CONTROLS & SAFETY EQUIPMENT

The Forage Box is provided with several features for operator safety and c.onvenience.

ACAUTION: Become familiar with and know how to use ALL Safety Devices and Controls on the Forage Box and Unloading Unit BEFORE attempting to operate this equipment. Know how to stop Unloading Unit operation BEFORE starting it.

APRON SPEED LEVER (Fig. 5-1)

The Apron Speed Lever is located at the front of the Unloading Unit. This Lever allows the operator to adjust the speed of the Feeder Aprons while the PTO and Beater Clutch are engaged and the Forage Box is being unloaded. The Apron Speed Lever only affects the speed of Apron travel. Further explanation of Lev7r operation is provided in the Operation chapter of this manual.

NOTE: To prevent the possibility of bending the Apron Speed Lever, do NOT force .the Lever when shifting to the "HI" or the "SWEEP" positions. To insure that the Clutch Is In gear, the Apron Speed Lever should be shifted when the Unloading Unit is running.

ing Unit. The Beater Clutch is engaged when the Levers are pulled down ("IN" positions). To disengage the Clutch, m9ve the Levers up ("OUT" positions).

Use pf the Beater Clutch Levers in the unloading sequence is further explained in the Operation chapter.

NOTE: Disengaging the Beater Clutch does NOT stop the CrossConveyor. To stop the Cross Conveyor, the tractor PTO MUST be disengaged or the Safety Clutch MUST be tripped.

GUARDS & SHIELDS (Figs. 5-1,5-2 & 5-3)

Whenever and wherever possible and without affecting machine operation, Guards and Shields have been used on this equipment to protect potentially hazardous areas. In many places, Decals are also provided to warn of potential dangers as well as to display special operating procedures.

Transmission Housing

Latched Cover

Fig. 5-1

Safety Clutch

Housing Guard

Beater Clutch Guard

BEATER CLUTCH LEVERS (Figs.

5-1 & 5-2)

The Beater Clutch Levers are provided for disengaging the Beaters and the Feeder Aprons. The Levers are located at the front right and left corners of the Unload-

·WARNING: Read and observe ALL Warnings on the unit BEFORE operating it. Do NOT attempt to operate this equipment unless ALL factory installed Guards and Shields are properly secured in place. BEFORE proceeding to perform any work on the Forage Box and prior to removing any Guards or opening any Covers or Shields, BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). BE SURE also to replace ALL Guards and Shields BEFORE operating the Forage Box Unloading Unit.

A.

Rotating PTO Shield

The Telescoping PTO Drive connection, between the Unloading Unit and the tractor, is equipped with a Rotating Shield.

AWARNING: BE SURE that the Rotating Shield on the Telescoping Drive turns freely BEFORE starting the tractor engine.

Front Guardil

Stationary and flexible Guards are provided on the front of the Unloading Unit to protect the area of the input Drive Universal Joint.

Rear Feeder Aprons Guard

A Guard assembly is provided over the entire Feeder Aprons area in the rear of the Forage Box. This Guard assembly is equipped with hinged and latched access Covers in appropriate locations for lubricating and adjusting the Apron Chain Takeup assemblies.

Miscellaneous Covers

Latched Covers are provided over the Transmissions, the Cross Conveyor Drive Chain, the Safety Clutch Mechanism and the Beater Clutch Drive. These Covers can be conveniently unlatched .and opened for lubrication, adjustment and/ or service access when required.

Locking Button against the spring tension and slide the Yoke onto the tractor PTO shaft. Release the Button and move the Yoke ahead or back until the Lock engages into the groove on the PTO shaft.

Safety Clutch Cable

Fig. 5-3

Numerous other Guards and Shields are bolted in place protecting potentially dangerous areas and pinchpoints. BE SURE to replace all bolt-on type Guards after any service or adjustments have been performed and before operating the Unloading Unit.

HOLDDOWN CHAINS (Fig. 5-4)

All Forage Boxes are equipped with four Holddown Chains which MUST be installed to insure that the Box remains in place on the Running Gear.

