Gehl Forage Harvester CB1085, CB1285 Operators Manual 908156C - PDF DOWNLOAD

1085/1285

Form No.

908156 Revision C



Forage Harvester

OPERATOR’S MANUAL

GEHL NEW AGRICULTURAL EQUIPMENT FORAGE HARVESTER WARRANTY GEHL AGRICULTURE DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl Forage Harvesters and attachments, to the original retail purchaser to be free from defects in material and workmanship for a period of twelve (12) months {ninety (90) days for commercial/custom use} from the warranty start date, except as set forth below: The crop processor rolls on the 1085 and 1285 Forage Harvesters are warranted for the life of the rolls for replacement only, labor and freight excluded, unless defect occurs during initial twelve (12) month warranty. Warranty on crop processor rolls does not include normal wear or foreign material entering rolls, which may cause damage.

GEHL AGRICULTURE WARRANTY INCLUDES: Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY DOES NOT INCLUDE: 1.

Transportation to selling dealer’s business location or, at the option of the original retail purchaser, the cost of a service call.

2.

Used equipment.

3.

Components covered by their own non-Gehl warranties, such as tires, trade accessories and engines.

4.

Normal maintenance service and expendable, high-wear items.

5.

Repairs or adjustments caused by: improper use; non-intended use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6.

Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind Gehl 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.

TABLE OF CONTENTS Warranty . . . . . . . . . . . . Inside Front Cover

Chapter 6 Care & Maintenance . . . . . . . . . . . . . 40-75 Adjustments . . . . . . . . . . . . . . . . . . . . . 40 Lubrication . . . . . . . . . . . . . . . . . . . . . . 58 Service . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Chapter 2 Specifications . . . . . . . . . . . . . . . . . . . . 3-4

Chapter 8 Troubleshooting . . . . . . . . . . . . . . . . . 77-89

Chapter 3 Checklists . . . . . . . . . . . . . . . . . . . . . . . 5-7

Chapter 9 Optional Features & Accessories . . . . 90-91

Chapter 4

Chapter 10 Decal Locations . . . . . . . . . . . . . . . . . 92-97

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Chapter 11 Maintenance Log . . . . . . . . . . . . . . . . 98-99

Chapter 5

Index . . . . . . . . . . . . . . . . . . . . . . . . 100-102

Operation . . . . . . . . . . . . . . . . . . . . . . 17-39 How Harvester Functions . . . . . . . . . . 17 Safety Equipment . . . . . . . . . . . . . . . . 17 Preparing Harvester For Field Operation 18 Typical Harvesting Cycle . . . . . . . . . . 22 Transporting . . . . . . . . . . . . . . . . . . . . . 35 Oiler Installation . . . . . . . . . . . . . . . . . 37

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Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Hydraulic Fitting Data . . . . . . . . . . . . . 104 Standard Hardware Torque Data . . . . . . . . . . Inside Back Cover

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CHAPTER 1 INTRODUCTION Your decision to purchase this piece of Gehl equipment was a good one. We are sure that your decision was carefully considered and that you are looking forward to many seasons of reliable performance from this machine.

MODEL NO. (Fill In)

SERIAL NO. (Fill In)

Gehl Company has invested much time and effort in developing its lines of equipment. The equipment you have purchased is built with a great deal of pride, and designed to provide long life, efficient operation, durability and dependability.



Typical Model & Serial Number Plate

Serial numbers for the 1085 and 1285 units are stamped on a plate located on the right side of the mainframe, underneath the feed roll housing.

NOTE: This manual includes information for “early model” 1085/1285 harvesters. “Early models” are 1085 before SN14150 and 1285 before SN20900.

“Right” and “left” are determined from a position standing behind the unit and facing forward. From this position, the telescoping drive is on the “left” and the feed roll housing and cutting cylinder are on the “right.”

Standard hardware and hydraulic fitting torques appear in charts at the end of the manual.

Gehl Company reserves the right to make changes or improvements in the design or construction of any part without incurring the obligation to install such changes on any unit previously delivered.

Throughout this manual information is provided that is set in italic type and introduced by the word NOTE or IMPORTANT. BE SURE to read carefully and comply with the message or directive given. Following this information will improve your operating or maintenance efficiency, help you to avoid costly breakdowns or unnecessary damage and extend your machine’s life.

The Gehl Company, in cooperation with the American Society of Agricultural Engineers and the Society of Automotive Engineers, has adopted this SAFETY ALERT SYMBOL

Modern machinery has become more sophisticated and, with that in mind, Gehl Company asks that you read and COMPLETELY understand the contents of this manual and become familiar with your new machine, BEFORE attempting to operate it.

This manual was developed specifically for the machine you have purchased. The information within is for your assistance in preparing, adjusting, maintaining and servicing your machine. More importantly, this manual provides an operating plan for safe and proper use of your machine. Major points of safe operation are detailed in the SAFETY chapter of this manual. Refer to the Table of Contents for an outline (by chapters) of this manual. Use the Index, located at the back of this manual, for specific chapter and topic/page number references.

If this machine is resold, Gehl Company recommends that this manual be given to the new owner.

If this machine was purchased “used,” or if the owner’s address has changed, please provide your Gehl dealer or Gehl Company with the owner’s name and current address, along with the machine model and serial number. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

Our wide dealership network stands ready to provide any assistance required, including genuine Gehl service parts. All parts should be obtained from or ordered through your Gehl dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

908156/CP0205

COMPANY

WEST BEND, WI 53095 USA

to pinpoint characteristics which, if not properly followed, can create a safety hazard. When you see this symbol in this manual or on the unit itself, you are reminded to BE ALERT! Your personal safety is involved.

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CHAPTER 2 SPECIFICATIONS All dimensions are in inches (millimeters) unless otherwise noted Model & description . . . . . . . . . . . . . . . 1085 & 1285 Forage Harvester Power requirement: 1085 . . . . . . . up to 225 PTO hp (170 kW) tractor with either 1-3/8″ or 1-3/4″ diameter PTO shaft operating at 1000 RPM 1285 . . . . . . . up to 300 PTO hp (224 kW) tractor with either 1-3/8″ or 1-3/4″ diameter PTO shaft operating at 1000 RPM

Overall Dimensions:

Width: 1085 Single axle, 11L x 14 tires . . . . . . . . . 122 (3100) Single axle, 16.5L x 16.1 tires . . . . . . 135 (3429) Tandem axle, 11L x 15 tires . . . . . . . 135 (3429) Width: 1285 Single axle, 16.5L x 16.1 tires . . . . . . 135 (3429) Tandem axle, 11L x 15 tires . . . . . . . 135 (3429) Height: Tandem axle, 11L x 15 tires . . . . . . . 115 (2921) Options available . . . . . . . . 115-163 (2921-4140) Length (to end of cap) . . . . . . . . . . . . . . . 238 (6045) Throat area: 1085 . . . . . . . . . . . . . . . . . . 120 sq. in. (770 cm2) 1285 . . . . . . . . . . . . . . . . . 142.5 sq. in. (919 cm2) Typical weights: 1085 with processor . . . . . . 5830 lbs. (2644 kg) 1085 without processor . . . . 5215 lbs. (2365 kg) 1285 with processor . . . . . . 6065 lbs. (2751 kg) 1285 without processor . . . . 5395 lbs. (2447 kg)

Cutting cylinder characteristics:

Width: 1085 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 (533) 1285 . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 (648) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 (457) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM Quantity of knives . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Length-of-cut: Standard . . . . . . . . 1/4″ (6), 3/8″ (10) & 1/2″ (13) Four knives . . . . . 1/2″ (13), 3/4″ (19) & 1″ (25)

Standard Features:

Blower characteristics:

Tungsten carbide-faced knives Tungsten carbide-faced reversible shearbar Single station shearbar adjustment Feed rolls & attachment engaged by an electro-magnetic 12″ (305 mm) diameter clutch driving a solenoid-reversed shifter transmission with sealed roller bearings running in oil Lower feed rolls shear-bolt protected (1085) Lower feed rolls slip-clutch protected (1285) Bevel gearbox with tapered bearings running in oil Multi-position wagon hitchplate Separate fixed-position wagon transport plate Horizontally and vertically adjustable wheel mounts Two serrated, one fluted and one smooth, feed roll Hydraulically-controlled attachment lift system with flotation spring Reverse grind knife sharpener Main input drive shear-bolt protected Replaceable blower wear liner Replaceable spout wear liner Compact cab-mounted electric control box Battery power supply harness (optional on early models)

Fan diameter . . . . . . . . . . . . . . . . . . . . . . . . 36 (914) Fan speed . . . . . . . . . . . . . . . . . . . . . . . . . . 888 RPM Quantity of paddles . . . . . . . . . . . . . . . . . . . . . . . . . 4 (Early 1285 models had six paddles) Auger characteristics:

Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 (305) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906 RPM Roller mill characteristics (optional):

Roll corrugation . . . . . . . . . 4 per inch (4 per 25 mm) Roll diameter . . . . . . . . . . . . . . . . . . . . . . . . 8.5 (216) Roll length: 1085 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 (559) 1285 . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 (673) Speed: Upper roll . . . . . . . . . . . . . . . . . . . . . 2426 RPM Lower roll . . . . . . . . . . . . . . . . . . . . . 2130 RPM Drive . . . . . . . . . . . . . . . . . Four double “B” V-Belts

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Chapter 2 - Specifications

Safety tow chain Automatic chain oiler system Oiler brush (to add extra locations to chain oiler system) Remote hydraulic outlet kit for dump box control Spout mounted work light Second spring kit for attachment flotation (recommended for use with a 1240 Hay Attachment) Single axle set with (2) 14 x 8.00 D.C. wheels, without tires (1085 ONLY) (NOT FOR USE WITH CROP PROCESSOR) or Single axle set with (2) 14 x 8.00 D.C. wheels mounted with 11L-14, 6-ply rated implement tires (1085 ONLY) (NOT FOR USE WITH CROP PROCESSOR) or Single axle set with (2) W11C x 16.1 wheels mounted with 16.5L-16.1, 8-ply rated implement tires or Single axle set with (2) W8B x 20 wheels mounted with 10.00-20, 12-ply rated recapped tires or Tandem axle set with (4) 15 x 8.00 D.C. wheels mounted with 11.00L-15, 8-ply rated implement tires

Electrically-controlled spout with full range from rear to side delivery Electrically-controlled spout cap 1-3/8″ or 1-3/4″ 1000 RPM telescoping equal-angle PTO connection with 40” (1016 mm) dimension from end of shaft to end of shaft Hydraulically-controlled drawbar with locking transport position Transport lighting A speed monitor disengages the feed roll and attachment drive if cross auger drive overloads Standard Features of Auto-max] Units: Metal Stop system Torque sensors disengage feed roll and attachment drive whenever an overload in either drive is sensed Optional Features & Accessories:

Crop processor Quick-attach drawbar 4-inch (102 mm) extension (for tractors without extendable drawbar to reach 20” (508 mm) PTO-to-hitch pin dimension) Wiring harness for a second tractor Long wiring harness for tractor 3-1/2-ft. (1027 mm) or 5-1/2-ft. (1676 mm) horizontal spout extension kits Spout tripod kit (for use with any extensions) 6-inch (152 mm), 1-ft. (305 mm) or 2-ft.

(610 mm) vertical spout extensions

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Remove dealer’s file copy at perforation

CHAPTER 3 CHECKLISTS PRE-DELIVERY

I acknowledge that pre-delivery procedures were performed on this unit as outlined above.

After the Harvester has been completely set up, the following inspections MUST be made before delivering it to the customer. Check off each item after prescribed action is taken.

Dealership’s Name Dealer Representative’s Name

Check that: Harvester has been assembled correctly according o Forage to instructions in the Set-up & Assembly instructions

Date Checklist Filled Out

grease fittings have been properly lubricated, chains o All oiled and the transmission and gearbox have been filled

Model/Serial Number

supplied.

DELIVERY

to the proper operating levels; see Adjustments, Lubrication & Service sections of the Care & Maintenance chapter of this manual for specific details.

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time the unit is delivered. Check off each item as you explain it to the customer.

guards, shields and decals are in place and securely o All attached. fasteners are properly secured, including the wheel o All lug nuts. are properly mounted and inflated to the appropriate o Tires pressure listed in the Service section of the Care &

the customer the Operator’s Manual (stored in a o Give compartment to the left of the blower). Instruct the customer and all operators to be sure to read and completely understand its contents BEFORE operating the unit.

Maintenance chapter.

adjustments are made to comply with the settings o All given in the Adjustments, Lubrication & Service sections

customer on how to use the index of this manual as o Direct a quick page number locating guide. and review SAFETY chapter of this manual with o Explain the customer. and review with customer the Operation chapter o Explain of this manual. that regular lubrication is required for continued o Explain proper operation and long life. Review the Lubrication

of the Care & Maintenance chapter of this manual.

number for this unit is recorded in spaces provided o Serial on this page and page 2.

Connect the unit up to a 1000 RPM tractor and test run the unit while making sure that proper operation is exhibited by all components.

section of the Care & Maintenance chapter of this manual with the customer.

Check that:

o With engine off, the rotating PTO shield turns freely. drives, chains and belts are rotating smoothly and o All operating properly. feed roll shifter transmission, deflector and cap o The control mechanisms are operating smoothly and properly.

and review the Service section of the Care & o Explain Maintenance chapter of this manual. Remind customer about rim sheet take-up nut torque.

the length-of-cut topic in the Adjustments section o Explain of the Care & Maintenance chapter. how to use the knife sharpener and the imporo Explain tance of sharp knives and correct adjustment of shearbar. the importance of correct tractor hitching o Explain dimensions and drive alignment. fill out the Owner’s Registration, including o Completely customer’s signature, and return it to the Gehl Company.

If Harvester is being delivered with a mounted and connected attachment, such as a Gehl Hay or Corn Head, make the following inspections.

Check that: Gehl attachment has been properly attached to the o The Harvester; check for correct drive fastener replacement. o The drive chain tension is properly adjusted. has been properly lubricated according to the o Attachment separate Operator’s Manual for the attachment. lift system is correctly adjusted for the o Harvester attachment. o Operator’s Manual for the attachment is provided.

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Customer’s Signature Date Delivered (Dealer’s file copy) 5

908156/CP0205

INTENTIONALLY BLANK (To be removed as dealer’s file copy)

908156/CP0205

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CHAPTER 3 CHECKLISTS PRE-DELIVERY

I acknowledge that pre-delivery procedures were performed on this unit as outlined above.

After the Harvester has been completely set up, the following inspections MUST be made before delivering it to the customer. Check off each item after prescribed action is taken.

Dealership’s Name Dealer Representative’s Name

Check that: Harvester has been assembled correctly according o Forage to instructions in the Set-up & Assembly instructions

Date Checklist Filled Out

grease fittings have been properly lubricated, chains o All oiled and the transmission and gearbox have been filled

Model/Serial Number

supplied.

DELIVERY

to the proper operating levels; see Adjustments, Lubrication & Service sections of the Care & Maintenance chapter of this manual for specific details.

The following checklist is an important reminder of valuable information that MUST be passed on to the customer at the time the unit is delivered. Check off each item as you explain it to the customer.

guards, shields and decals are in place and securely o All attached. fasteners are properly secured, including the wheel o All lug nuts. are properly mounted and inflated to the appropriate o Tires pressure listed in the Service section of the Care &

the customer the Operator’s Manual (stored in a o Give compartment to the left of the blower). Instruct the customer and all operators to be sure to read and completely understand its contents BEFORE operating the unit.

Maintenance chapter.

adjustments are made to comply with the settings o All given in the Adjustments, Lubrication & Service sections

customer on how to use the index of this manual as o Direct a quick page number locating guide. and review SAFETY chapter of this manual with o Explain the customer. and review with customer the Operation chapter o Explain of this manual. that regular lubrication is required for continued o Explain proper operation and long life. Review the Lubrication

of the Care & Maintenance chapter of this manual.

number for this unit is recorded in spaces provided o Serial on this page and page 2.

Connect the unit up to a 1000 RPM tractor and test run the unit while making sure that proper operation is exhibited by all components.

section of the Care & Maintenance chapter of this manual with the customer.

Check that:

o With engine off, the rotating PTO shield turns freely. drives, chains and belts are rotating smoothly and o All operating properly. feed roll shifter transmission, deflector and cap o The control mechanisms are operating smoothly and properly.

and review the Service section of the Care & o Explain Maintenance chapter of this manual. Remind customer about rim sheet take-up nut torque.

the length-of-cut topic in the Adjustments section o Explain of the Care & Maintenance chapter. how to use the knife sharpener and the imporo Explain tance of sharp knives and correct adjustment of shearbar. the importance of correct tractor hitching o Explain dimensions and drive alignment. fill out the Owner’s Registration, including o Completely customer’s signature, and return it to the Gehl Company.

If Harvester is being delivered with a mounted and connected attachment, such as a Gehl Hay or Corn Head, make the following inspections.

Check that: Gehl attachment has been properly attached to the o The Harvester; check for correct drive fastener replacement. o The drive chain tension is properly adjusted. has been properly lubricated according to the o Attachment separate Operator’s Manual for the attachment. lift system is correctly adjusted for the o Harvester attachment. o Operator’s Manual for the attachment is provided.

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Customer’s Signature Date Delivered (Pages 5 and 6 have been removed at perforation)

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908156/CP0205

CHAPTER 4

SAFETY The above Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of ‘‘Heads Up for Safety’’ and can be found throughout this Operator’s Manual and on the machine itself.

