in the expansion chamber is free of dirt or debris.
Figure 1-12.
Section 1-12 Operation, Safety & Maintenance
Power Drivetrain Maintenance

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4. Each input and output shaft should be checked for excessive endplay after each crop cycle.
Disconnecting the driveline coupler & tapping the input shaft on both sides with a dead blow
hammer or mallet does this. If play is present, input shims should be installed to eliminate
bearing backlash.
5. All cover and end cap bolts should be torqued to 28-31 ft.-lbs (38-42 N-m).
6. All wheel lug nuts should be torqued to 115-120 ft.-lbs (156-162 N-m).
7. Remove drain plug located at bottom of gearbox and completely drain gearbox. If oil is con
taminated or emulsied, ush gearbox with a cup of specied oil and let drain completely.
8. Replace drain plug and rell gearbox through top ll hole to the proper operating level
(top of worm gear) as shown below. After one or two hours the oil should be re-checked. Air
may be trapped in the gearbox during initial lling. Top o󰀨 with oil as needed.
Figure 1-13.
Section 1-13
Operation, Safety & Maintenance
Power Drivetrain Maintenance

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B. Final drive gearbox lubricants
A GL-5 SAE 140 or MIL-C-2105 gear lube must be used in nal gearboxes. Some common brands
meeting this specication are shown below. Contact your dealer or local petroleum products dis-
tributor for other equivalent products. Use of improper oil will void the gearbox warranty.
• Hector S-150 Philube 1-LB Gear Oil #140
• Chevron Gear Compound #140
• Valvoline 85-140 Gear Oil
• Mobil 85-140 Gear Oil
• Pennzoil 85-140
• Texaco Multigear Lubricant EP SAE 85W-140
• Sprinkler Lube 1200
Oil capacity is approximately 1 U.S. Gallon, (3.8 Liters).
C. In-season nal drive gearbox Maintenance:
Final drive gearboxes should be inspected periodically during the operating season, for the follow-
ing:
1. The proper oil level should be maintained at all times.
2. Contaminated or emulsied oil should be replaced with fresh oil.
3. Input seal drain holes on the nal drive gearbox should be kept clear.
4. Input & output shaft seals should be inspected for excessive leaks and re
placed if necessary.
5. Expansion chamber vent holes should be kept clean.
Note: Failure to maintain gearboxes as specied will void the gearbox warranty.
Section 1-14 Operation, Safety & Maintenance
Power Drivetrain Maintenance

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A. The Helical gear center drive must be serviced as follows after each crop cycle
(Minimum of once per year):
1. Inspect input and output seals for leakage. Should either of the seals show excessive leak
age, the seals should be replaced. All replaced seals must be installed with generous
amounts of #2 Barium/Lithium based grease or equivalent quality #2 water resistant grease.
2. External seals should be used to keep dirt and water out of internal seal locations. If the ex
ternal seals are damaged or worn, replace with new seals.
DIAGRAM-SG-1
Figure 1-15.
3. The two (2) drain holes located under the motor can must be kept clear to allow for drain
age of accumulated moisture inside the motor if required. Do not Western or remove plug.
4. The two (2) drain holes located under the end bell must be kept clear to allow drainage of
accumulated moisture inside of the junction box.
5. Remove drain plug located at bottom of gearbox and completely drain gearbox.
If oil was contaminated or emulsied, ush gearbox with a cup of specied oil and let drain
completely.
6. Replace drain plug and rell to 1-1/2” (45 mm) from top of gear case as shown in the draw
ing. Refer to gearbox oil specications. After one or two hours the oil should be re-checked.
Air may be trapped in the gearbox during initial lling. Top o󰀨 with oil as needed.
Section 1-15
Operation, Safety & Maintenance
Power Drivetrain Maintenance

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B. Helical gear center drive lubricants Reference Figure 1-15. :
Use only SAE 30W, SAE 40W, SAE 50W, or SAE 20W-50 multi viscosity engine oil. Use of im-
proper oil will void the gearbox warranty. Oil capacity is approximately one (1) U.S. gallon (3.8 Li-
ters).
C. In-season spur gear center drive maintenance.
Helical gear center drive gearboxes should be inspected periodically during the operating season
as follows:
1. The proper oil level (1-1/2” [45 mm] from top of gear case) should be maintained at all
times.
2. Contaminated or emulsied oil should be replaced with fresh oil.
3. Input & output shaft seals should be inspected for excessive leaks and replaced if neces
sary.
4. Motor drain holes must be kept clear to allow moisture to drain.
5. Expansion chamber vent holes.
Figure 1-16.
Section 1-16 Operation, Safety & Maintenance
Power Drivetrain Maintenance