PTO LOCKING COUPLER (Fig. 5-5)

A Spring-loaded Locking Device is provided on the tractor connection end of the Telescoping Drive to positively lock it onto the tractor PTO shaft. Depress the

Tie-down Chain

AWARNING: BE SURE that the Springloaded Locking Device is properly locked onto the tractor shaft BEFORE starting the tractor and proceeding to unload the Forage Box.

SAFETY CLUTCH (Figs. 5-5 & 5-6 and See Figs. 5-1 & 5-2)

ACAUTION: In case of an EMERGENCY, Push the Safety Bar or Pull the Safety Cable to trip the Safety Clutch and DISENGAGE the Cross Conveyor, Beaters and Feeder Aprons.

The Safety Clutch Mechanism on the BU960 Forage Box is an EMERGENCY SHUT -DOWN trip-type device which STOPS ALL movement of the Cross Conveyor, Beaters and Feeder Aprons. The Safety Clutch is tripped by either pushing the Safety Bar which extends across the entire front of the Unloading Unit or, by pulling the Safety Cable which runs along both sides and across the back of the Box. Refer to the Operation chapter for additional operating details.

REFLECTOR STRIPS (See Figs. 5-2 & 5-3)

For transporting the Forage Box on a public road, all BU960 Boxes are furnished with two Red Reflectors, located on the outside Rear Guard Doors, and an Amber Reflector Strip, located on the front left Cross Conveyor Chain Guard.

SIGHT HOLES (See Fig. 5-5)

The Unloading Unit is provided with Sight Holes to permit the operator to safely see inside the Forage Box and view the progress of material flow or the unloading action.

NOTE: The recommended tractor PTO speed for unloading the Unit is 300 to 400 RPM.

ACAUTION: BEFORE starting the tractor engine and running the Unloading Unit, review and comply with All Safety recommendations set forth in the SAFETY chapter of this manual.

SAFETY CLUTCH (Figs. 6-1,6-2 & 6-3)

AActivation

CAUTION: In case of an EMERGENCY, PUSH the Safety Bar or PULL the Safety Cable to trip the Safety Clutch and disengage the Cross Conveyor, Beaters and Feeder Aprons.

3. Pull the Driving Pin Handle forward and rotate it 180° counterclockwise to the position illustrated.

4. Rotate (by hand) the Clutch Plate until the Driving Pin snaps back into the slot in the Driven Plate.

5. Close the Clutch Housing Guard and relock the Latches.

To trip the Safety Clutch, either PUSH the Safety Bar which spans across the entire front of the Unloading Unit or, PULL the Safety Cable whichruns along both sides and across the back of the Forage Box. When the Clutch is tripped, the Spring-loaded Trip Lever will be moved into contact with the rotating Driving Pin Handle. As the Handle moves along the Cam Surface, the Driving Pin is pulled from its slot in the Driven Plate.

ACAUTION: After the Safety Clutch has been tripped, BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8), BEFORE proceeding.

Resetting Clutch

1. Unlock the two Latch Handles and ra1se the Clutch Housing Guard for access.

2. Depress the Loading Tab and move the Safety Bar forward. Then, while moving the Safety Bar forward, release the Loading Tab and allow it to spring back into the "RESET" position.

Maintenance

To insure continuous proper operation of the Safety Clutch Mechanism, BE SURE to perform the following:

1. Inspect the Safety Cable condition and test the Safety Clutch operation frequently (once a day or at least every 10 hours).

2. Lubricate the Double Driven Sprocket on the Safety Clutch assembly after every 50 hours of operation.

3. Check the Safety Clutch Cable tension after every 10 hours of operation. Readjust the Cable tension, as required, for a minimum amount of slack.

4. Clean out the Safety Clutch Housing after every 10 hours of operation.

NOTE: If, for some reason, the Safety Clutch Mechanism is NOT functioning properly, refer to the Adjustments chapter for corrective action.