MANDATORY SAFETY SHUTDOWN PROCEDURE BEFORE unclogging, cleaning, adjusting, lubricating or servicing the unit:

BEFORE YOU ATTEMPT TO OPERATE THIS EQUIPMENT, READ AND STUDY THE FOLLOWING SAFETY INFORMATION. IN ADDITION, BE SURE THAT EVERYONE WHO OPERATES OR WORKS WITH THIS EQUIPMENT, WHETHER FAMILY MEMBER OR EMPLOYEE, IS FAMILIAR WITH THESE SAFETY PRECAUTIONS. Our Company ALWAYS takes the operator and his/her safety into consideration when designing machinery, and guards exposed moving parts for his/her protection.

However, some areas cannot be guarded or shielded in order to assure proper operation. Furthermore, this Operator’s Manual, and decals on the machine, warn of additional hazards and should be read and observed closely.

Disengage the tractor PTO.

2.

Shut off the tractor engine, place transmission in park and/or apply parking brake to prevent any tractor movement.

3.

Remove the ignition switch key and take it with you when leaving the tractor seat.

4.

Turn the control box power switch to “OFF.”

5.

Wait for all movement to stop, and remove the telescoping PTO drive and ALL power connections from the tractor.

ONLY when you have taken these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious bodily injury.

DANGER

ADDITIONAL SAFETY REMINDERS

‘‘DANGER’’ indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Forage Harvesters are designed and intended to ONLY be used with a mounted Gehl Company attachment. The Gehl Company will NOT be responsible for operator safety if the Harvester is used without a properly mounted Gehl attachment.

WARNING

Some photographs used in this manual may show doors, guards and shields open or removed for illustration purposes ONLY. BE SURE that all doors, guards and shields are in their proper operating positions BEFORE starting the tractor engine to operate the unit.

‘‘WARNING’’ indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

To ensure continued safe operation, replace damaged or worn-out parts with genuine Gehl service parts, BEFORE attempting to operate this equipment.

CAUTION ‘‘CAUTION’’ indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. May also alert against unsafe practices.

908156/CP0205

1.

BE SURE to review and comply with ALL safety recommendations in the tractor operator’s manual.

This Harvester is NOT intended to be used as a stationary unit.

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SAFETY (Continued)

ALWAYS wear safety glasses with side shields while operating the knife sharpener. In addition, ALWAYS wear safety glasses with side shields whenever striking metal against metal. It is further recommended that a softer (chip-resistant) material be used to cushion the blow. Failure to heed could lead to serious injury to the eyes or other parts of the body.

The Harvester may have a factory-installed Metal Stop system that will automatically sense the presence of ferrous metal in the feed roll area. Metal detection activates a de-clutch mechanism, which stops the feed roll drive, preventing metal from entering the cutting cylinder. When metal is detected, the feed rolls and attachment will stop and the horn will sound inside the control box. To turn off the horn, safely locate and remove the metal, reset the detection system, and perform the following steps in the sequence given:

For implements without brakes, safety codes recommend that total weight of implement and load DO NOT exceed one-and-one half (1-1/2) times the weight of the towing vehicle. For any public highway travel and to be in compliance with this rule, BE SURE that your tractor is heavy enough to counterbalance the weight of the Harvester and loaded wagon.

Metal Location and Removal

ALWAYS follow state and local regulations regarding use of a safety chain and auxiliary lighting when towing farm equipment on public highways. Restrict highway towing speeds to 20 mph (32 km/h) maximum. BE SURE to check with local law enforcement agencies for your own particular regulations. Unless otherwise prohibited, use a slow moving vehicle (SMV) emblem.

Only a safety chain (NOT an elastic or nylon/plastic tow strap) should be used to retain the connection between the towing and towed machines, in the event of separation of the primary attaching system.

NEVER use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause a serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

1.

Stop tractor travel when horn sounds.

2.

Move the feed roll switch to “Neutral” to turn off the horn.

3.

Back up the Harvester 15 to 20 feet (5-7 m) so that there is NO crop under the attachment.

4.

Idle tractor engine; reverse the crop out of the feed roll area, and then allow the feed roll switch to return to “Neutral.”

5.

Turn off the control box power switch.

6.

Disengage the tractor PTO and shut off the tractor engine. Remove the ignition key and take it with you when leaving the tractor seat.

7.

Wait for ALL parts to stop moving.

8.

Leave the tractor seat to remove the metal from the crop.

9.

Reset system by following the reset instructions in the Operation chapter.

Tire mounting, service or inflation can be hazardous.

Whenever possible, trained personnel should be called to service and/or mount tires, following the tire manufacturer’s instructions. If you do not have such instructions, contact your tire dealer or our Company. In any event, to avoid possible fatal or serious injury, follow the specific directives given in the Service chapter of this manual.

To safely locate the metal after it has been detected, and to remove it from the crop, it is recommended that the Harvester be backed away from the windrow or crop row a sufficient distance so that the portion of the crop containing the metal can be located and picked out, or that the small amount of crop can be set on the side for disposal later.

REMEMBER, it is the owner’s responsibility for communicating information on the safe use and proper maintenance of this machine.

NEVER attempt to hand-feed the crop into the Harvester, because the crop will feed faster than you can react to let go.

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908156/CP0205

SAFETY (Continued)

Instruction card 159837 (not shown in photo)

091444

Tractor End

908156/CP0205

READ

READ

154226

READ

Beneath Guard

143007

Implement End

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SAFETY (Continued)

093202 093653

093374

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908156/CP0205

SAFETY (Continued)

093367 093373

163941

908156/CP0205

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SAFETY (Continued)

163957

093381

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908156/CP0205

SAFETY (Continued)

163957

093378

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SAFETY (Continued)

163957

093378

READ READ

Top View of Processor (when installed)

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SAFETY (Continued)

163957

163962

093379

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CHAPTER 5 OPERATION HOW HARVESTER FUNCTIONS

A: Implement Driveline Guards (Fig. 1)

The Harvester is used to harvest and cut various forage crops into short particle lengths and deliver the cut forage into a transport container.

The telescoping PTO drive connection to the tractor is equipped with rotating shields.

SAFETY EQUIPMENT

WARNING

This Harvester is provided with several features for operator safety and convenience.

BE SURE that the rotating shields on the telescoping drive turn freely BEFORE starting the tractor engine.

Guards & Shields Wherever possible and without affecting machine operation, guards, shields and/or hinged covers 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.

CAUTION Become familiar with and know how to use ALL safety devices and controls on the Harvester (and tractor) BEFORE operating this equipment. Know how to stop Harvester operation BEFORE starting it. This Gehl Harvester is designed and intended to be used ONLY with a mounted Gehl Company attachment. The Gehl Company will NOT be responsible for operator safety if used without a completing attachment.

WARNING Read ALL warnings on the unit BEFORE operating it. DO NOT operate this equipment unless ALL factory-installed guards and shields are properly secured in place.

2 1

2

4

1

3

3 4

1 - Speed monitor cover 2 - Knife sharpener cover 3 - Auger cover 4 - Auger and processor drive cover

1 - Drive chain guard 2 - Front guard 3 - Telescoping PTO drive rotating shields 4 - Guard over fixed-length driveline

Fig. 2

A guard is provided over the entire fixed-length portion of the implement driveline, from the front bearing support back to the bevel gearbox input shaft.

Fig. 1

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908156/CP0205

Chapter 5 - Operation

B: Miscellaneous Guards (Figs. 1 & 2)

CAUTION

Various latched and hinged guards and covers are provided on the Harvester to protect service and/or adjustment access points.

ALWAYS follow state and local regulations regarding use of a safety chain and transport lighting when towing farm equipment on public highways. ONLY a safety chain (NOT an elastic or nylon/plastic tow strap) should be used to retain the connection between the towing and towed equipment, in the event of separation of the primary attaching system.

BE SURE to check with local law enforcement agencies for your own particular regulations.

Unless otherwise prohibited, use a slow moving vehicle (SMV) emblem.

WARNING BEFORE performing any work on the Harvester and BEFORE removing or opening any guards or covers, BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). BE SURE to replace ALL guards and covers BEFORE resuming operation.

Safety Chain & Transport Lighting (Figs. 3 & 4)

1

As required or when desired, the Harvester should be equipped with a safety chain for operation on public highways. See your Gehl dealer for ordering information. The safety chain should be attached to the tractor and Harvester as shown in Figure 3. The Harvesters are equipped with transport lights as standard equipment.

The light harness uses an SAE J560 standard 7-pin connector. See your tractor dealer if your tractor is not equipped with this connector.

3

2

4

1 - Left transport light arm 2 - Right transport light arm 3 - Supplied SMV emblem 4 - Socket for wagon transport lights

Fig. 4

4

1

PREPARING HARVESTER FOR FIELD OPERATION

2

The Harvester, having a 1000 RPM 1-3/8″ PTO shaft or 1-3/4″ PTO shaft configuration, utilizes an equal-angle driveline length of 20″ (508 mm). This horizontal dimension is measured from the end of the tractor PTO shaft to the center of the drawbar pin hole. To operate the 1-3/8″ drive, your tractor must have an extendable drawbar. If your tractor does not have this feature, a 4″ (102 mm) quick-attach drawbar extension is available.

3 1 - Locking hitch pin (1.25″ [32 mm] diameter) 2 - Chain loop on Harvester 3 - 30,000 lb. (13635 kg) accessory safety chain 4 - Quick-attach drawbar extension (4″ [102 mm])

Fig. 3

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Chapter 5 - Operation

2

should be 20″ (508 mm) from the end of the tractor PTO shaft, or 16″ (406 mm) from the end of tractor PTO shaft when using the quick-attach drawbar 4″ (102 mm) extension.

8

3

4 2

5

6

1

8

3

7

4

1 5

1 - Tractor drawbar* 2 - 1000 RPM tractor 1-3/8″ or 1-3/4″ PTO shaft* 3 - 20″ (508 mm) - Measured from the end of the tractor PTO shaft to center of tractor drawbar hitch pin hole 4 - 20″ (508 mm) - Measured from the end of the Harvester main drive shaft to center of tractor drawbar hitch pin hole 5 - 7.9 - 13.8″ (150 - 300 mm)* 6 - 13 - 22″ (330- 560 mm)* (Top of drawbar to ground) 7 - Locking hitch pin (1.25″ [32 mm] diameter] 8 - Tractor drawbar hitch pin hole alignment decal on PTO

6

9

7

1 - Tractor drawbar* 2 - 1000 RPM tractor 1-3/8″ or 1-3/4″ PTO shaft* 3 - 20″ (508 mm) - Measured from the end of the tractor PTO shaft to center of tractor drawbar hitch pin hole 4 - 20″ (508 mm) - Measured from the end of the Harvester main drive shaft to center of tractor drawbar hitch pin hole 5 - 7.9 - 13.8″ (150 - 300 mm)* 6 - 13 - 22″ (330- 560 mm)* (Top of drawbar to ground) 7 - Locking hitch pin (1.25″ [32 mm] diameter) 8 - Tractor drawbar hitch pin hole alignment decal on PTO 9 - 4″ (102 mm) quick attach drawbar extension

* Tractor PTO MUST comply with ASAE Standard S203

Fig. 5: 1-3/8″ or 1-3/4″ PTO 1000 RPM

Tractor Hitch Alignment (Figs. 5 & 6)

* Tractor PTO MUST comply with ASAE Standard S203

Fig. 6: 1-3/8″ or 1-3/4″ PTO 1000 RPM with 4″ (102 mm) quick-attach drawbar extension

Position the tractor drawbar hitch hole centerline directly in line with the tractor PTO drive shaft, and secure so as to eliminate any side-to-side movement of the tractor drawbar. If the tractor drawbar can NOT be positioned in line, position it toward the left, as close as possible to the centerline of the PTO shaft. It is important to use a 1.25″ (32 mm) diameter hitch pin (supplied) with the Harvester to help center the Harvester tongue with the tractor drawbar and reduce the amount of side-to-side movement. The tractor drawbar height should be adjusted to position the PTO as parallel as possible to the drawbar. Keeping the drawbar in line and minimizing side-to-side movement is essential in eliminating driveline vibration, especially when maneuvering around corners.

IMPORTANT: If this unit is connected to a tractor equipped with a clevis-style drawbar, the clevis parts shown in dashed lines MUST be removed to prevent damage to the unit driveline. See Fig. 7 for details.

1

On tractors that are unable to adjust the drawbar to the proper dimension, a quick-attach drawbar 4″ (102 mm) extension is available. Refer to Fig. 6 for proper positioning.

The front-to-rear position of the tractor drawbar hitch hole centerline MUST be correct to ensure the proper universal joint relationship. The tractor drawbar hole

Printed in U.S.A.

1 - Clevis parts to be removed

Fig. 7

19

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Chapter 5 - Operation

Fig. 8

Quick-Attach Drawbar 4″ (102 mm) Extension (Optional) (Fig. 8)

Transport Lighting The transport lighting is properly connected to a tractor equipped with a SAE J560 7-pin connector if:

NOTE: The following information applies only to a Harvester that is going to be equipped with optional 4″ (102 mm) quick-attach drawbar extension.

Install the drawbar extension following the instructions given in Fig. 8.

Vertical Driveline Alignment Optimum performance and minimum driveline vibration are achieved when the Harvester input drive shaft and the tractor PTO shaft are at or near the same height.

The Harvester hitch clip is vertically adjustable to accommodate the tractor PTO shaft height variations.

For applications using the 4″ (102 mm) quick-attach drawbar extension, additional height adjustment is available by locating it above or below the tractor drawbar. After any adjustments are made, reinstall and tighten the hitch clip retaining bolts to 260 lb.-ft.

(352 Nm).

908156/CP0205

1.

When transport lights are activated, both red lights illuminate at lower intensity and both amber lights blink slowly.

2.

When right turn signal is activated, right amber and red lights blink quickly, left amber light burns steady and left red light increases in brightness.

3.

When left turn signal is activated, left amber and red lights blink quickly, right amber light burns steady and right red light increases in brightness.

See your tractor dealer if your tractor is not equipped with the proper connector.

Preparing Harvester The following points of preparation will have to be made on the Harvester with respect to the attachment being mounted. Refer to the Adjustments section of the Care & Maintenance chapter of this manual and, if necessary, the appropriate attachment operator’s manual for specific adjustment details and requirements.

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Chapter 5 - Operation

1.

Move the Harvester axles in or out and relocate the wheel spindles to match the row spacing and height required for the particular attachment.

2.

Adjust the attachment float spring on the Harvester.

3.

Make appropriate Harvester lift height and downstop adjustments. Refer to Attachment Positioning topic in the Adjustments section of the Care & Maintenance chapter.

4.

5.

Make the appropriate attachment positioning adjustments according to the details provided in the Adjustments section of the Care & Maintenance chapter of this manual.

WARNING Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) before servicing this unit.

Adjust the wagon hitch plate position, if required.

Harvester-Attachment Alignment (Figs. 9 & 10) Before proceeding to mount the attachment, make sure that it is standing on level ground. Also check that the quick-switch yokes of the attachment align vertically with the quick-switch pivots on the Harvester. Adjust the attachment stands to obtain the right height.

NOTE:

To better enable one person to mount the attachment, it MUST be squared up, properly leveled and at the correct height. In addition, the Harvester approach into the attachment MUST be squarely and directly head on. BE SURE also to adjust the attachment throat sheets to match the Harvester side sheet opening.

1.

2.

3.

1

1 - Downstop pin locked in hole above lift link and cylinder fully retracted

Position the Harvester lift arms down to their lowest possible position by inserting the downstop pin (1″ square bar) into the hole above the cylinder link and then retracting the lift cylinder completely. This prevents the lift rollers from interfering with the attachment while it is being mounted.

Fig. 9

1

Drive the Harvester into the attachment and observe that the attachment yokes slide over the Harvester quick-switch pivots and that the attachment throat sheets slide between the Harvester feed roll side sheets.

2

Connect the attachment to the Harvester. Insert the quick-switch pins (from the toolbox) into the holes and secure them with the hairpin cotter pins.

NOTE:

It may be necessary to use a pry bar to completely engage the attachment yokes onto the pivots of the Harvester.

1 - Typical HA1210 driven sprocket 2 - Attachment drive chain

4.

6.

Fig. 10

Slowly extend the hydraulic lift cylinder and remove the downstop pin from above the lift cylinder link.

Printed in U.S.A.

21

Align the attachment drive sprocket with the attachment driven sprocket by adding or removing washers.

908156/CP0205

Chapter 5 - Operation

After proper alignment is obtained, secure the drive sprocket with the capscrew, lock washer and special washer.

Row Widths that Can Be Harvested with Corn Heads

IMPORTANT: Tighten the sprockets. Operating

Width

the Harvester with loosely secured sprockets can cause excessive shaft spline wear.

Model Attachment TR3038 (2-row narrow)

28-34″

7.

TR3038 (2-row wide)

36-42″

TR330 (3-row narrow)

28-34″

Wrap the attachment drive chain around the drive and driven sprockets. Adjust the chain length by adding or removing links, as required. Refer to the Drive Chain Length table for the necessary chain length to match the attachment being mounted.

Crop Processor Roller Mill (Optional)

Drive Chain Length Model Attachment

Number of Links

HA1110

48

HA1200, HA1210, HA1240

58

TR3038, TR330

64

The purpose of the processor is to increase digestibility and therefore utilization of corn silage by breaking open kernels and reducing size of cob and stem particles.

Machine performance will be best and most efficient if you use the greatest roll clearance and longest length-ofcut which achieves the desired forage consistency. The amount of processing is directly affected by roll clearance, crop moisture content and sharpness of rolls.

TYPICAL HARVESTING CYCLE NOTE: This topic is divided into two separate sections. The first section pertains to the Harvester. The second section pertains only to the metal detector system.

The recommended starting clearance for the rolls is 1/2 turn of the adjustment handle open from the minimum 0.015″ (0.38 mm). This equals 0.115″ (2.92 mm). For finer adjusting, each link on the chain represents a change of 0.010″ (0.25 mm).