Nloading Sequence

ACAUTION: BEFORE proceeding to unload the Forage Box, BE SURE to engage the tractor parking brake.

NOTE: Wherever possible, try to arrange to park the Forage Box on level for unloading. BE SURE the proper tractor hookQup and PTO connections are made before proceeding. Refer to the Preparing for Field Operation chapter of this manual for details.

The sequence for unloading a BU960 Forage Box is as follows: l. With the tractor engine off and the parking brake engaged, proceed to remove the Telescoping Drive connection from its PTO Transport Hanger. Install and properly lock the PTO Drive onto the tractor PTO shaft.

2. Check to see that the Beater Clutch Levers are in the up ("OUT" positions) and that the Apron Speed Lever is centered ("LOW" position).

NOTE: The Beater Clutch MUST ALWAYS be positioned to the "OUT" location before tractor is started and the PTO is engaged. Failure to set the Clutch Lever to the "OUT" position may result in material in the Cross Conveyor being forced back into the Box by the Beaters. This will overload the Beater Transmission and shear the Input Coupler Bolts.

3. Start the tractor engine, set throttle to idle, engage PTO and clean out the Cross Conveyor.

4. Engage the Beater Clutch to start the Beaters and the Feeder Aprons to unload the Box.

Proceed to unload the Forage Box using the tractor throttle and PTO speed to control the rate of unloading. Normal PTO speeds range between 300 and 400 PTO RPM. If a faster unloading speed is desired, reposition the Apron Speed Lever to up ("HIGH" position).

NOTE: Do NOT exceed a PTO speed of 540 RPM.

5. Reposition the Apron Speed Lever to down ("SWEEP" position) to clean out the Forage Box at the end of the load.

NOTE: The "SWEEP" speed is only intended for and should only be used to clean out the Box at the end of the load.

6. After the Forage Box is cleaned-out and before disengaging the tractor PTO, place the Beater Clutch Levers to up ("OUT" position) and center the Apron Speed Lever ("LOW" position).

7. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). Then, place the PTO into the Transport Hanger.

ACAUTION: BE SURE to test the Safety Clutch operation frequently.

APRON SPEED LEVER (Fig. 6-4)

The Apron Speed Lever is used only to adjust the feeding rate of the Feeder Aprons. A Decal, on the front of the Unloading Unit marks the positions for "LO", "HI" and "SWEEP" speeds. When the Lever is down, it is in the "HI" position. When the Lever is up, it is in the "SWEEP" position. The middle location is the "LO" position.

NOTE: To prevent the possibility of bending the Apron Speed Lever, do NOT force the Lever when shifting to the "HI" or the "SWEEP" positions. To Insure that the Clutch Is in gear, the Apron Speed Lever should be shifted when the Unloading Unit is running.

BEATER CLUTCH LEVERS (Fig. 6-4)

NOTE: The Beater Clutch Levers do NOT stop the Cross Conveyor. To stop the Conveyor, the tractor PTO MUST be disengaged or the Safety Clutch MUST be tripped.

The Beater Clutch Levers are provided at the top front corners of the Unloading Unit and attached to a common shaft. The Levers are used only to disengage the Beaters and the Feeder Aprons. The Beater Clutch is engaged when the Levers are moved down ("IN" positions). To disengage the Clutch, move the Levers up ("OUT" positions).

CROSS CONVEYOR CLEAN-OUT DOOR (Fig. 6-5)

ACAUTION: BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding to remove the Cross Conveyor Clean-out Door.

A Clean-out Door is provided under the right end of the Cross Conveyor for removing debris and build-up from on top of the Cross Conveyor Return Slide. To remove the Clean-out Door, disengage the Spring-loaded Retainer Pins.

After the Door has been removed, run the Cross Conveyor to remove the debris. BE SURE to replace and rclatch the Door before resuming operation.

NOTE: In freezing weather conditions, BE SURE to open the Clean-out Door and remove the material build-up at the end of each day.