Harvester

Although primarily intended for corn processing, this Harvester will also work with hay crops. With the processor rolls opened to their maximum (3.00″ [76 mm]), hay can be harvested. Be aware that any stones or foreign objects will damage the processor rolls. The processor assembly should be removed from the Harvester for normal hay harvest. Refer to the Crop Processor Operator’s Manual for details.

WARNING BEFORE starting the tractor engine and running the Harvester, review and comply with ALL applicable recommendations in the SAFETY chapter.

Water Applicator (Optional)

General Information

The purpose of the water applicator system is to apply fluids into the blower area:

Preparing Crop to Be Harvested Widths of Windrows that Can Be Picked Up by Hay Heads Model Attachment

Width (Max.)

HA1100, HA1110

6 feet

HA1200, HA1210

7 feet

HA1240

9 feet

908156/CP0205

•

To reduce gum build-up in the blower and spout, which will increase harvesting efficiency and reduce frictional heating.

•

To apply crop preservatives or biological inoculants to the chopped material.

The control for the system features a three-position switch:

•

22

Off

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Chapter 5 - Operation

•

Manual - operates the pump continuously

•

Automatic - operates the pump only when the feed roll transmission clutch is engaged

An indicator light on the water applicator control box signals when the pump is operating.

Electric Controls Identification (Figs. 11 & 12) NOTE: The tractor control box is NOT waterproof and MUST be kept dry during operation and storage.

Basic Operation of Controls 1: Power Switch The power switch (item 1 in Fig. 11) controls power to the tractor box and the implement box located on the Harvester. Make sure the feed roll switch (item 4 in Fig. 11) is in the centered “neutral” position before moving the power switch to the “on” position. Depress the right side of the power switch to activate the Harvester electrical system. The power switch is illuminated when pushed to the right.

5

4

Fig. 12: Instruction card (front)

2: Spout Rotation The spout switch (item 2 in Fig. 11) is used to rotate the spout. Depress the right side of the switch to rotate the spout to the left side of the Harvester. Depress the left side of the switch to rotate the spout to the right. If the operator prefers the spout to operate in the opposite direction as described above, the wires installed in the spout motor connector may be removed and reinstalled in the opposite direction.

3

3: Cap Movement The cap switch (item 3 in Fig. 11) is used to move the cap up and down. Depress the lower part of the switch to move the cap down or depress the upper part of the switch to move the cap up.

Both the spout switch and cap switch can be easily and efficiently operated by placing the right hand on the lower right side of the control box and using the thumb to activate the two switches. The spout switch can be operated by depressing the right side of the switch or by pushing against the paddle to operate the left side of the switch. The cap switch can be operated in a similar manner. Both switches may be operated simultaneously if desired. See Fig. 11.

1 2

6

7 1 - Power switch 2 - Spout switch 3 - Cap switch 4 - Feed roll switch 5 - Alerts 6 - Horn (on bottom left side of control box) 7 - Mount 8 - Instruction reference card (not shown; see Figs. 12 & 13)

4: Feed Roll Switch The feed roll switch (item 4 in Fig. 11) controls the rotation direction of the feed rolls and crop head and is also used to reset the control system alerts and horn.

The feed roll switch is a lighted switch. The light in the lower portion of the switch is on whenever the power switch is on. The upper portion of the switch lights whenever the switch is in either the “Forward” or “Reverse” position.

Fig. 11: Electric controls

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Chapter 5 - Operation

Reset

Forward

•

To operate the feed rolls in the forward direction and take crop into the Harvester, depress the upper part of the feedroll switch.

•

When the control system is initially powered, or if any of the alerts are illuminated, the control system must be reset to operate the feed rolls in forward rotation.

The switch will latch in this position and may be run continuously in this position.

•

•

If the horn sounds when the switch is pushed for forward operation, the system is not reset and needs to be reset.

To reset the control system:

•

1.

Press and release lower portion of feed roll switch to be in “neutral”.

2.

Engage PTO and increase PTO speed above 400 RPM.

3.

Press and release lower portion of feed roll switch (“Reverse”) to turn all alert lights off.

To shut off the feed rolls, tap the lower portion of the feedroll switch. The switch will unlatch and be in “Neutral.” If the operator switches rapidly from “Forward” to “Reverse,” “Reverse” will not be activated and any alert illuminated will not be reset until the switch is released and pushed a second time. Refer to Neutral Pause topic that follows.

Neutral

Neutral Pause

•

•

For safety reasons, this control system is designed so the feed rolls will not operate in forward rotation when the power is initially turned on until the control system has been reset.

The centered position of the feedroll switch is “neutral.”

In this position, the feed rolls, crop head, and horn do not operate.

Reverse

•

Depressing the lower portion of the feed roll switch performs two functions: — activates reverse feed roll operation to back feed out of the Harvester — resets the alert lights when the PTO is operating above 400 RPM.

•

This is a momentary switch; “Reverse” will only be active while the switch is depressed. When the switch is released, it will return to “Neutral.”

•

Reverse operation is automatically limited to less than 10 seconds to prevent overheating the reverse solenoid.

•

If reversed for more than 5 seconds, further operation is blocked for 10 to 20 seconds to allow the reverse solenoid to cool.

•

In most cases, reversing is short duration and will never be blocked.

•

When reverse is blocked due to cooling, the feed rolls may still be operated in forward rotation.

908156/CP0205

•

Rapidly switching the feed rolls from reverse to forward, or from forward to reverse, is automatically blocked by the control system.

•

This prevents the alert lights from being accidentally cleared when shifting from “Forward” to “Neutral.”

•

Similarly, it prevents switching the direction of the feed roll rotation while the feed rolls are still in motion.

•

When switching from “Forward” to “Reverse” or “Reverse” to “Forward,” allow the feed roll switch to pause in the “Neutral” or center position for 1 second.

5: Alerts The alert lights (item 5 in Fig. 11) and the horn (item 6 in Fig. 11) inform the operator that one of four alert conditions has occurred and caused the Harvester feed rolls and header to automatically shut down. The 1085 shear bolt model has only one alert function (“Speed”).

For all alerts, the operator must follow the instructions shown in Fig. 13.

In addition, the operator should back up the tractor to separate the crop in the attachment from the crop on the ground.

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Chapter 5 - Operation

7: Mount

WARNING

The control box mount (item 7 in Fig. 11) may be attached to a solid, secure surface in practically any orientation: horizontal, vertical or overhead. To adjust the control box, loosen the adjustment thumb screw in the middle of the mount and adjust the control box position to suit the operator. Re-tighten the thumb screw when the desired position is achieved. The control box can be operated effectively when adjusted so the thumb of the right hand can manipulate both the cap and the spout switches.

BEFORE searching for detected metal, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). REMEMBER also that, when PTO is engaged, cylinder and blower continue to rotate when feed rolls and attachment are stopped.

NOTE: DO NOT reverse the crop too far. Corn should NOT be allowed to back out past the front feed rolls or it will not feed back in when the forward mode is re-engaged. Hay could auger sideways and jam into the attachment side sheets if it is backed out too far, bending the auger flighting away from the side sheets.

8: Instruction Reference Card The instruction card (Figs. 12 & 13) should be attached to the control box mounting channel with four split rings. The instruction card is only a quick reference for operating the control system. Complete operating instructions are in the Operator’s Manual. Read the Operator’s Manual before operating the Harvester.

Start-up

WARNING BE SURE ALL guards and shields are properly secured in place BEFORE starting the tractor engine and operating the Harvester.

Emergency Shutdown In an emergency or in case a foreign object enters or becomes lodged in the feed roll area, STOP Harvester operation IMMEDIATELY by disengaging the tractor PTO.

Fig. 13: Instruction card (rear)

IMPORTANT: To

protect the driveline components of both the Harvester and the tractor, avoid engaging the tractor PTO at faster than idle speed.

Rolls and Head (1085 Shear-Bolt Model) Refer to Unplugging topic in this chapter.

To start harvesting:

6: Horn The horn (item 6 in Fig. 11) is located on the bottom left side of the control box. If any alert light is illuminated or if the control system is initially powered, the horn will sound when the feed roll switch is in the “Forward” position. The horn will stop sounding when the feed roll switch is in “Neutral” or “Reverse.” Resetting the control system will disable the horn with respect to the feed roll switch “Forward” position until an alert condition occurs.

Printed in U.S.A.

25

1.

Move feed roll switch to centered “Neutral” position.

2.

Turn on control box power switch.

3.

Engage PTO at engine idle speed.

4.

Increase tractor PTO speed above 400 RPM.

5.

Press feed roll switch into reverse and then release into neutral for one second.

908156/CP0205

Chapter 5 - Operation

6.

Press feed roll switch to “Forward.”

7.

Increase tractor PTO speed to 1000 RPM.

8.

Drive into crop.

Unplugging (See Fig. 11)

WARNING

Entering the Crop

When any part of the Harvester other than the feed rolls or attachment becomes plugged, stop Harvester operation IMMEDIATELY by moving the feed roll switch to NEUTRAL. Then disengage the tractor PTO and wait for ALL movement to STOP. Next, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). BEFORE leaving the tractor seat to remedy the plugging problem, turn the control box power switch to OFF.

NOTE: The PTO should be brought up to the rated 1000 RPM before entering the crop and then maintained at that speed while harvesting.

To maintain the rated RPM, choose the correct tractor gear position to adjust ground speed rather than the tractor throttle.

Sharp cutting cylinder knives and proper shear bar adjustment will provide for more efficient Harvester operation and will reduce horsepower waste.

Spout

Leaving the Crop

If the spout becomes plugged with chopped forage, proceed as follows: 1. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8).

Maintain the rated RPM for a short time after leaving the crop. This will allow the Harvester blower, cutting cylinder and spout to be emptied. After the forage stops coming out of the spout, the PTO speed can be reduced.

As long as the PTO speed is above 400 RPM, the feed rolls and attachment will continue to operate. When the PTO speed drops below 400 RPM, the speed monitor will stop the attachment, the control box horn will sound, and the “Speed” alert light will come on.

NOTE:

Except for the brief time that the reverse switch is activated, gearing in the transmission is always in the forward condition. It has NO neutral.

The neutral condition is created solely by opening the electric clutch.

After all cutting cylinder and blower movement has STOPPED, remove the cleanout cover from the base of the spout.

3.

Remove any plugging material which may be wedged inside the spout or spout extension through the cleanout cover(s).

4.

Check and, if necessary, unplug the blower. To unplug this area, refer to the information under the Blower topic in this chapter.

Blower If the blower becomes plugged with chopped forage, proceed as follows to clear it: 1. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8).

Stopping Harvester The feed rolls and attachment are stopped by moving the feed roll switch to the centered (“Neutral”) position.

The cutting cylinder, auger, blower, and optional Crop Processor will continue to run when the tractor PTO is operating.

2.

Before proceeding with cleaning out the blower, wait for the cylinder to stop turning.

NOTE:

Even if the blower outlet is plugged, the fan could continue to rotate.

Disengage the tractor PTO to stop all Harvester component movement. The Harvester power switch should be switched OFF when the Harvester is NOT being used. This will avoid unnecessary drain on the battery.

908156/CP0205

2.

26

3.

The cleanout cover at the upper left side of the back of the blower and the auger cover may be opened.

4.

After the forage has been cleaned out of the blower and the fan turns freely, check the blower outlet to ensure that it is NOT also plugged.

Printed in U.S.A.

Chapter 5 - Operation

5.

If the blower outlet is plugged, use a rod to poke down from the top through the spout cleanout holes.

6.

After the fan is free to rotate, replace the cleanout covers and close the auger cover.

2.

Auger If the auger becomes plugged with chopped forage, proceed as follows to clear it: 1.

Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8).

2.

Open auger cover and clean out the auger.

3.

Close auger cover.

4.

Replace shear bolts if necessary.

5.

Refer to the Cutting Cylinder topic in this chapter if the cylinder is not free to turn.

If the Crop Processor is installed, refer to the Crop Processor topic in this chapter for procedures.

Crop Processor If the Crop Processor roller mill becomes plugged with chopped forage, proceed as follows to clear it: 1.

Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8).

2.

Release Crop Processor drive belt tension using the roll spacing adjustment wrench.

3.

Adjust the Crop Processor rolls to their greatest clearance position using the roll spacing adjustment wrench.

4.

Open auger cover and clean out all crop from the processor rolls. If the cutting cylinder or any other part of the Harvester is plugged, refer to the other “Unplugging” topics in this chapter for instructions.

5.

Adjust the Crop Processor rolls to their operating position.

6.

Close auger cover.

7.

Re-tension Crop Processor drive belts.

Inspect the cylinder by removing the cover. Check to see if the knives are wedged with forage. If they are hung up, do the following: a.

Pry the cylinder backward as far as possible so that the cylinder can build up momentum before it enters the crop.

b.

If the Crop Processor is installed, clean out all crop from the processor rolls.

c.

Reinstall and secure the cylinder cover, guards, auger and/or Crop Processor covers.

d.

Start the tractor, run the engine at 3/4 to full throttle and engage the PTO to clear the plug; this may partially shear the main drive shear bolts.

e.

Again, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8) and then check the cylinder to make sure it is unplugged.

f.

Inspect the main drive shear bolts (and replace them, if necessary) following the procedure as described under the Overload Protection - Main Driveline topic in this chapter.

WARNING After the cylinder is freed and cleaned out and the main drive shear bolts have been inspected (and replaced), reinstall all guards and covers BEFORE resuming Harvester operation.

Feed Rolls (Auto-MaxTM Models) By design, the feed rolls allow various mat thicknesses to pass between them. If, however, the mat thickness tries to exceed 6″ (152 mm) or if an obstruction gets between the feed rolls, the torque sensor will detect this condition. This will cause the electric clutch to open and stop feed roll operation and the crop will NOT feed into the cutting cylinder. The horn will sound and the “Rolls” alert light will come on.

•

Stop tractor travel.

•

If the cutting cylinder becomes plugged with forage, proceed as follows:

Move the feed roll switch to center position to shut off the horn.

•

Observe that “Rolls” alert light is activated.

1.

•

Back up the tractor to separate the crop in the attachment from the crop on the ground.

Cutting Cylinder

Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8).

Printed in U.S.A.

27

908156/CP0205

Chapter 5 - Operation

•

DO NOT idle the tractor engine.

•

Reset the control system.

•

Resume feed roll forward rotation.

•

If the condition is not cleared, back out the feed 6″ (152 mm) and try forward rotation again. Repeat until condition is cleared.

sheets; although it should NEVER need to be backed up that far.

WARNING NEVER hand feed crop into the feed rolls because the crop will feed faster than you can react to let go.

NOTE: Special care should be taken NOT to reverse the crop too far. Corn should NOT be allowed to back out past the front feed rolls or it will NOT feed back in when the forward mode is re-engaged. Hay should be watched so that the attachment auger does NOT “auger” the material sideways and jam it into the attachment side sheets; bending the auger flighting away from the side sheets.

Overload Protection Main Driveline (Fig. 14) The main drive is protected from “sudden start” impact damage by shear bolts. The shear flange is secured with two 5/16 x 2″ Grade 8 shear bolts with 5/16″ lock nuts.

The flange is equipped with a grease fitting in the pilot area to prevent the shaft from seizing; the fitting MUST be greased daily. Additional shear bolts are provided in the toolbox. More shear bolts can be obtained by ordering Gehl part number 153753 for a package of eight 5/16 x 2″ Grade 8 shear bolts and 5/16″ lock nuts.

WARNING NEVER hand feed crop into the feed rolls because the crop will feed faster than you can react to let go.

3

2

1

4

Feed Rolls (1085 Shear-Bolt Model) By design, the feed rolls allow various mat thicknesses to pass between them. If, however, the mat thickness exceeds 6″ (152 mm) or if an obstruction gets between the feed rolls, the shear bolt in upper feed roll drive will shear and thus stop feed roll operation and the crop will NOT feed into the cutting cylinder.

4 1 - Main drive joint 2 - Shear flange 3 - Shear bolts (two 5/16 x 2″ Grade 8 with lock nuts) 4 - Grease fittings (two)

If the shear bolt has failed, it is possible to reverse the plugging material out of the feed roll area by idling the tractor and shifting the feed roll drive transmissions into reverse.

Fig. 14

IMPORTANT: ALWAYS use lock nuts on shear bolts to prevent them from loosening.

NOTE: Upper feed roll drive is protected by a one-way shear-bolt protective device. This mechanism allows the drive to be reversed before installing a new shear bolt. The shear bolt holes will self-align when the feed rolls are reversed.

Auger Drive (Fig. 15) The auger drive is protected by a shear flange on the input shaft. The shear flange is secured with two 1/4 x 1″ Grade 5 shear bolts with 1/4″ locknuts.

Additional shear bolts can be obtained by ordering Gehl part number 904400 for a package of eight 1/4 x 1″ Grade 5 shear bolts and 1/4″ lock nuts. If the bolt shears, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8), remove the cause of the overload and replace the shear bolt before attempting to resume harvesting.

NOTE: Special care should be taken NOT to reverse the crop too far. Corn should NOT be allowed to back out past the front feed rolls or it will NOT feed back in when the forward mode is re-engaged. Hay should be watched so that the attachment auger does NOT “auger” the material sideways and jam it into the attachment side 908156/CP0205

28

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Chapter 5 - Operation

Feed Roll & Attachment Drive (1085 Auto-Max Model) (Fig. 17)

1

The lower feed roll drive is protected by a shear flange on the input shaft. The shear flange is secured with a 1/4 x 1-1/2″ Grade 8 shear bolt with a 1/4″ lock nut. The flange is equipped with a grease fitting in the pilot area to prevent the shaft from seizing; the fitting MUST be greased daily. Additional shear bolts can be obtained by ordering Gehl part number 080079 for a package of eight 1/4 x 1-1/2″ Grade 8 shear bolts and 1/4″ lock nuts.