AWARNING: The safest method to manuaiiy unload the Forage Box and a method, which TWO PEOPLE can safety use, is to pitch the forage out the front of the Box over the Beaters. Two men can also manually unload the Box using the Cross Conveyor to carry the forage out the front of the Box. Before attempting either procedure of unloading, first exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8), BEFORE anything else is done. With the tractor engine OFF and the PTO UNCOUPLED from the tractor, proceed to steps 1 and 2.

FEEDER APRON CLUTCH BREAKAGE (Fig. 6-6)

If the Apron Chain(s) break, while the Forage Box is being unloaded, it will be necessary to manually remove the forage before proceeding to repair the Chain(s).

NOTE: By all means, to avoid the difficult and time consuming task of having to manually unload the Forage Box to repair a broken or damaged Apron, frequently inspect the Apron with the Box empty from outside the unit. Proper tension adjustment and regular lubrication of the Sprockets and Front Bearings is very important in maintaining a properly operating machine.

NOTE: The sequence to follow for manually unloading the Forage Box is also outlined by a Decal which is provided inside the Transmission Housing Door.

1. Move Beater Clutch Levers up ("OUT" positions).

2. With tractor engine off and the Telescoping Drive disconnected, remove the Front Coupler bolts from both the Beater Transmission and the Worm Gear Transmission Shaft Couplers. Refer to the illustration provided for Coupler bolt locations.

AWARNING: The following steps MUST be carried-out with extreme caution since the Beaters are now free to rotate with the Coupler bolts removed.

3. One person should carefully climb into the Forage Box and over the Beaters to manually unload the Box with a fork.

NOTE: If the forage is going to be pitched out of the Box without running the Cross Conveyor, skip the next step.

4. The second person should wait outside the Box and proceed to reconnect the Telescoping Drive, start the tractor engine and engage the PTO to run the Cross Conveyor only.

5. The first person should proceed to unload the forage to uncover the broken Apron Chain(s).

AWARNING: The second person should stay out of the Forage Box and then, as instructed by the man inside, stop operation when the break is found and exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

6. The first person should carefully climb out over the Beaters and out of the Box.

With the repair completed and the first man out of the Box, the Coupler bolts can be replaced and the unit restored to normal operating conditions.

APRON SPROCKET PINS (Fig. 6-7)

When an Apron Front Sprocket Pin fails or if an Apron Chain breaks it is recommended that all four (074441) Pins be replaced. Any Pins which may NOT have sheared will have been weakened by the overload condition, during a Pin or Chain failure.

Material Bridging

Depending on the type of material and amount of moisture in the forage filling the Box, unloading may be hampered because of the forage bridging across the Cross Conveyor. If this occurs, BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE attempting to knock-down the bridging material and resuming the unloading procedure.

NOTE: To help reduce the possibility of the bridging problem reoccurring on the next load, do NOT fill the Box as full.

OVERLOAD PROTECTION (Shear Bolts)

(See Fig. 6-6)

The Input Drive Line to the Worm Gear Transmission is protected from overloading by a Shear Flange, if the Worm Transmission is overloaded. The Bolt used in this Shear Flange is a I I 4 x I Grade 2 which shears through the threads.

If this Bolt fails, replace it with another from the Shear Bolt Holder which is attached to the Rear Bearing Bracket.

NOTE: Additional Shear Bolts and attaching hardware are available in packaged quantities of 8 per package by ordering GEHL part #900061.

Chapter 7

Adjustments

ACAUTION: BEFORE proceeding to perform any adjustments on this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

APRON SPEED LEVER (Fig. 7-1)

The Apron Speed Lever should be checked and readjusted (as necessary) after every 50 hours of operation. To adjust the Lever, proceed as follows:

I. Loosen the (3) Adjustment bolts.

2. Place the Apron Speed Lever in the "LOW" position.

3. Position the Double Drive Clutch midway between the two Driven Clutch Hubs.

4. Retighten the (3) Adjustment bolts.

Adjustment Slots (3)

To adjust the Beater Clutch, proceed as follows:

I. With the Beater Control Lever down ("IN" tion) there should be I; 16" ( 1.6 mm) clearance between the right Safety Cable Lever and the Beater Control Lever. If NOT, loosen the bolts on theY oke which is attached to the Beater Lever and lengthen or shorten the Lever to Throw-out Cam Link. Retighten the bolts after the proper clerance is set.