If the bolt shears, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8), remove the cause of the overload and replace the shear bolt before attempting to resume harvesting.

3 2 1 - Shear bolts (two 1/4 x 1″ Grade 5 with lock nuts) 2 - Auger drive shear device 3 - Auger drive sprocket (behind Crop Processor drive sheave)

Fig. 15

Feed Roll & Attachment Drive (1285) (Fig. 16) 2

The lower feed roll drive is protected by a slip clutch on the input shaft. The clutch is factory-adjusted and should require NO additional adjustment. If the clutch is slipping, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8), and then remove the cause of the overload before attempting to resume harvesting.

1 - Attachment drive torque sensor 2 - Upper feed roll drive torque sensor 3 - Lower feed roll drive shear flange

Fig. 17

2

The upper feed roll and the attachment are protected by torque sensors. They shut off the electric clutch at a pre-determined torque to protect the feed rolls and attachment.

In order for the attachment drive torque sensor to operate, non-shear bolts (provided) must be installed into the attachment shear device. These non-shear bolts are listed on a decal inside the hinged cover on the left side of the Harvester.

1 3

Feed Roll & Attachment Drive (1085 Shear Bolt Model) (Fig. 18)

1 - Attachment drive torque sensor 2 - Upper feed roll drive torque sensor 3 - Lower feed roll drive slip clutch

The lower feed roll drive is protected by a shear flange on the input shaft. The shear flange is secured with a 1/4 x 1-1/2″ Grade 8 shear bolt with a 1/4″ lock nut. The flange is equipped with a grease fitting in the pilot area to prevent the shaft from seizing; the fitting MUST be greased daily. Additional shear bolts can be obtained by ordering Gehl part number 080079 for a package of eight 1/4 x 1-1/2″ Grade 8 shear bolts and 1/4″ lock nuts.

If the bolt shears, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8), remove the cause of the overload and replace the shear bolt before attempting to resume harvesting.

Fig. 16

The upper feed roll and the attachment are protected by torque sensors. They shut off the electric clutch at a pre-determined torque to protect the feed rolls and attachment.

In order for the attachment drive torque sensor to operate, non-shear bolts (provided) must be installed into the attachment shear device. These non-shear bolts are listed on a decal inside the hinged cover on the left side of the Harvester.

Printed in U.S.A.

3

1

29

908156/CP0205

Chapter 5 - Operation

Electrical System (Fig. 19)

The upper feed roll drive is protected by a one-way shear bolt protective device. The protective device allows the feed rolls to be reversed without having to first replace the sheared bolt. The shear device uses a 1/4 x 1-1/2″ Grade 8 shear bolt. To install a replacement bolt, BE SURE to first idle the tractor and then reverse the feed roll transmission to align the mounting holes in the protective device. Additional shear bolts are provided in the toolbox, or may be purchased by ordering Gehl part number 080079 for a package of eight 1/4 x 1-1/2″ Grade 8 shear bolts and 1/4″ lock nuts.

The electrical system is protected by fuses.

1. A 30-Amp fuse is used in the battery power supply harness (near the tractor battery).

2. If the 3-pin power outlet in the tractor is used, the tractor outlet should use a 30-Amp fuse. Refer to your tractor operator’s manual.

3. A 30-Amp fuse is used in the control box wiring harness (near the power plug, inside the tractor cab).

4. A 10-Amp fuse is used in the control box wiring harness (near the control box plug, inside the cab).

5. On early models a 1-Amp type AGC fuse is used in the metal detector amplifier box on AutoMax models.

1

2

Tractor Control Box 10A Fuse Tractor Harness

1 - Upper roll drive one-way shear bolt protective device 2 - 1/4 x 1-1/2″ Grade 8 shear bolt and lock nut 3 - Lower roll drive shear flange

Battery

Fig. 18

Implement Box

30A Fuse

The attachments are protected by their own shear bolt device when used with the 1085 shear-bolt model. Use the attachment shear bolts specified on the Harvester shear bolt decal. This decal is on the inside of the large hinged cover on the left side of the Harvester.

908156/CP0205

30A Fuse

Tongue Harness

1A Fuse in Metal Detector Amplifier Box on Early Models (not shown)

Harvester Harness

3

(In battery power supply harness)

Fig. 19

If the speed monitor system malfunctions and cannot be repaired immediately, disconnect the speed monitor plug at the auger.

30

Printed in U.S.A.

Chapter 5 - Operation

METAL DETECTOR

3 4

5

1

6 2

1 - Shielded cable 2 - Grease tube 3 - Feed roll side sheets

4 - Magnetic field (detection area) 5 - Detector 6 - Stainless steel lower front feed roll

Fig. 20

Introduction (Fig. 20)

— steel pipe — steel fence posts — plow points — sickle sections — chains — nails — wire — rocks containing iron Regardless of system adjustment, the following objects will NOT be detected:

The metal detector contains a Metal Stop system which is designed to prevent ferrous (containing iron) metal objects from entering the Harvester cutting cylinder. It can be used with all approved mounted attachments.

When a ferrous metal object passes through the magnetic field over the lower front feed roll, a low voltage signal is sent to the metal detector module (amplifier box on early models). When the signal reaches the metal detector module (amplifier box on early models), an electrical contact is opened which, in turn, interrupts power to the pawl solenoid. The feed rolls are stopped immediately by the stop pawl. At the same time, the electric clutch opens to stop power to the attachment and feed rolls.

When the Metal Stop system is functioning properly, the following ferrous metal objects can be detected: — hitch pins — scrap iron — bolts — wrenches — rake teeth

Printed in U.S.A.

31

—

aluminum

—

stainless steel

—

wood

—

tile

—

cement

—

stones

908156/CP0205

Chapter 5 - Operation

NOTE: The optimum performance of your Metal Stop system depends on it being kept in proper operating condition and properly maintained. Like any other electrical system, the Metal Stop system is subject to malfunction due to defects, occasional breakdowns, misuse and human error.

As with any mechanical device, components can breakdown or wear. Therefore, it is highly recommended that the system be tested daily.

2

The Metal Stop system is only sensitive to moving objects; keep this in mind when performing the test procedures. There is also an area at the center and ends of the lower feed roll where sensitivity is reduced.

Sensitivity also decreases as the distance from the object to the lower front feed roll increases. During normal operation, a high detection rate is achieved because of the forces of gravity and the stirring action of the feeding mechanism, which cause most of the ferrous metal objects to descend to the bottom of the incoming crop material.

1 1 - Lower front feed roll with detector magnet inside 2 - Amplifier box (on early models)

Fig. 21

Then, idle the tractor, engage the PTO, and reverse the feed rolls until the rolls move. The “Metal” alert light should stay off.

To Start Harvesting: 1.

2.

3.

4.

5.

6.

Engage PTO at engine idle speed.

Increase tractor PTO speed above 400 RPM. Reset control box to turn all alert lights off.

Move feed roll switch to “Forward.”

Increase tractor PTO speed to 1000 RPM. Drive into crop.

NOTE: The Harvester will NOT operate with the feed roll switch in “Forward” unless all of the alert lights are off. If, after attempting to reset system, an alert light is still on, refer to the Troubleshooting chapter.

As with all Gehl equipment, the Metal Stop system is initially warranted against defects in material and workmanship. However, because of the above described conditions, the Metal Stop system CANNOT and MUST NOT be expected to be 100% effective at detecting ferrous metal objects.

General Information (See Fig. 11) The Metal Stop system is operated from the tractor seat with the Harvester control box.

System Start-up (Figs. 21 & 22; See Also Fig. 11)

2 1

To reset the metal detector for harvesting, follow the Start-up procedure in the Harvester section of this chapter.

3 5

If the “Metal” alert light comes back on, the stop pawl is probably stuck in the ratchet wheel, as shown in the illustration provided. When the pawl sticks, a sensor in the metal detector module shuts off electrical power to the pawl solenoid (when the pawl sticks on early models, it causes the circuit breaker in the amplifier box to open, wait about 10-15 seconds for the [heat activated] breaker to cool).

4 1 - Stop pawl solenoid 2 - Stop pawl 3 - Ratchet wheel 4 - Spring (in operating position) 5 - Three rings

Fig. 22

908156/CP0205

32

Printed in U.S.A.

Chapter 5 - Operation

Metal Detection

WARNING

When metal is detected, the feed rolls and attachment are stopped, the horn sounds and the “Metal” alert light comes on. The operator must do the following:

•

Stop tractor travel.

•

Move the feed roll switch to center position to shut off the horn.

•

Observe that “Metal” light is activated.

•

NEVER hand feed crop into the feed rolls because the crop will feed faster than you can react to let go.

2.

Back up the tractor to separate the crop in the attachment from crop on the ground.

With no one near the Harvester, reset the metal detector system and start up the feed rolls. Slowly move forward and harvest the windrow.

3.

•

The ferrous metal object should be detected a second time.

Idle the tractor engine.

4.

•

Reverse the feed rolls to back out feed.

Repeat the procedure at the beginning of the Metal Detection topic.

•

STOP the PTO and SHUT OFF the tractor engine.

•

Turn the control box power switch OFF.

•

Wait for ALL parts to STOP rotating.

Making a hand-made windrow and driving slowly into it should drastically reduce the amount of material that has to be searched. The small amount of material going into the feed rolls should also make the second detection more likely to occur.

However, it is possible that the metal object stayed on the ground when harvesting the hand-made windrow or during the search.

WARNING

The metal detector system resets itself when the feed rolls are reversed to remove the detected ferrous metal.

The Metal Stop system sometimes may also detect metal while the feed rolls are being run in reverse. This type of metal detection will cause the Metal Stopt system to stop again. Activate the reverse switch again to reset the system.

BEFORE searching for detected metal, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). REMEMBER also that, when PTO is engaged, cylinder and blower continue to rotate when feed rolls and attachment are stopped.

•

Search the crop for metal and remove it.

•

Reset the control system by using the start-up procedure.

Bypassing the Metal Detector System (Figs. 22, 23 & 24) If the Metal Stop system malfunctions and cannot be repaired immediately, it can be bypassed as follows:

The ferrous metal object will usually be within 1 foot of the end of the crop which was about to enter the cutting cylinder. If the metal object CANNOT be discovered through an initial search, continue the search after exercising the proper precautions in the following manner: 1.

Take the hay that was reversed out of the hay attachment and spread it onto the ground in front of the attachment.

Printed in U.S.A.

33

1.

Move the pawl spring from the “Operating” position to the “Bypassed” position, as shown.

After the spring is removed, make sure that the stop pawl is away from the ratchet wheel.

2.

Disconnect the wiring harness plug underneath the knife sharpener cover (underneath the left end of the feed roll box cover on early models) as shown. Using electrical tape, cover the ends of the plugs to keep foreign material and moisture out of the plugs.

908156/CP0205

Chapter 5 - Operation

After the metal detector system is bypassed, the Harvester can be used in the same manner (less metal detector). The torque sensors and the speed monitor will still be operational.

To restore the metal detector system, return the spring and plugs to their original operating positions.

1

Daily System Inspections (Figs. 21 & 22)

2

Since the Metal Stop system is factory installed, the unit has been checked for proper operation before leaving the factory. The following inspections should be made on a periodic basis to maintain proper operation:

1 - Stop pawl in “Bypassed” position 2 - Pawl spring

Fig. 23: Stop pawl spring in “Bypassed” position

1.

Check the stop pawl solenoid for correct adjustment and proper ring alignment. Each of the three rings are to be 90 degrees to the ring next to it.

2.

Check that the Metal Stop system is operating properly. Refer to and carry out the procedures under the System Test topic below.

System Test

WARNING BEFORE testing or adjusting the Metal Detector system, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

1

1 - Plug (tape ends of plugs to prevent foreign material and moisture from entering plugs)

Fig. 24: Plug underneath knife sharpener cover

1.

Unplug the speed monitor.

2.

Operate control box.

34

b.

Reset control box to turn off all alert lights.

c.

Move control box switch to “Forward.”

Make sure the tractor engine is off.

4.

Pass a ferrous metal object between the upper and lower front feed rolls. The pawl solenoid should release the stop pawl into the ratchet wheel, the electric clutch should open, the control box horn should sound and the “Metal” alert light should come on.

5.

If the pawl is stuck in the ratchet wheel or the system fails to operate in the manner described, refer to the Troubleshooting chapter of this manual to determine the cause and remedy for the problem(s).

6.

Reconnect the speed monitor to the Harvester electrical harness.

1 - Plug (tape ends of plugs to prevent foreign material and moisture from entering plugs)

908156/CP0205

Turn on power switch.

3.

1

Fig. 25: Plug underneath feed roll cover on early models

a.

Printed in U.S.A.

Chapter 5 - Operation

TRANSPORTING

1

Tongue (Fig. 26)

2

The Harvester is provided with a tongue lock mechanism which MUST be securely locked for transporting the Harvester on a public highway. After the tongue is relocated in the “Transport’’ position, BE SURE to lower lock pin into transport position and lock it in place with the provided lock pin.

3

2 1 - Downstop bolt 2 - Lift cylinder fully extended 3 - Downstop pin locked in highest hole position

Fig. 27

4

Safety Chain (Fig. 28) As required or when desired, the Harvester can be equipped with a safety chain for operation on public highways. Refer to the Optional Features & Accessories chapter for ordering information. The safety chain should be attached to the tractor and Harvester as shown. When attached in this manner, the safety chain should have the following characteristics:

3

1 1 - Tongue swing cylinder 2 - Transport lock pin 3 - Tongue 4 - Lock pin

Fig. 26: Harvester tongue in transport position

Lift System Lock (Fig. 27) 4

1

WARNING

2

The attachment lift system should be locked up whenever it is necessary to work under a mounted attachment

3 1 - Locking hitch pin (1.25″ [32 mm] diameter) 2 - Chain loop on Harvester 3 - 30,000 lb (13635 kg) accessory safety chain 4 - Quick-attach drawbar 4″ (102 mm) extension

The hydraulically operated lift system can be locked-up in order to maintain the attachment in the “Raised” position during transporting. To place the lift system into the “Locked-up” position, first fully extend the lift cylinder and completely raise the attachment. Exercise he MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) and install the down stop pin into the “highest” possible (one of three) holes in the lift mechanism. BE SURE to lock the pin in this position with the cotter pins provided. Then, turn the downstop bolt fully downward into contact with the downstop pin.

Printed in U.S.A.

Fig. 28

35

1.

Chain is sufficiently slack to allow turns and movements of either the tractor or the implement, without placing tension on chain.

2.

Chain is of sufficient strength to hold the decoupled implement (and its load) and tow it to the shoulder.

908156/CP0205

Chapter 5 - Operation

widths, it may be necessary to adjust the width of the lights. The width can be adjusted by removing two bolts and sliding arms in or out until holes line up. Secure with removed hardware. During harvesting, the right side light arm can be rotated back and out of the way of standing row crops.

CAUTION ALWAYS follow state and local regulations regarding use of a safety chain and transport lighting when towing farm equipment on public highways. ONLY a safety chain (NOT an elastic or nylon/plastic tow strap) should be used to retain the connection between the towing and towed equipment, in the event of separation of the primary attaching system.

BE SURE to check with local law enforcement agencies for your own particular regulations.

Unless otherwise prohibited, use a slow moving vehicle (SMV) emblem.

The transport light arms are factory assembled in their shortest position but may need to be repositioned depending on what configuration is used during harvesting. Check the Harvester condition table and adjust light arm positions as described.

Transport Light Arm Position

SMV Emblem, Reflectors and Transport Lighting (Fig. 29)

2

4

4

left arm short (inward)

Any left side tire position EXCEPT maximum width setting.

left arm long (outward)

Left side tire position at maximum width setting.

right arm short (inward)

S Without crop heads.

2

5

S Without crop heads.

S With HA1240 hay head S With TR338 row crop head

7 6

Towing on Highway (Fig. 29)

1 - SMV (slow moving vehicle) emblem 2 - Red reflector 3 - Amber reflector (both sides and fronts of light arms) 4 - Orange reflectors (1 on left side, 2 on right side) 5 - Transport light arm (both sides) 6 - Wagon hitch for highway transport 7 - Socket provided for wagon transport lighting

WARNING For implements without brakes, safety codes recommend that total weight of implement and load DO NOT exceed one-and-one half (1-1/2) times the weight of the towing vehicle.

For any public highway travel and to be in compliance with this rule, BE SURE that your tractor is heavy enough to counterbalance the weight of the Harvester and loaded wagon.

Fig. 29

The Harvester is equipped with a slow moving vehicle emblem (SMV) on the rear of the Harvester. Red, amber and orange reflector strips are also provided on the rear corners of the Harvester and on the light arms.

An additional transport hitch plate, at the right end of the hitch channel, is also provided for long distance transporting. This hitch plate will position the wagon all the way to the right, locating it more directly behind the Harvester, to reduce the overall width and making it easier for the tractor operator to view rearward.

Transport lighting is standard on all machines. The lighting and reflectors conform to ASAE Standard S279.12 for on-highway transport. During transport, rotate light arms forward so they stick straight out from the machine. Because of the variations in the safety laws for different states and localities, and attachment 908156/CP0205

S With HA1100, HA1110, HA1200, HA1210 hay heads S With TR3038, TR330 row crop heads

1 right arm long (outward)

3

Harvester Condition

36

Printed in U.S.A.

Chapter 5 - Operation

Hitchjack (Fig. 30)

WARNING

A hitchjack is furnished with the Harvester to support the machine when the tractor is disconnected as well as to facilitate aligning the Harvester hitch with the tractor drawbar during hookup.

BEFORE installing the chain oiler kit on this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

WARNING

Preparation (Fig. 31)

BE SURE the lock pin is properly seated through the holes in the jack tube and the jack mount hub of the Harvester, BEFORE disconnecting the Harvester from the tractor.