2. Place Beater Clutch Levers up ("OUT" positions).

3. Position the Throw-out Cam upward and tight against the Hub of the Driving Sprocket.

4. Push the Beater Clutch Shifter in (by hand) and fully engage the Clutch Hub with the Hub of the Sprocket.

Beater Clutch

Driven Clutch Hub

Double Driving Clutch

Apron Speed Lever (in Low Speed Position)

Driven Clutch Hub

BEATER CLUTCH (Figs. 7-2,7-3 & 7-4)

NOTE: The Beater Clutch Levers are mounted on a common Shaft and interconnected with the Safety Clutch Mechanism so that when the Safety Clutch is tripped, the Beater Clutch will likewise disengage as a backup for positive operation shutdown. Because they are interconnected, BE SURE to check and readjust the Beater Clutch Mechanism (if necessary) any time the Safety Clutch is adjusted. Adjust the Safety Clutch first, per details under the Safety Clutch topic.

Fig. 7-4

NOTE: In order to fully engage the Clutch components, it may be necessary to align the Clutches by manually turning the PTO Shaft. When these Clutch components are fully engaged, there MUST be clearance in the forward end of the activating slot.

5. Adjust and maintain a 1I 8" (3 mm) gap between the Beater Clutch Shifter and the 3 I 8" diameter Pin of the Shifter Clutch linkage. To adjust the gap, loosen the (3) bolts that hold the Throw-out Bracket to the Front Bearing bracket. Rotate the Throw-out Bracket until the proper clearance is obtained. After the gap is set, retighten the(3) bolts.

SAFETY CLUTCH & CABLE (Fig. 7-5 & 7-6)

To insure proper Safety Clutch operation, the following Clutch adjustments MUST be made: v/ Safety Clutch ab Yoke Trip Lever

1. Remove excess slack from the Safety Cable using the Cable Clainp near the Right Safety Lever.

NOTE: The Safety Cable comes from the factory attached to the left Hopper Side as shown. A Cable Clamp is located on the rear side of the Angle Bracket which is bolted to the left Hopper Side. Slack in the Cable between the left Safety Lever and the Angle Bracket should be adjusted to a minimum amount. Because the Beater Clutch is connected with the Safety Clutch, BE SURE to adjust the Beater Clutch after adjusting the Safety Clutch.

2. Adjust the Safety Clutch Yoke so that Tab engages the Spring-loaded Trip Lever by I I 2" (13 mm).

3. Endplay on the component parts of the Input Shaft for the Safety Clutch should be 11 16" (1.5 mm) or less. If the end play is greater than I I 16" (1.5 mm), the Clutch assembly MUST be removed, by detaching the four mounting fasteners and Washer (GEHL part #042855) inserted in front of the rear 1-118" (29 mm) diameter Bearing on the Input Shaft.

L 112, (13 mm) (Fully) Engaged)

Roller Chains

General

Fig. 7-5

All Roller Chain tensions should be checked on a routine basis after every 10 hours of operation and maintained at a slack side free movement of approximately I I 4 to 1" (6 to 25 mm). Wooden Idler Blocks are used to adjust the Cross Conveyor Drive Chain, the 2nd Beater, the optional 3rd Beater and optional Cross Conveyor Extension Drive Chains. Metal Shoe Tighteners are used for the Speed Shifter Drive Chains. An Idler Sprocket is used to tighten the front right #50 Feeder Drive Chain.

Cross Conveyor Apron Chains (Figs. 7-7 & 7-8)

To adjust the tension on the Cross Conveyor Apron Chains, proceed as follows:

I. Loosen the front and rear Jam Nuts which are located on the right end of the Cross Conveyor.

2. Adjust the Chain tension by turning the Adjusting Nuts until correct Chain tension is obtained. Proper tension is obtained when an Apron Slat can be raised 2" (51 mm) above the Apron Slide at the midpoint between the right and left Conveyor Shafts.

3. After correct tension is obtained, lock the Adjusting Nut positions with the Jam Nuts.

NOTE:

BE SURE to both Ule front and the rear Chains evenly. On new units or after installing a new Cross Conveyor Apron, BE SURE to readjust the Chain tension initially and repeat the adjustment procedure after the second or third load (and as often as necessary thereafter) until the new Chain slack or give disappears.

Cross Conveyor Drive Chain (Figs. 7-8 & 7-9)

The following procedure MUST he used to adjust the #40 Chain which drives the Cross Conveyor:

1. Loosen the #50 Feeder Drive Chain by loosening the 1I 2 x 2-1 I 2 Carriage Bolt on the Idler Sprocket.

2. Remove the Guard which covers the #40 Cross Conveyor Drive Chain by unfastening the (4) Finger Latches which secure the Guard.

3. Loosen (but do NOT remove) the (4) 318 xI fasteners in the slotted holes of the Safety Clutch assembly. This allows the Safety Clutch assembly to move freely.

4. Take up slack in the Cross Conveyor Drive Chain by moving the Safety Clutch assembly to the right. Then, after proper tension is obtained, retighten the (4) Clutch assembly mounting fasteners.

5. Make the final #40 Chain tension adjustment by repositioning and tightening the Wooden Block Idler.

6. Adjust tension on the #50 Feeder Drive Chain by lowering the Sprocket until the proper Chain tension is obtained and then, tightening the I 12 x 2-1 I 2 Carriage Bolt.

7. Replace all Guards after tension is adjusted and before attempting to operate unit.

Fig. 7-10

Feeder Apron Chains (Figs. 7-10 & 7-11)

NOTE: New units are delivered from the factory with the Locking Washers unbent. On new machines or after installing new Feeder Aprons, BE SURE to readjust the Chain tension Initially and repeat the adjustment procedure after the second or third load (and as often as necessary thereafter) until the new Chain slack or give disappears.

To adjust the Feeder apron Chain tension, proceed as follows:

I. Straighten-out all (4) bent Locking Washers on the (4) Adjusting Bolts.

2. Turn the Adjusting Bolts until the correct tension is obtained.

NOTE: Proper Apron Chain tension is obtained when the rear two Apron Slats have lifted 1/8 to 1/4" (3 to 6 mm) off of the Apron Return Slides. Maintainmg proper Apron Chain tension is important to extending Chain life and preventing early failure.

3. After proper Apron Chain tension is obtained on both Aprons, relock the Locking Washers to fix the positions of the Adjusting Bolts.

TRANSMISSIONS & COUPLERS ALIGNMENT (Fig.

7-12 & See Fig. 7-7)

The Transmission Drive Shafts are locked into correct position and alignment by Eccentric Collars and Bearing, Retainers. Proper 4-1/2" (114 mm), for the Beater Transmission Coupler, and 4-5 I 8" (117 mm), for the Worm Gear Transmission, spacings MUST be maintained within 1/8" (3 mm) in both planes. The (3) 5 j 16 x 2-1/4 Hi-strength (H263E) and (I) 5/16 x 2 (H263C) Bolts MUST fit freely into the Couplers since this assembly MUST function as a universal joint which allows for as much as 1I 8" (3 mm) of misalignment between the two Shafts. The Worm Gear Backstop Bolt and the Turnbuckle should be used to obtain correct Worm Gear Shaft alignment with the Drive Shafts. Additional H263E and H263C Coupler Bolts are provided in Holders which are attached to the rear Bearing Bracket.

NOTE: To maintain proper Unloading Unit operation, the correct Coupler Bolts MUST always be used in the Couplers. Worm