When the jack is NOT being used to support the tongue, remove the lock pin and swing the jack into its “storage” position. Wrap the lock pin chain around the jack handle (to hold it up) and then insert the lock pin through jack tube and tongue hub to secure it.

1.

On a bench, assemble the oil pump, short hose and oil tank securing with the two wire clamps provided (orient clamp ears to the rear). The port on the pump for the hydraulic hose should be facing to your right. Install hydraulic elbow in port. Install valve on top right manifold.

2.

Mount the pump and tank assembly to the mounting bracket securing the pump to the bracket with the u-bolt and two 5/16″ lock washers and nuts.

Secure the tank to the bracket with four 1/4 x 3/4″ carriage bolts, lock washers and nuts.

8

7

5

4

1

6

3

9 2

1 1 - Hitchjack in “Support” position

1 - Oil pump 2 - Hydraulic hose port with elbow 3 - U-bolt 4 - Mounting bracket 5 - Short hose 6 - Clamps (2) (ears facing rearwards) 7 - Tank and cap 8 - 1/4 x 3/4″ carriage bolts, lock washers and nuts (4 places) 9 - Valve and tubing manifold

Fig. 30

Chain Oiler Installation The chain oiler provides lubrication to the various chain drives on the Harvester every time the header is raised.

Operation of the oiler is described in the Lubrication section of the Care and Maintenance chapter of this manual. The chain oiler kit is designed to fit more than one application, so there will be parts left over. The following installation will only call for the parts needed for lubrication to the various chain drives on the Harvester. Referring to the photographs, install the kit by the following steps:

Printed in U.S.A.

Fig. 31

Installation (Figs. 32 through 39) 3.

37

Mount the tank and pump assembly to the Harvester knife sharpener bracket with two 3/8 x 1-1/4″ cap screws, nuts and lock washers. See Figure 32.

908156/CP0205

Chapter 5 - Operation

Route hydraulic hose through chopper, running it back and then along the axle tube to where the oiler is mounted. Connect end of hydraulic hose to 90-degree fitting on pump as shown in Figure 32.

Secure hydraulic hose to machine using the provided wire ties. See Figure 33.

2 3 4

1

5.

Referring to Figures 34 through 39, install four brackets and brushes using hardware described in each figure. Brushes are correctly positioned when they will rub slightly on the chain being oiled.

6.

Referring to Figures 34 through 39, install tubing routing as shown. Determine an appropriate route for the tubing that goes between the manifold and the brush. Cut tubing to length needed. Route tubing as shown and install into brush by pushing tubing into top of brush. Brush fitting will automatically grab tubing once it is inserted far enough. Should the tubing need to be released from the brush, push down on the red plastic collar that the tubing slides into, on the top of the brush, and slide the tubing out of the brush. To connect the tubing to manifolds of the pump, remove the nut and ferrule from the end of the manifold. Slip the nut and then the ferrule onto the tubing. Slide tubing into end of manifold till it stops, and then slide the ferrule and nut into manifold. Tighten the fitting. Secure tubing to machine as shown, using the provided clamps and wire ties.

5 1 - Oiler, tank and mounting bracket assembly 2 - 3/8 x 1-1/4″ cap screws lock washers and nuts (2 places) 3 - Auger chain oiler brush shut-off valve 4 - Hydraulic elbow 5 - Hydraulic hose

Fig. 32

WARNING DO NOT remove any hydraulic lines or fittings until the system is depressurized and there is no load on any hydraulic component. Failure to heed may result in personal injury.

2

3

1

1

2 1 - Attachment lift cylinder fully retracted (attachment lower to the ground) 2 - Tee and hose connected to top port on cylinder 3 - Male adapter and hoses routed to oiler

4 3

Fig. 33

4.

1 - Bracket (bend into position) 2 - Bracket mounting hardware (5/16″ thread cutting screw and flat washer) (existing hole) 3 - Brush and nut 4 - Tubing routed back to oiler

After verifying that there is NO pressure in the header hydraulic system and the header has been lowered to the ground, disconnect the hydraulic hose connected to the top port of the cylinder that controls the header. Install the supplied hydraulic tee and reconnect hose to tee. Install one end of 24″ hydraulic hose onto tee. On the other end of the hydraulic hose, install male adapter and connect one end of 54″ hydraulic hose to adapter.

908156/CP0205

Fig. 34: Brush on length-of-cut chain

7.

38

Add some clean oil to the oil tank. Cycle a few times by raising and lowering the header. Verify operation and that there are no leaks.

Printed in U.S.A.

Chapter 5 - Operation

This completes the oiler installation. See the Lubrication section of the Care and Maintenance chapter for operating details.

2

3

1

1 5

2

1 - Tubing routed through hole in mounting bracket 2 - Tubing secured with wire ties

4

Fig. 37

1 - Existing bracket with existing hole 2 - Brush and nut 3 - Tubing from pump 4 - Tubing from pump (routed through existing clamps) 5 - Wire tie securing oil tubing

Fig. 35: Brush on transmission chain

1

1

4

1 1 - Tubing from oiler manifold with shut-off valve trapped by existing cover hardware

3

Fig. 38

2

4 2 1 - Bracket (bend into position) 2 - Bracket mounting hardware (existing) 3 - Brush and nut 4 - Tubing from pump

1

Fig. 36: Brush on electric clutch chain

3

1 - Bracket (bend into position) 2 - Bracket mounting hardware (existing) 3 - Brush and nut 4 - Tubing from pump routed through existing clamp

Fig. 39: Brush on auger drive chain

Printed in U.S.A.

39

908156/CP0205

CHAPTER 6 CARE & MAINTENANCE B: Downstop (Fig. 40)

This chapter contains information required to perform the care and maintenance expected of the owner or operator of this Harvester in order to keep the unit in a safe and proper operating condition. The chapter is divided into three sections: 1.

Adjustments (those not required as a part of normal operation)

2.

Lubrication (as part of preventative maintenance)

3.

Service (component repair or replacement)

The downstop adjustment can be used to limit how far down the lift arms will travel when a row crop attachment is being used on the Harvester. Adjust the downstop so that, with the lift cylinder retracted, the height to which the attachment will be lowered is that level which will keep the skids off the ground and the rotary sickles out of the dirt and stones. To adjust the downstop position:

ADJUSTMENTS

1.

Extend lift cylinder and remove downstop pin.

2.

Lower the attachment to the desired position.

3.

Insert downstop pin into its highest hole possible.

WARNING

1

2

BEFORE adjusting this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

Attachment Positioning

3

WARNING

1 - Downstop bolt 2 - Lift cylinder fully extended 3 - Downstop pin locked in highest hole position

Operate the tractor and the hydraulic lift controls and make the attachment and Harvester lift system adjustments by yourself. For your own safety, keep everyone away from the tractor and Harvester while making the following adjustments.

Fig. 40

4.

A: Axles & Wheels The Harvester axles and wheel spindles have several mounting hole positions for adjusting the wheels and axles in or out. Also, several hole positions are provided in the spindle assemblies for adjusting the height of the Harvester with respect to the mounted attachment and the ground conditions. Refer to the Tires, Wheels & Axles topic for appropriate positions related to the different attachments.

908156/AP0205

Adjust the downstop bolt against the downstop pin. If the bolt will NOT go down and touch the square pin, retract the bolt enough to allow moving the square pin upwards one hole. Then adjust the bolt down against the square pin. The downstop adjustment will vary with different row crop attachments.

C: Lift Height (Fig. 41) A lift height adjustment cam, located underneath the lift cylinder link, is used to control the height to which the lift arms will raise the crop attachment. The cam requires readjustment anytime the mounted attachment rises too high and strikes the Harvester feed roll housing.

40

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Adjustments)

For an HA1100, HA1110, HA1200 or HA1210 Hay Attachment, the spring tension should be adjusted to counterbalance the attachment. It should take approximately 50 lbs. (222 N) of lift at the hay holddown bar to raise the attachment. For an HA1240 Hay Attachment, the lift spring should be adjusted to provide maximum tension.

4

An additional lift spring is available (see Optional Features & Accessories chapter) if greater attachment flotation is required. It is recommended for use with the HA1240 Hay Attachment.

1 2

3

1 - Lift cylinder link 2 - Lift height adjustment cam 3 - Left wheel 4 - Lift assembly plates

1

2 3

Fig. 41

To adjust the cam, retract the lift cylinder and loosen the 3/4″ bolt which clamps the cam between the lift assembly plates. Loosen the bolt only enough to allow the cam to be rotated. Turn the cam to position its high side toward the lift link for the maximum upward travel of the attachment, or turn the cam to position its low side toward the lift link for the minimum upward travel of the attachment. After the desired position is tested and obtained, retighten the nut on the 3/4″ bolt to lock the cam in the position selected.

5

4 1 - Lift spring 2 - Spring nut 3 - Transport lock and pin 4 - Tongue control cylinder 5 - Spring bolt

Slowly raise the attachment and recheck the attachment clearance to the feed roll housing. Also check for ample clearance between the feed roll side sheets and the attachment. If the attachment, when raised, is still striking the Harvester, readjust the cam to reduce the maximum height of attachment travel.

Fig. 42

Blower A: Belt Idler (Fig. 43)

D: Lift Spring (Fig. 42)

Belt tension is maintained by a spring-loaded belt idler.

Tension on the belt is to be 110 lbs. (490 N) measured at the idler pulley. If the belt slips or becomes noticeably hot, the belt tension should be checked and adjusted if necessary. A tension strap with multiple holes is provided to accomplish the adjustment.

The Harvester lift spring is provided to counterbalance the weight of the attachment to either lighten its pressure on the ground or to better enable it to raise up and over stones, ruts or obstacles in the field. Spring tension can be readjusted to match the flotation requirements of various attachments, as required.

Shims are provided at the base of the idler to effect idler alignment of the idler pulley with respect to the driver and driven sheaves. Shim addition will compensate for normal pivot wear.

To adjust lift spring tension, first completely retract the lift cylinder and lower the attachment to the ground to determine the required spring length setting. Then, using two wrenches, hold the spring nut with one wrench and turn the spring bolt with the other wrench to obtain the desired tension.

B: Drive Belt (Fig. 43) The drive belt can be removed, for replacement, by raising the idler above the belt, pushing the slack belt toward the blower, and then lowering the idler until the spring is loose. Use an appropriate length of 1″ (25 mm) pipe, or equivalent, for additional leverage.

NOTE:

Raise the attachment to reduce the spring load on the spring adjusting bolt to make it easier to turn the bolt. Then lower the attachment again to gauge the float effect of the spring.

Printed in U.S.A.

41

908156/CP0205

Chapter 6 - Care & Maintenance (Adjustments)

3.

2

Check to see if the blower paddle arms are bent; replace or straighten, as required.

NOTE: For easier access to the blower paddles, the auger assembly may be removed. If the auger is not being removed, proceed to Step 11.

1

3

4

5

1 - Drive belt 2 - Idler 3 - Spring strap 4 - Idler arm 5 - Shim

3

4

Fig. 43

2

C: Fan Paddles (Figs. 44 & 45) Over long periods of Harvester use, the tips of the blower fan paddles will wear and therefore require readjustment. The position of the fan paddles should be checked (and, if necessary, readjusted) after every 100 hours of operation.

1 - Drive belts (not shown) 2 - Pivot shaft 3 - Crop Processor (shown) Transition box (not shown) 4 - Auger drive chain

Fig. 44

Each paddle tip should be 1/32-1/16″ (0.8-1.6 mm) away from the blower rim sheet at the 6 o’clock (bottom) position. An excellent method for checking the setting is to place a nickel and a dime side by side on the rim sheet. When the paddle is rotated across the coins, it should pick up the nickel and leave the dime. To adjust the paddles, proceed as follows: 1.

2 1

Make sure the rim sheet is clean (free of grass, gum or dirt). Clean the rim sheet by running wet forage through the Harvester or by scraping it.

4

1 - Right side shield 2 - Rear cover 3 - Auger assembly 4 - Chute bottom (under auger assembly)

WARNING BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE adjusting this unit.

2.

Fig. 45

Check the rim sheet wear liner for dents and holes; replace if necessary.

908156/AP0205

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42

4.

Remove the right side shield.

5.

If the Crop Processor is installed, remove the drive belts and pivot shaft.

6.

Remove the auger drive chain.

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Adjustments)

7.

If the transition box is installed, remove it.

8.

Remove the fasteners that attach the rear cover to the auger assembly.

9.

NOTE: If the auger was not removed, proceed to Step 22.

Loosen, but do not remove, the fasteners on the chute bottom and move the chute bottom down.

10.

Remove the auger assembly.

11.

Loosen the four 1/2″ nuts on each paddle only enough so that the paddles can be tapped toward the rim sheet. Access to the nuts can be gained through the blower inlet opening in the rear side sheet. Align the paddles over their full width so that the tips are 1/32-1/16″ (0.81-1.6 mm) away from the rim sheet.

NOTE: If the paddles are worn to the point that the 1/32″ to 1/16″ space to the rim sheet cannot be obtained across their full width, they should be replaced with new paddles.

12.

Check the screws and nuts which secure the paddle arm to the blower disc to see that they are properly secured.

13.

After all paddles are adjusted and the attaching hardware is torqued properly, rotate the fan again (by hand) to ensure that it turns freely; if not, check and remove the obstruction.

Printed in U.S.A.

14.

Place auger assembly onto Harvester frame.

Install fasteners, but do not tighten them.

15.

Install transition box if it was removed, and secure fasteners.

16.

Secure the auger assembly fasteners.

17.

Adjust chute bottom against bottom of the auger assembly and secure the fasteners.

18.

Install the fasteners that attach the rear cover to the top of the auger assembly and secure the fasteners.

19.

Install and adjust the auger drive chain.

20.

Install the Crop Processor pivot shaft and drive belts if they were removed. Adjust drive belts.

21.

Install the right shield.

22.

Replace all shields and guards. Run the Harvester at idle speed and listen for noise from the blower.

Increase the tractor RPM to full throttle and again listen for noise from the blower. If any noise problem is heard, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) and then proceed to identify and correct the problem.

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Shear Bar (Figs. 46 through 50)

NOTE: It is not necessary to loosen the holddown bolt on the right end of the shear bar while adjustments are being made. Also, the spring-loaded holddown pin on the left side should NEVER be loosened, even when removing the shear bar.

NOTE: The two routine maintenance procedures that have the most significant effect on the quality of cut and on fuel efficiency are knife sharpening and shear bar adjustment. Frequent sharpening of the knife edge accompanied by the proper shear bar adjustment will significantly increase the life of the knives and the shear bar, as well as reduce the amount of fuel required to chop the forage. In most cases, daily sharpening of the knives and proper adjustment of the shear bar to the knives will be sufficient. However, in areas where the soil is very sandy, more frequent knife sharpening and shear bar adjustment may be necessary.

A: 1085 (Figs. 47 & 48) The 1085 shear-bar adjustment procedure is shown in Figure 47.

NOTE: When the cutting edge of the reversible shear bar no longer stays sharp, the shear bar can be removed and reversed (end-for-end) to place a new sharp edge toward the knives. After both edges are worn down, the shear bar MUST be removed and replaced with a new shear bar.

After sharpening the cylinder knives, the shear bar requires a slight amount of adjustment toward the knives. All shear bar adjustments are performed on the right side of the Harvester with all covers and shields kept in place. With the Harvester cylinder operating at tractor engine idle speed and the shifter transmission deactivated by turning the power switch OFF, proceed to adjust the shear bar as follows: Fig. 47: 1085 shear bar adjustment

1 1

2

9 5

4

2

7 8

6

1 - Shear bar right adjustment nut 2 - Stem guide mounting bolts (both sides) 3 - 1/2″ retaining bolt, spacer, 1/2″ lock nut 4 - Nut 5 - Smooth feed roll scraper 6 - Shear bar support 7 - Shear bar 8 - Left remote adjusting shaft 9 - Clamp bolt

1 - Holddown pin assembly (do NOT loosen) 2 - Lockstrip

Fig. 46

Setting the shear bar requires listening for the knives to tick the shear bar. It is possible for the knives to hit the right side of the shear bar when you are adjusting the left side and vice versa, thus giving a wrong indication of the closeness of a knife to the shear bar.

908156/AP0205

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Fig. 48: 1085 shear bar

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Chapter 6 - Care & Maintenance (Adjustments)

B: 1285 (Figs. 49 & 50)

1

2

The 1285 shear-bar adjustment procedure is shown in Figure 49.

7 4 3 8

5 9

6

1 - Shear bar right adjustment nut 2 - Stem guide mounting bolts (both sides) 3 - 1/2″ retaining bolt, spacer, 1/2″ lock nut 4 - Center adjustment shaft 5 - Smooth feed roll scraper 6 - Shear bar center adjustment lock nut 7 - Right side clamp bolt 8 - Remote left shear bar adjustment 9 - Shear bar

Fig. 50: 1285 shear bar

Spout (Fig. 51) The Harvester spout is equipped with electric controls.

Horizontal extensions and/or vertical extensions are available to respectively lengthen and/or raise the point of discharge from the cap end of the spout. Approximate length and height variations for the spout with or without different accessory extensions are shown.

Fig. 49: 1285 shear bar adjustment

WARNING Properly support the spout whenever it is necessary to remove the attaching hardware between it and the blower outlet or a vertical extension. The spout, outlet and extensions have matching flanges which are bolted together; when the hardware is removed, the components will separate and fall.

Printed in U.S.A.

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908156/CP0205

Chapter 6 - Care & Maintenance (Adjustments)

A - Spout B - Vertical extension C - Horizontal extension D - Wagon hitch pin to end of cap E - Height from ground F - Tongue pin hole to wagon hitch pin hole (201-1/4″ [5112 mm])

A C

B

E

F

D

All dimensions are in inches (millimeters) unless otherwise noted

A

Spout

B (TOTAL)

C

D

E

Without Vert. Ext.

36-1/2 (927)

115-1/4 (2927)

w/ 6 in. (152) Vert. Ext.

36-1/2 (927)

121-1/4 (3080)

w/ 1 ft. (305) Vert. Ext.

36-1/2 (927)

127-1/4 (3232)

w/ 2 ft. (610) Vert. Ext.

36-1/2 (927)

139-1/4 (3537)

w/ 3 ft. (915) Vert. Ext.

36-1/2 (927)

151-1/4 (3842)

w/ 4 ft. (1220) Vert. Ext.

36-1/2 (927)

163-1/4 (4146)

Without Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

122-1/4 (3105)

w/ 6 in. (152) Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

128-1/4 (3258)

w/ 1 ft. (305) Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

134-1/4 (3410)

w/ 2 ft. (610) Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

146-1/4 (3715)

w/ 3 ft. (915) Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

158-1/4 (4020)

w/ 4 ft. (1220) Vert. Ext.

w/ 3-1/2 ft. (1062) Horz. Ext.

77-1/2 (1969)

170-1/4 (4324)

Without Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

128-1/4 (3258)

w/ 6 in. (152) Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

134-1/4 (3410)

w/ 1 ft. (305) Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

140-1/4 (3562)

w/ 2 ft. (610) Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

152-1/4 (3867)

w/ 3 ft. (915) Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

164-1/4 (4172)

w/ 4 ft. (1220) Vert. Ext.

w/ 5-1/2 ft. (1677) Horz. Ext.

101-1/2 (2578)

176-1/4 (4477)

Dimension “E” based on unit with tandem axles and 11L x 15 tires at loaded radius.

Spindles positioned in middle of adjustment. Actual measurements vary based on tire size and wheel spindle position.

Fig. 51

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Chapter 6 - Care & Maintenance (Adjustments)

Spout Motor Drive Chain (Fig. 52)

1 2

The spout motor drive chain is adjusted by loosening the motor mounting bolts and sliding the motor. Tension on the chain should be checked after every 100 hours of operation. The chain is properly tensioned when there is 1/4-3/8″ (6-9.5 mm) slack in the strand of chain between the two sprockets.

3 5

4

1 - Adjustment knob lock 2 - Length-of-cut chain adjustment knob 3 - Length-of-cut drive chain (check slack here) 4 - Length-of-cut sprocket 5 - Shifter transmission input drive chain

3

Fig. 53: Length-of-cut frame

2

B: Attachment Driver (Fig. 54)

1

The attachment driver chain has an idler sprocket on the slack side of the chain. Tension on the chain should be checked after every 10 hours of operation and readjusted (if necessary) for a slack of 1/4-3/8″ (6-9.5 mm) in the strand of chain between the attachment driver shaft sprocket and the shifter transmission drive sprocket.

1 - Spout motor mounting hardware (four) 2 - Spout motor drive chain 3 - Top drive sprocket

Fig. 52

IMPORTANT: When re-tightening the idler

Drive Chains

sprocket mounting bolt, make sure the idler sprocket aligns with the chain. Also, too much chain tension can result in excessive chain and sprocket wear; avoid applying too much tension.

The various drive chains of the Harvester are provided with appropriate adjustable-position or self-tensioning mechanisms.

A: Length-of-Cut Drive Chain (Fig. 53) Unlock the chain adjustment knob on the length-of-cut frame and adjust the chain tension with the knob for a slack of 1/4-3/8″ (6-9.5 mm) in the strand of chain between the upper feed roll drive sprocket and lengthof-cut sprocket. This setting can usually be obtained by rotating the knob by hand until chain is tight. Then rotate knob 1/4 turn counterclockwise to provide correct slack.

After the chain slack is adjusted, BE SURE to lock the knob.

Printed in U.S.A.

1 1 - Attachment driver chain idler sprocket

Fig. 54

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Chapter 6 - Care & Maintenance (Adjustments)

C: Lower Feed Rolls (Fig. 55)

F: Upper Feed Rolls (Fig. 57) The upper feed roll drive chain has self-adjusting roller slides to maintain proper operating chain tension; no further adjustment is required. If, after a time, slide wear is detected, the attaching hardware can be temporarily loosened and the slide rotated to a new position.

The lower feed roll drive chain tension is adjusted with a chain slide mechanism. Chain deflection should be checked after every 50 hours of operation and readjusted (if necessary) for a 5/16″ (8 mm) deflection on the strand of chain opposite the slide.

1 2

1 - Upper feed roll drive chain roller slides

1

Fig. 57

Feed Roll Springs (Fig. 55) Tension springs are provided on both sides of the feed roll housing to apply pressure on the feed rolls while material is traveling between them. The feed roll springs are factory-adjusted so that all looseness (play) is eliminated. Tension needs only to be checked and adjusted if they are loose or after service has been performed which requires removing the feed roll springs and rolls.

1 - Lower feed roll drive chain tension adjustment slide 2 - Remove spring looseness, then turn bolt (at bottom of spring) three more revolutions.

Tighten nut against spring nut casting

Fig. 55

D: Shifter Transmission Drive (Fig. 53)

Tension on each spring can be readjusted by tightening each spring tensioning bolt until there is no looseness and then three additional revolutions of the bolt. Then, tighten the nut against the nut casting. Do not tighten the nut against the frame flange because the bolt must be free to tilt with the spring.

The shifter transmission drive chain has a self-adjusting idler which requires no further readjustment.

E: Auger Drive Chain (Fig. 56) The auger drive chain has an adjustable idler on the slack side of the chain. Tension on the chain should be checked after every 10 hours of operation and readjusted (if necessary) for a slack measurement of 0.50″ (13 mm) with hand pressure placed on the chain between the shear device and drive sprocket.

2

Crop Processor Roller Mill (Optional) A: Roll Spacing The lower mill roll is in a fixed position and the upper roll is adjustable to allow for changing the clearance and resultant coarseness or fineness of the processed material. Reposition the adjustment sprocket to change the position of the upper roll. To move the upper roll downward (reducing the clearance), remove the chain lock pin and use the provided wrench to turn the adjustment sprocket counterclockwise. To move the upper roll upward, remove the chain lock pin and use the wrench to turn the adjustment sprocket clockwise.

When adjusting, each revolution of the wrench will move the upper roll 0.20″ (5 mm). Moving the chain one link will move the upper roll 0.010″ (0.25 mm). After the adjustment has been made, always lock your setting

3

4 1 1 - Auger drive chain 2 - Adjustable auger drive chain idler 3 - Check chain tension here 4 - Idler positioning bolt and lock nut

Fig. 56

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Chapter 6 - Care & Maintenance (Adjustments)

by inserting the chain lock pin. Store the wrench in the toolbox.

should NOT be readjusted. the correct spring length is 4.5″ (114 mm). these springs allow the rolls to separate so foreign objects, such as stones, can pass between the rolls. After the object passes, the spring pressure will restore the roll to its original position.

B: Roll Alignment If the rolls ever become out of alignment, (more gap between rolls on one end than on the other) they MUST be realigned to maintain feed consistency. This can be accomplished by first positioning the rolls at minimum clearance with the adjustment wrench and then removing the chain from the control sprockets by removing its connecting link. The rolls can then be brought back into alignment by turning the adjustment sprocket. The space between the rolls should be checked with a feeler gauge to establish an even gap. The minimum clearance is intended to be 0.015″ (0.4 mm).

When a satisfactory setting has been established, replace the chain and connecting link.

D: Belt Tensioner (Fig. 58) The matched set of four mill drive belts are tensioned with a spring. The mill drive belts should be checked for cracks, tears, evidence of oil and proper spring tension every 50 hours and the adjustment checked every time the roll spacing is changed. The spring is properly tensioned when a gap of 7/8″ (22 mm) is measured as shown. Adjustment is accomplished by retracting the lock and rotating the nut shown. The Crop Processor wrench or a socket can be used to make the adjustment.

NOTE: It is not necessary to remove the drive shield to measure the gap. This distance is visible with the shield installed.

C: Minimum Roll Spacing The rolls require clearance between them as they rotate at different speeds. Without clearance the rolls will self-destruct.

The minimum roll clearance setting is preset at the factory and should not require additional readjustment.

However, if the rolls are disassembled or require adjustment to compensate for wear, use the following procedure.

First, verify that the rolls are parallel to each other and adjust if necessary (see instructions above).

Position the rolls at their minimum clearance by turning the adjustment sprocket counterclockwise until the stop bottoms out.

1

1 - Adjustment lock 2 - Adjustment nut 3 - Adjustment measured here (7/8″ [22 mm])

The clearance at this position should be 0.015″ (0.4 mm). Use a feeler gauge to verify this. If adjustment is necessary, it can be adjusted by loosening the jam nut of the 3/4″ stop bolt and turning the bolt up or down as required to attain the 0.015″ (0.4 mm) minimum roll spacing. There is an adjustment for each end of the upper roll. After adjustment is completed, MAKE SURE to re-lock the jam nuts to the adjusting bolts.

Fig. 58: Drive shield removed for clarity

Knives (Fig. 59) The cutting cylinder knives will have to be readjusted whenever 1/4″ (6 mm) or more is ground-off through repeated sharpening because the shear bar has only 1/4I (6 mm) of actual adjustment.

The roll tension springs on the lower roll are set at the factory to maintain the correct amount of pressure, and

Printed in U.S.A.

3 2

49

908156/CP0205

Chapter 6 - Care & Maintenance (Adjustments)

To adjust the knives, proceed as follows:

shear bar according to the instructions under those topics.

Length-of-Cut (Fig. 53)

WARNING

The Harvester length-of-cut is regulated by two factors: the number of cylinder knives and the length-of-cut sprocket which is mounted on the shifter transmission output shaft.

BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE adjusting the knives.

1.

Refer to the length-of-cut chart provided for sprocket and knife combinations. Refer to the Service section of this chapter for knife removal and replacement details.

Open the sharpener cover. Remove the cylinder covers. While it is not necessary, it is recommended to remove the Crop Processor or transition. Crop Processor removal is covered in the Crop Processor Operator’s Manual.

2.

Remove the rear cylinder side sheet tie support.

3.

After cleaning out the space between the shear bar and the scraper, move the shear bar forward to the end of its travel.

4.

Install the knife set-up rod (which is stored under the knife sharpener cover) through the access holes in the cylinder side sheets as shown.

5.

Loosen the (three) knife bolts just enough to permit the knife to be tapped into position.

6.

Adjust the knife to just clear or just touch the set-up rod along the entire length of the knife.

7.

Tighten all (three) knife bolts to 220-240 lb.-ft.

(300-325 Nm) of torque and recheck clearances.

DO NOT overtighten!

8.

Repeat steps 5, 6 & 7 for all of the knives.

NOTE: Only eight knives (or four knives equally spaced) should be used. Any other quantity or spacing of knives is NOT recommended.

To change the length-of-cut sprocket, proceed as follows: 1.

Unlock the chain adjustment knob on the lengthof-cut frame and completely release chain tension.

2.

Install the desired length-of-cut sprocket using the existing washers to align the new sprocket.

3.

After the desired length-of-cut sprocket is installed, readjust the slack on the length-of-cut drive chain. Adjust the chain tension with the knob for a slack of 1/4 to 3/8″ (6 to 9.5 mm) in the strand of chain between the upper feed roll drive sprocket and length-of-cut sprocket. This setting can usually be obtained by rotating the knob by hand until chain is tight. Then rotate knob 1/4 turn counterclockwise to provide correct slack. After the chain slack is adjusted, BE SURE to lock the knob.

Length-of-cut chart in inches (millimeters)

1 Sprocket used

Number of knives used 8

4

18 Tooth

1/4 (6)

1/2 (13)

28 Tooth

3/8 (10)

3/4 (19)

37 Tooth

1/2 (13)

1 (25)

Torque Sensor Contact Points (Auto-Max Models) (Fig. 60) 1 - Knife set-up rod

To operate with maximum capacity with Auto-Max machines, the contact points for each torque sensor (one on the feed roll drive and one on the attachment drive) MUST be maintained with a 0.030-0.060″ (0.8-1.5 mm) gap between the sensor contact point and the adjacent

Fig. 59

Remove and store the knife set-up rod. Reinstall all removed components EXCEPT the cylinder cover sharpener access insert. Sharpen the knives and set the 908156/AP0205

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Printed in U.S.A.

Chapter 6 - Care & Maintenance (Adjustments)

sprocket. A lesser gap causes the contact point to touch the sprocket due to sprocket wobble or under lighter loads. A greater gap causes the torque sensor device to ratchet without releasing the electric clutch.

1

2

NOTE: The torque sensor device has a very short ratchet life.

6 3 1

4 5

4

7

1 - Solenoid mount attaching bolts 2 - Stop pawl 3 - Solenoid 4 - Eyebolt 5 - 3 rings 6 - 1/8″ (3 mm) 7 - Ratchet wheel

2 3

Fig. 61

Scraper (Fig. 48)

1 - Contact point 2 - Chrome-plated sprocket 3 - 0.030 to 0.060″ (0.8 to 1.5 mm) gap 4 - Gap adjustment screw & locknut

WARNING

Fig. 60

Metal Stop System Solenoid and Stop Pawl (Auto-Max Models) (Fig. 61)

BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE adjusting the scraper.

The (three) rings between the solenoid and the stop pawl MUST NOT be twisted. The ring in the solenoid eyebolt and the one in the stop pawl are to be horizontal (positioned sideways). The center ring is to be vertical (perpendicular to the other two). Rotate the eyebolt inside the solenoid boot to untwist the rings.

IMPORTANT: The scraper MUST ALWAYS be set within 0.010″ (0.25 mm) of the smooth feed roll in order to prevent excessive horsepower consumption and component wear.

The scraper for the smooth lower rear feed roll can be adjusted or removed (if necessary) from outside the Harvester. The scraper should be maintained in contact with the entire width of the feed roll. If readjustment is required, loosen the 1/2″ hexagon nuts on each end of the scraper and tap the scraper ends down. If material is caught between the scraper tip and the feed roll, remove the scraper by loosening the nuts to permit the mounting bolts to drop down in the slots in the scraper and shear bar support.

When the solenoid is retracted (normal operating position), the stop pawl is to be held 1/8″ (3 mm) away from the highest point on the ratchet wheel as shown. To adjust this distance, first loosen the (three) bolts in the solenoid mount and slide the mount toward or away from the ratchet wheel. After the 1/8″ (3 mm) clearance is obtained, tighten the (three) bolts until they are secure.

NOTE:

Raise the stem guides, above each end of the scraper, 1/4″ (6 mm) to provide clearance for removing the scraper.

After the preceding adjustments are made, recheck the solenoid operation to insure that the stop pawl moves freely.

Printed in U.S.A.

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Pull the scraper out the right side and clean it. If the scraper is badly worn or bent, replace it. Reinstall the scraper by reversing the above procedure. Raise the 1/2″ bolts and nuts, at each end of the scraper, in the slots and tighten the nuts so they are snug. Then tap the ends of the scraper down and secure it by tightening the nuts.

A single 1/2 x 6″ bolt, lock washer and hexagon nut are used to secure the extension to the frame.

The single wheel spindles can also be raised or lowered to adjust the height of the Harvester frame to match the requirements of the attachment and field conditions.

The various positions for the spindles are illustrated.

Each spindle is secured to the axle extension with four bolts, lock washers and nuts.

IMPORTANT: When the scraper is reset, BE SURE to set the stem guides down against the shear bar and 1/32 - 1/16″ (0.8 - 1.6 mm) from the knives at their lower end. Carefully rotate the cutting cylinder (by hand) to make sure the knives do not strike the top of the stem guides. MAKE SURE that the stem guide bolts are tight. Loose bolts will allow the crop to push the guides into the knives and severely damage the cutting cylinder.

WARNING BE SURE to properly position the jack under the frame axle and make sure that the jack base is firmly supported so that the jack does not slip off the frame axles.

Periodically check the area between the scraper and smooth feed roll to make sure that it is clean. This area can be cleaned from the outside of the Harvester by pushing a rod through the hole in the side sheet, between the scraper and feed roll. It is build-up in this area that causes increased horsepower consumption and excessive wear on drive components.

To move the wheels and tires in or out or to adjust the spindle heights, block the Harvester and jack the frame up. Remove the attaching hardware, adjust the axle extensions in or out and then re-secure the attaching hardware. To change the spindle height on 8-bolt wheel hubs, temporarily loosen (but do not remove) the four carriage bolts in each spindle. Then slide the spindle up or down. The 6-bolt wheel hubs require removal of the four mounting bolts for height adjustment. Re-secure the spindle attaching hardware. BE SURE to set both spindles to the same height.

Stem Guides (Fig. 48) Right and left stem guides are located above the shear bar at each end. These guides prevent forage stems from moving around the ends of the knives. The bottom edges should be set down against the shear bar and the curved rear edges should be positioned about 1/32-1/16″ (0.8-1.6 mm) from the knives.

B: Tandem Wheel Axles, Spindles, Wheels and Tires (Figs. 63 & 64)

To adjust the guides, loosen the two 3/8″ hexagon head cap screws which are threaded into the guides. Move the guide by tapping the 3/8″ screws. When the guides are properly positioned, re-tighten the two screws.

The tandem axle extensions can be placed into and secured to the Harvester frame in any one of several positions to align the wheels and tires between the crop rows. The various positions of the axle extensions are illustrated. A single 1/2 x 6″ bolt, lock washer and nut are used to secure each extension to the Harvester frame.

IMPORTANT: MAKE SURE that the stem guide bolts are tight. Loose bolts will allow the crop to push the guides into the knives and severely damage the cutting cylinder.

The tandem wheel spindles can also be raised or lowered to adjust the height of the Harvester frame to match the requirements of the attachment and field conditions.

Each spindle is secured with a total of six 1/2 x 1-1/2″ cap screws, lock washers and plain washers. The various positions for the spindles are illustrated. BE SURE to adjust all four spindles to the same height.

Tires, Wheels & Axles The Harvester can be obtained with either single or tandem axle configuration.

NOTE: The top-most spindle mounting bolts require only to be temporarily loosened when the spindle positions are readjusted.

A: Single Wheel Axles, Wheels & Spindles (Figs. 63 & 64)

To move the wheels and tires in or out or to adjust the spindle positions, block the Harvester and jack the frame up. Remove the attaching hardware, readjust the axle extensions or spindles and re-secure the hardware.

The axle extensions can be placed into and secured to the Harvester frame in any one of several positions to align the wheels and tires between crop rows. The various positions for the axle extensions are illustrated.

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Chapter 6 - Care & Maintenance (Adjustments)

Two metal doughnut-shaped spacers (Gehl part number 076279) are provided with the tandem axle assemblies. These spacers can be assembled onto the short shafts which protrude between the fork of each axle extension and secured with the cotter pins provided. When installed, the spacers greatly limit the wheel beam oscillation. They are recommended for use where center pivot irrigation systems are employed. DO NOT use the spacers in any other conditions.

WARNING BE SURE to properly position the jack under the frame axle and make sure that the jack base is firmly supported so that the jack does not slip off the frame axles.

NOTE:

Wagon Hitch Plate (Fig. 65)

The following information applies only to operating a Harvester equipped with tandem axles in fields rutted by the wheels of center pivot irrigators.

Printed in U.S.A.

The wagon hitch plate can be placed in any one of many positions to align the wagon tires between crop rows.

53

908156/CP0205

Chapter 6 - Care & Maintenance (Adjustments) A - Tandem axle tires B - Single axle tires C - Wagon hitch plate D - 46-1/8 to 68-1/2 (1172 to 1740) E - 83-1/8 to 103-1/8 (2110 to 2620) single (11L x 14) 86 to 103-1/2 (2185 to 2630) single (16.5L x 16.1) F - 88-7/8 to 102-3/8 (2260 to 2600) G - Centerline of cutting cylinder H - 28 to 51 (711 to 1300) single (11L x 14) 30-1/2 to 51-1/4 (775 to1303) single (16.5L x 16.1) (1085) 32-1/2 to 51-1/4 (826 to 1303) (CB1285) J - Transport hitch K - 53-1/2 to 107 (1359 to 2718) L - 33-1/4 to 51-1/4 (840 to 1303) (1085) 35-1/2 to 51-1/4 (902 to 1303) (1285) M - Tongue

All dimensions are in inches (millimeters) unless otherwise noted

L

F

K

G

M

A

B

J H C

D

E Fig. 62

908156/AP0205

54

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Adjustments)

A - Single axle extension 6-bolt hubs (top surface) (11L-14 tires) B - Axle extension C - Spindle plate E H D - Wheel E - Middle Harvester spindle position A F - High Harvester spindle position J G - Gusset H - Unused holes I - Short end of spindle plate J - Spindle bolt (one of four) K - Spindle bolt in middle of slot (one of four) G L - Spindle bolt at end of slot J (one of four) H A

8-bolt hubs (16.5L-16.1 tires) E

A

K

I A L

C B

I

G H

D

F

F

Attachment

Row Width in inches (mm)

Left Axle Hole

Right Axle Hole

Harvester Height

Hay

-

3

S = 1, F = 1, F* = 2

Middle

28 (710)

3

S = 1, F = 1, F** = 2

30 (760)

4

S = 2, F = 1, F** = 2

32 (810)

6

S = 2, F = 1, F* = 2

34 (860)

7

3

36 (910)

7

4

38 (960)

3

4

40 (1020)

3

5

28 (710)

6

5

30 (760)

7

6

32 (810)

3

6

34 (860)

3

7

36 (910)

4

7

38 (960)

5

7

40 (1020)

6

7

2-Row

3-Row

Middle or High

Middle or High

S = 11L x 14 Tires on single axle, F = 16.5L x 16.1 tires on single axle, * = 1285 only, ** = 1285 only and requires 10.00 - 20 recapped truck tires Fig. 63: Single wheel axle & spindle positions

Printed in U.S.A.

55

908156/CP0205

Chapter 6 - Care & Maintenance (Adjustments)

A

D

F

D B

D

C A - Right front wheel B - Axle extension C - Spindle plate (typical) D - Beam (top surface) E - Right rear wheel F - Spindle plate assembly in “Middle” Harvester position G - Spindle plate assembly in “High” Harvester position H - Spindle bolt (One of six)

H

G

E

Attachment

Row Width in Inches (mm)

Left Axle Hole

Right Axle Hole

Harvester Height

6-ft Hay

-

3

5

Middle

7-ft & 9-ft Hay

-

3

4

Middle

28 (710)

3*

1*

30 (760)

3*

1*

32 (810)

5

1, 2**

34 (860)

6

1, 2**

36 (910)

6

3

38 (960)

6

3

40 (1020)

3

4

28 (710)

5

4

30 (760)

6

5

32 (810)

3

6

34 (860)

3

6

36 (910)

3

6

38 (960)

5

6

40 (1020)

6

6

2-Row

3-Row

Middle or High

Middle or High

* 1285 Requires the use of single axles with 10.00 - 20 recapped truck tires, ** 1285 only Fig. 64: Tandem wheel axle & spindle positions 908156/AP0205

56

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Adjustments)

A

C

B

1

2

3

4

5

6

7

D A - Left side B - Main frame C - Right side D - Transport hitch hole E - Wagon hitch plate

E

Attachment

Row Width in Inches (mm)

Wagon Hitch Plate Holes

Highway Transport

-

D

Hay

-

3, 5

28 (710)

2, 4

30 (760)

1, 3

32 (810)

1, 3

34 (860)

1, 3

36 (910)

1, 3

38 (960)

1, 3

40 (1020)

5, 7

28 (710)

3, 5

30 (760)

3, 5

32 (810)

3, 5

34 (860)

2, 4

36 (910)

2, 4

38 (960)

2, 4

40 (1020)

1, 3

-

1, 3

2-Row

3-Row

Wet Ground

Fig. 65: Wagon Hitch Plate Positions

Printed in U.S.A.

57

908156/CP0205

Chapter 6 - Care & Maintenance (Lubrication)

LUBRICATION 1

General Information

2

WARNING NEVER lubricate this unit when any part of the machine is in motion. ALWAYS BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE lubricating this equipment.

1 - Reverse delay switch 2 - Front reservoir breather plug

Fig. 67

It is important to apply sufficient oil and grease to prevent excessive part wear and early failure.

NOTE: DO NOT remove the reverse delay switch; this switch MUST be precisely set for proper operation of the “reverse engagement’’ cycle.

IMPORTANT: Whenever service is performed on hydraulic components (valves, cylinders, hoses, etc.) or transmissions, care must be taken to prevent discharging fluid onto the ground.

Catch and dispose of fluid per local waste disposal regulations.

The rear reservoir requires 1 U.S. pint (0.5 liter) of SAE 10W40 motor oil and is filled by removing the plate on which the rear reservoir breather is mounted.

Transmission Lubrication (Figs. 66 & 67)

1

The lubricant level in both the bevel gearbox and shifter transmission should be checked after every 200 hours of operation and replenished, when necessary. The bevel gearbox requires 7 U.S. pints (3.3 liters) of SAE 140 EP gear lube. The shifter transmission has two oil reservoirs. The front reservoir requires 7 U.S. pints (3.3 liters) of SAE 10W40 motor oil and is filled through the breather plug hole in the front of the reverse delay switch, as shown.

2 1 - Rear reservoir breather plug and plate 2 - Rear reservoir oil level plug

Fig. 68

Both the bevel gearbox and the shifter transmission should be checked occasionally for oil drips and dust accumulation around the seals. Oil drips or dust accumulation indicates that the seals are leaking. Oil that is tan in color and foams excessively indicates that it has water present. Unless rust spots appear inside the housings, the fluid does NOT require replacement.

2

1

NOTE: DO NOT overfill either assembly; only fill them to the bottom of their level plug holes.

1 - Front reservoir oil level plug 2 - Rear reservoir breather plug and oil level (accessed from rear of drive frame)

Drive Chains Lubricate all drive chains every six to eight hours of operation using a good grade of foaming aerosol

Fig. 66

908156/CP0205

58

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Lubrication)

lubricant such as NAPA Chain and Cable Lubricant.

This type of lubricant increases the life of the chain three to four times over those lubricated at eight hour intervals with new motor oil. The recommended method is to spray the entire length of chain on the center of the rollers. It is more effective to oil chains after use, while they are still warm (after use, rather than before).

It should only be introduced at the blower in the top portion of the blower outlet, in order to keep the ammonia away from bearings. The ammonia will cause the oil-carrying substance of the grease to dissolve in the bearings, causing them to fail. Special grease MUST be used which can withstand the ammonia vapor effects.

Two greases which stand up fairly well in the presence of ammonia are Aero Shell #7 (by Shell Oil Co.) and Chevron SRI (by Chevron Oil Co.). But even these two greases will have to be replenished twice a day in those bearings that are exposed to ammonia vapor.

On Harvesters equipped with an optional automatic chain oiler, the oiler dispenses a measured amount of oil every time the attachment is raised. The amount of oil used can be regulated with the adjusting screw at the base of the pump. Turning the screw in decreases amount of oil dispensed and turning screw out increases amount of oil dispensed. Use only enough oil to keep the chains moist. Lubrication is excessive if oil is dripping or being thrown off the chains. Be sure to use a good grade of clean petroleum oil (SAE 20 to SAE 40).

Oiling Apply motor oil on all of the points listed at the intervals specified.

Lubricate Every 10 Hours (or Daily)

NOTE: The oiler is equipped with a shut-off valve to stop oil flow to the auger drive chain when a Crop Processor is installed. This prevents processor drive belt slippage from over-oiling. A non - slinging foaming aerosol should be used on the auger drive chain while the Crop Processor is being used.

Rotating telescoping PTO drive guard

IMPORTANT: DO NOT use drain oil for chain

Blower belt idler pivot points

oiling.

Rear feed roll guides (both sides)

Lubricate Every 50 Hours (or Weekly) Torque sensor contact pivot points Auger drive shear bolt flange Spout worm drive chain

IMPORTANT: To

minimize wear on the sprockets, the chains should be replaced after they become worn and are 3% longer than their original length, or when the tightener (where provided) has reached the end of its adjustment.

Lubricate Every 100 Hours (or Monthly) Tongue pivot pin All hinged-cover hinges

Shearbar

Feed roll spring strap pivots (both sides)

An extreme pressure NLGI #2 Moly Grease, such as Schaeffer 238 #2, should be used between the shearbar and the shearbar support. It should also be used on the left side shearbar cam u-bolt and inside the right side shearbar adjustment nut.

Feed roll stabilizer pivots (both sides) Deflector control worm bushings Crop Processor roll adjustment screws and guides Crop Processor drive belt tension adjustment screw

Ammonia Silage Additive

Hydraulic Circuits

IMPORTANT: Gehl Company recommends against running ammonia silage additives through any part of the Harvester because of their damaging effects on bearings.

The Harvester is equipped with two hydraulically powered control systems; the attachment lift cylinder system and the tongue control system. BE SURE to check and maintain the tractor hydraulic fluid level in accordance with the total circuit requirements of your particular Harvester.

If an ammonia silage additive must be added to the silage in the field, certain precautions MUST be taken.

Printed in U.S.A.

59

908156/CP0205

Chapter 6 - Care & Maintenance (Lubrication)

Greasing

16.

Right cylinder bearing housing

IMPORTANT: Grease all fittings at intervals of

17.

Left cylinder bearing housing

operation listed, after pressure washing, before and after storing unit, and as listed. Use a good grade of lithium-base grease.

18.

Remote front blower bearing

19.

Rear blower bearing

20.

Crop Processor upper roll bearings (2 places)

21.

Crop Processor lower roll bearings (2 places)

Wipe dirt from the fittings before greasing to prevent dirt from being forced into the bearing or pivot. Replace any missing fittings. Force grease into the fitting until it comes out at the bearing seal or the shaft. To minimize dirt build-up, avoid excessive greasing.

Grease Every 50 Hours (or Weekly)

IMPORTANT: In addition to the fittings, repack the wheel bearings at least once a year. Apply a coat of grease at least twice each season to front feed roll guides (both sides) and to the spout worm and gear. Periodically lubricate the telescoping drive shaft and tube.

Grease Fitting Locations

22.

Blower outlet flange (4 places)

23.

Right lower rear feed roll bearing

24.

Right lower front feed roll bearing

25.

Right upper front feed roll bearing

26.

Right upper rear feed roll bearing

27.

Remote left upper front feed roll bearing

28.

Remote left upper rear feed roll bearing

Grease Every 10 Hours (or Daily)

29.

Remote left lower rear feed roll bearing

1.

Telescoping drive (3 places)

30.

Remote left lower front feed roll bearing

2.

Main drive reversing transmission (3 places)

31.

Feed roll input chain idler arm

3.

Main drive cross

32.

Auger end bearings (2 places)

4.

Main drive spline

5.

Right feed roll stabilizer bar bearing

6.

Left feed roll stabilizer bar bearing

7.

Right feed roll guide bearing

8.

Left feed roll guide bearing

9.

Upper feed roll drive (3 places)

10.

Lift tube cast bearing

11.

Cylinder drive crosses (2 places)

12.

Right lift tube sleeve bearing

13.

Left lift tube sleeve bearing

38.

Left lift roller

14.

Electric clutch hub

39.

Right lift roller

15.

Attachment drive cross

908156/CP0205

Grease Every 100 Hours (or Monthly)

60

33.

Knife sharpener adjustment screw

34.

Left quick-switch attachment drive hub

35.

Crop Processor belt idler arm pivot

36.

Left shear bar adjustment cam

37.

Feed roll shear flange(s) a.

1085: Torque Sensor units (1 place) and shear bolt-equipped models (2 places)

b.

1285: None

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Lubrication)

Grease every 10 hours (or daily) 1

Grease every 50 hours (or weekly) Grease every 100 hours (or monthly) 2 (3) 37

10

1085 Shear Bolt (2) 1085 Torque Sensor (1) 1285 (NONE)

13

8, 9, 14, 15

29, 30 27, 28

(6)

(2)

(2) 34, 36, 38 12

39

3, 4

7

(2)

23, 24, 25, 26 16

(4) 33

22

20, 21 Crop Processor (2)

(4) 20, 21 Crop Processor (2) 31, 32 11, 17, 18, 19 (5)

Printed in U.S.A.

32 5, 6

61

35 Crop Processor

908156/CP0205

Chapter 6 - Care & Maintenance (Service)

SERVICE

authorized Gehl dealer. Make sure to use thread locking compound on the retaining bolt.

WARNING

4

BEFORE servicing this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

1

NOTE: The following information is referred to in both the Troubleshooting Guide and the Maintenance Schedule chapters of this manual. It should be understood that all services detailed in this chapter are Owner-Operator responsibilities.

Where indicated, certain service routines should only be carried out under the direction of an authorized Gehl equipment dealer. Furthermore, all hydraulic hoses and fittings should be routinely checked after every 100 hours of operation for leaks and secure attachment.

6

5

1 - Retaining washer 2 - Idler 3 - Driven sheave (on blower) 4 - Drive belt 5 - Drive sheave (on gearbox) 6 - Idler arm

Bevel Gearbox IMPORTANT: Internal bevel gearbox component repairs and replacements should only be performed by (or under the direction of) an authorized Gehl dealer. The bevel gearbox is a mechanism that requires special tools and training to repair; only your Gehl dealer has the facilities and trained personnel to provide this service.

Fig. 69

Rim Sheet Wear Liner The blower rim sheet wear liner should be inspected after every 100 hours of operation. The rim sheet assembly should always be kept tightly secured to prevent cut forage from wedging between the rim sheet grooves and the blower side sheets.

Blower

IMPORTANT: If the rim sheet wear liner has to be removed and replaced, follow the instructions provided with the liner kit. In addition, DO NOT transport the Harvester without securing the rim sheet in place; doing so could result in damage to the blower outlet or side sheets.

A: Drive Belt (Fig. 69) The blower drive belt should be checked for cracks, tears and evidence of oil after every 50 hours of operation. To remove the belt, lift the idler arm to relieve belt tension. The use of a pipe or breaker bar as an aid is suggested. Move the belt clear of the idler and then release the idler arm tension. Guide the belt off of the drive and driven sheaves. To install a new belt, reverse the removal process. Make sure that the new belt is completely into the grooves of the sheaves before lowering the idler.

IMPORTANT: After the first 10 hours of operation following rim sheet assembly or replacement, the take-up nuts torque should be checked and readjusted to 40 lb.-ft. (54 Nm), as necessary.

Chains & Sprockets

B: Sheaves (Fig. 69)

Sprocket wear is most often caused by an excessively worn chain. A chain that has worn 3% (1.03 times the original length) should be removed and replaced.

IMPORTANT: The bevel gearbox MUST be removed from the Harvester frame in order to remove the drive sheave. This procedure should be performed by (or under the direction of) an 908156/CP0205

2

3

This Harvester is designed so that when the chain tightener reaches the limit of its adjustment, the chain 62

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Service)

has reached a condition of maximum wear. To calculate the original chain length, multiply the number of links by 3/4″ for a #60 chain, or by 5/8″ for a #50 chain.

1

Cutting Mechanism (Figs. 70 thru 75) A: Shear Bar The edge of the reversible shear bar will remain sharp provided the knives are kept sharp and the shear bar is properly set up to the knives. When the cutting edge NO longer stays sharp, the shear bar can be removed and changed (end-for-end) to place a new sharp edge toward the knives. To remove and replace the shear bar, proceed as follows:

2

3

1: Removal

NOTE: Depending on the size of the tires, spindle height and position of the axle extension, it may be necessary to remove the wheel or move the axle extension out on the right side of the Harvester to obtain clearance for removing the shear bar.

1.

2.

3.

4.

5.

1 - Proper wear 2 - Shear bar (see proper & improper wear views) 3 - Improper wear

Fig. 70

It may be necessary to remove the trash between the shear bar and the feed roll scraper before the shear bar can be moved. Adjust the shear bar forward until the rear edge of the shear bar is flush with the rear edge of the shear bar support channel.

6.

Remove lock nut and spacer from 1/2″ bolt on right side of shear bar. Move bolt rearward until it clears shear bar. Remove 3/8″ lock nut and bolt from right side of shear bar.

7.

Remove clamp force on right side of shear bar.

Remove the right-side shield that covers the sheave and/or cutting cylinder shaft. If more room is desired, remove the processor mill drive belts and/or the right guard.

On the 1085, remove vertical bolt, lock nut and washer.

b.

On the 1285, loosen (but do not remove) the shear bar holddown bolt on right side only.

NOTE: In order to remove the shear bar, it may be necessary to loosen both pairs of stem guide mounting bolts and move the stem guides up to free the shear bar. After the guides are moved, retighten the bolts to keep the guides away while replacing the shear bar.

On the 1285 ONLY, remove and retain the shear bar center adjustment lock nut and pull the center shear bar adjustment shaft approximately 3″ (76 mm) toward the right side of the Harvester to disengage the shear bar center adjustment shaft pin from the notch in the bottom of the shear bar.

If desired, remove the shear bar center adjustment shaft for additional clearance.

8.

DO NOT remove, loosen or alter the position of the shear bar holddown pin on the left side.

From the right side, pull the shear bar out from under the left-side shear bar holddown pin and remove the shear bar.

NOTE:

If the right-side shear bar adjustment parts were loosened or removed, reassemble all parts per Figure 75. To readjust, clamp belleville spring washer flat, then loosen EXACTLY 1/3 turn (two flats) and secure nut.

Loosen and remove the lock nuts, slot baffle and shear bar cam U-bolt on the left side; retain all attaching hardware. BE SURE to use new lock nuts when shear bar is replaced.

Printed in U.S.A.

a.

63

908156/CP0205

Chapter 6 - Care & Maintenance (Service)

2: Replacement 9.

1

Before attempting to replace the shear bar or install a new shear bar, BE SURE that it is thoroughly cleaned. In addition, clean off the shear bar support behind the smooth feed roll scraper. Apply an extreme pressure NLGI #2 Moly Grease, such as Schaeffer 238 #2, to the entire bottom side of the shear bar to facilitate sliding it back into its mounting position and to facilitate adjustment.

1

2

3

4

5

2

6

1 - Stem guide mounting bolts (both sides) 2 - Right side clamp bolt 3 - Shear bar right adjustment nut 4 - Smooth feed roll scraper 5 - Remote left shear bar adjustment 6 - 1/2″ retaining bolt, spacer, 1/2″ lock nut

3 8

Fig. 72: 1085 shown

6

4

14.

5 7

Clamp right side of shear bar to frame. a.

On the 1085, install and tighten the right-side clamp bolt, washer and lock nut.

b.

On the 1285, tighten the right-side holddown bolt and locking nut.

1 - Stem guide mounting bolts (both sides) 2 - Right side clamp bolt 3 - Shear bar right adjustment nut 4 - Smooth feed roll scraper 5 - Remote left shear bar adjustment 6 - Center adjustment shaft 7 - Shear bar center adjustment lock nut 8 - 1/2″ retaining bolt, spacer, 1/2″ lock nut

1 2

3

Fig. 71: 1285 shown

10.

11.

Install the shear bar so the triangular notches are facing up. Force the left end of the shear bar under the spring-loaded shear bar holddown pin on the left side.

DO NOT attempt to loosen the left-side holddown pin sleeve. Make sure, however, that the pin is free to slide in its sleeve.

12.

Install the shear bar so that its right end is flush with the end of the shear bar support. Align the shear bar hole with the 1/2″ bolt on the right shear bar adjustment. Move bolt through the shear bar and loosely install the spacer and lock nut. Secure right shear bar adjustment strap to shear bar with 3/8″ bolt and lock nut. Tighten 1/2″ lock nut.

13.

Apply an extreme pressure NLGI #2 Moly Grease, such as Schaeffer 238 #2, in the shear bar cam groove and reinstall the left-side shear bar cam U-bolt, the slot baffle and the lock nuts.

Tighten the lock nuts so that the U-bolt pulls the cam tightly against the slot baffle and shear bar.

908156/CP0205

4

8

7

5 6

1 - Holddown pin assembly (DO NOT loosen) 2 - Cam 3 - Lockstrip 4 - Shear bar clamp U-bolt 5 - Cam pivot U-bolt 6 - Slot baffle 7 - Shear bar (left end) 8 - Lock nut (2)

Fig. 73

15.

64

On the 1285 ONLY, reinstall (if removed in step 3) and/or reposition the shear bar center adjusting shaft pin so that it engages the notch in the bottom of the shear bar. DO NOT attempt to force the adjusting shaft pin into position, but instead rotate Printed in U.S.A.

Chapter 6 - Care & Maintenance (Service)

the center adjusting shaft back and forth until the pin engages the notch.

16.

Reinstall all guards and the processor mill drive belts, if they were removed.

17.

BE SURE to reset the stem guide positions if they had been changed. Set the stem guides down against the shear bar and make sure that they are clearing the cutting cylinder by 1/32-1/16″ (0.8-1.6 mm) to prevent damage to the knives.

Then retighten the stem guide bolts.

IMPORTANT: Be sure to tighten the stem guide mounting bolts, because loose bolts will allow the crop to push the stem guides into the knives and severely damage the cutting cylinder.

18.

Refer to the shear bar topic in the Adjustments section of this chapter to make the proper shear bar adjustments for operation.

1 - Shear bar 2 - Spacer 3 - 1/2″ lock nut 4 - 1/2″ retaining bolt 5 - Shear bar adjustment stud 6 - Split lock nut 7 - Belleville washer 8 - Shear bar adjustment nut (right side) 9 - Shear bar adjustment (left side)

Fig. 75

B: Knife Replacement (Fig. 76) NOTE: Do not mix knife types on the cutting cylinder. Use all double bevel knives or all single bevel knives.

After numerous sharpenings, knives will be ground down to where the hard-facing has disappeared. In addition, knives may become deeply gouged or broken and require replacement. To replace a knife, proceed as follows:

1 - Plastic cover over sleeve 2 - Cotterpin 3 - Holddown pin sleeve 4 - Left cylinder side sheet 5 - 3/4″ locking nut 6 - Left-side shear bar holddown pin 7 - Shear bar support 8 - Spring washers 9 - 5/8″ (16 mm)

WARNING Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) before servicing this unit.

Fig. 74: Left-side holddown assembly

Printed in U.S.A.

65

908156/CP0205

Chapter 6 - Care & Maintenance (Service)

1.

Open the sharpener cover. Remove the cylinder covers. While it is not necessary, it is recommended to remove the Crop Processor or transition. Crop processor removal is covered in the Crop Processor Operator’s Manual.

Remove and store the knife set-up rod. Reinstall all removed components EXCEPT the cylinder cover sharpener access insert. Sharpen the knives and set the shear bar according to the instructions under those topics.

2.

Remove the rear cylinder side sheet tie support.

3.

After cleaning out the space between the shear bar and the scraper, move the shear bar forward to the end of its travel.

4.

Loosen and remove the three 3/4″ bolts that secure the knife. The knife header plate prevents the nut from turning, so the 3/4″ bolts will have to be held up in order to position the nut between the plates and prevent the nut from turning.

NOTE: BE SURE to control the balancing of the cutting cylinder knives when mixing old and new knives. An old knife should ALWAYS be balanced on the opposite side of the cylinder with another old knife and a new knife should ALWAYS be balanced on the opposite side with another new knife. Do not mix knife types on the cutting cylinder. Use all double bevel knives or all single bevel knives.

5.

C: Knife Sharpening (Figs. 77-79) 1: General Information

Position a new knife in place and insert three 3/4″ bolts through the washers, knife and nuts.

Partially tighten the bolts, but NOT so tight that the knives cannot be adjusted.

The knife sharpener is designed to operate by having a sharpening stone come in contact with the cylinder knives while the cylinder is rotating in a reversed direction. The tractor PTO will supply power to rotate the cylinder in reverse through a reversing transmission located on the front of the Harvester tongue.

2: Preparation

2

1 1 - Knife set-up rod 2 - 3/4″ knife bolt (1 of 3 per knife)

Fig. 76

6.

7.

Place the knife set-up rod (stored under the knife sharpener cover) into position in the holes in the side sheets and follow the procedure outlined in the “Knife Adjustment” and “Shear Bar Adjustment” topics in this chapter. BE SURE to tighten the 3/4″ bolts with 220-240 lb.-ft. (300-325 Nm) of torque. Do not overtighten!

Rotate the cylinder by hand to check for interference.

908156/CP0205

66

1.

Make sure that cutterhead and auger are clear of material before sharpening knives or setting shear bar.

2.

Shut off the PTO and tractor engine and make sure all parts have stopped rotating before removing shields and covers.

3.

Open the sharpener cover.

4.

Remove the narrow cylinder access cover.

5.

Verify proper stone position or adjust as necessary to be just clear of the cylinder knives.

6.

To retract the stone, loosen the hardware on the ratchet wheel flat spring and rotate the wheel clockwise.

7.

ALWAYS use the sharpener handle to move the sharpener carriage.

8.

To advance the stone, pull the sharpener carriage completely to the right end of travel. This will engage the ratchet wheel into the advancing pawl.

Each pawl engagement advances the stone 0.0046″ (0.118 mm).

9.

Close all shields and the sharpener cover.

Printed in U.S.A.

Chapter 6 - Care & Maintenance (Service)

IMPORTANT: Move the carriage in a smooth motion across the entire length of the knife to prevent burning and to insure a smooth, uniform grind.

1

15.

After some amount of stone cycling, disengage PTO and shut off tractor. Wait for the cutterhead to stop, then open sharpener cover and check knives for sharpness.

16.

After the knives are sharp, reinstall the implement end of the PTO to the upper (forward rotation) shaft. Reinstall the cylinder access cover and all shielding.

2 1 - PTO in normal operating location 2 - Reversing location for knife sharpening

Fig. 77

5

4

3

IMPORTANT: Failure to install the cylinder covers correctly could cause them to be pulled into the cutting cylinder during operation.

2

17.

Set the shear bar using the instructions in the Adjustments section of this chapter.

2 1 6

5

1

1 - Narrow cylinder access cover & retaining knobs 2 - Sharpener handle 3 - Carriage 4 - Ratchet wheel 5 - Ratchet wheel spring 6 - Sharpener stone

3 4 6

Fig. 78

1 - Knife sharpener cover closed for sharpening 2 - Wear safety goggles warning decal 3 - Knife sharpener operating instructions decal 4 - Knife sharpener operating handle 5 - Shear bar adjusting instructions decal 6 - Shear bar adjustments

3: Cylinder Knife Sharpening 10.

Remove the rear end of the PTO shaft and reinstall it onto the lower reversing shaft.

11.

Move and keep the control box power switch in the “Off” position.

12.

Start the tractor engine and engage the PTO slowly. Run the PTO speed up to 900 RPM for sharpening.

13.

ALWAYS wear safety goggles (provided) when sharpening knives.

14.

To sharpen, pull stone across knives using the sharpener handle. Advance stone as necessary by pulling the sharpener handle completely to the right end of travel.

Printed in U.S.A.

Fig. 79

C: Stone Replacement (Fig. 80) The knife sharpening stone should be replaced when it has been worn to 1/8″ (3 mm) remaining between the cutting surface of the stone and the stone clamp. To replace the stone, remove the two socket-head capscrews that hold the locking plate in place and remove the worn stone. Thoroughly clean the stone clamp, locking plate and screws. Lightly coat the beveled sides of the locking plate and stone clamp with grease and assemble with the new stone. Tighten the socket head capscrews to 20 lb.-ft. (27 Nm). DO NOT overtighten!

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Chapter 6 - Care & Maintenance (Service)

Ï Ï ÓÓÑÑÑ ÌÌ ÎÎ ÓÓ ÎÑÑÑÑ ÑÑ ÌÌÎÎ ÎÎÎ ÓÓÓ

9

shaft must be checked and reset if necessary. Shims can be added from the left-side rail mounting bracket to make the rear (rectangular bar) sharpener rail parallel to the cylinder shaft within 0.010″ (0.25 mm). Shims are called out in the Parts Manual.

11

4

8

3

1

NO GREASE IN THIS BORE

4

5

7 10 1

2

3

2 1 - Front knife sharpener rail (shaft) 2 - Rear knife sharpener rail (bar) 3 - Left-side rail mounting bracket 4 - Add/delete shims here

6

Fig. 81

1 - 1/8″ (3 mm) wear measured here 2 - Sharpening stone 3 - Locking plate 4 - Stone clamp 5 - Socket head cap screw 5/16 x 3/4″ 6 - Grease lightly here 7 - 0.010-0.020″ (0.25-0.5 mm) measured here 8 - Carriage rail 9 - Slide block 10 - Roller bearing follower 11 - Ratchet wheel tension shims

F: Ratchet Pawl (Fig. 82) The pawl which engages the ratchet wheel of the stone advance mechanism may require periodic adjustment.

This is accomplished by turning the 5/16″ lock nut to obtain a 0.10″ (2.5 mm) dimension as indicated between the mounting bracket and the tip of the pawl.

Fig. 80 3

4

2

D: Ratchet Wheel Tension (Fig. 80) The ratchet wheel is tensioned so that a torque of 50-120 lb.-in. (5.7-14 Nm) is required to turn the wheel.

Tension is controlled by adding or removing shims to change the spring tension of the belleville washer.

E: Sharpener Carriage Rails (Figs. 80 & 81) 1

Both the front and rear carriage rails need to be clean to assure a smooth, minimum resistance carriage movement. The slide block on the rear rail is adjustable so a 0.010-0.020″ (0.25-0.5 mm) clearance between the rear rail and the lower roller bearing follower can be maintained.

1 - Measure dimension here 2 - Bolt 3 - Lock nut 4 - Spring

Fig. 82

The sharpener carriage rails are set in parallel with the knife cylinder shaft during factory assembly. If the knife sharpener assembly is removed for any reason, the parallelism of the sharpener rails to the knife cylinder 908156/CP0205

Spout The spout has a replaceable wear liner. The liner kit includes installation instructions.

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Chapter 6 - Care & Maintenance (Service)

Remote Grease Lines

The speed monitor module is mounted on a bracket on the left side of the auger housing. When replacing the speed monitor, make sure that it is installed so that the magnetic pickup of the module is centered directly over the monitor gear. Also, the air gap must be set (0.06-0.22″ [1.5-5.5 mm]) to assure proper operation.

Several steel remote grease lines are provided on the Harvester to facilitate lubrication of otherwise difficult to reach relubeable bearings. If a steel remote grease line is damaged or broken, it can be replaced by ordering a tubing kit (Gehl part number 065185).

Procedures for steel grease line replacement are covered in instructions packaged with the kit.

Auger Drive Chain (Fig. 84) The auger is driven by a chain. The drive sprocket for the chain is located on the cutting cylinder shaft. When the drive chain is removed, the auger should be free to rotate. For access to the drive chain and idlers, remove the drive guard.

Shifter Transmission IMPORTANT: Shifter transmission component repairs and replacements should only be performed by (or under the direction of) an authorized Gehl dealer. The transmission is a mechanism that requires special tools and training to repair. Only your Gehl dealer has the facilities and trained personnel to provide this service.

2

3

4

Speed Monitor (Fig. 83) The speed monitor module is NOT repairable. If it is not operating properly, your dealer will have to determine if it must be replaced.

1

2

1

1 - Auger drive chain 2 - Adjustable idler 3 - Auger sprocket with shear device 4 - Drive sprocket on cutting cylinder shaft (behind Crop Processor drive sheave)

Fig. 84

1 - Speed monitor 2 - Monitor gear

Fig. 83: Speed monitor

Printed in U.S.A.

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Chapter 6 - Care & Maintenance (Service)

Tires and Wheels

Tire (Inflation) Pressures

The Gehl Company does NOT sell replacement tires.

In addition, tire mounting, repair and replacements should ONLY be attempted by a qualified tire manufacturer’s representative or by properly trained personnel following the tire manufacturer’s instructions. If you do not have such instructions, contact your tire dealer or the Gehl Company.

Inflation Pressure

WARNING Inflating or servicing tires can be hazardous.

Whenever possible, trained personnel should be called to service and/or mount tires. In any event, to avoid possible injury, follow the safety precautions below:

•

BE SURE the rim is clean and free of rust.

Lubricate both the tire beads and rim flanges with a soap solution. DO NOT use oil or grease. DO NOT weld, braze, or otherwise attempt to repair and use a damaged rim.

•

Use a clip-on tire chuck with a remote hose and gauge, which allows you to stand clear of the tire while inflating it. DO NOT place fingers on tire bead during inflation.

•

•

PSI

kPa

11L - 14 6-ply Rating*

26

182

16.5L - 16.1 8-ply Rating

24

170

10.00 - 20 12-ply Rating

45

310

Tandem 11L - 15 8-ply Rating

36

250

* NOT approved for use with Crop Processor

Electric Controls (Figs. 87 & 88) The control box is located on the tractor and is linked to the implement control module on the Harvester. The implement control module operates the feed roll drive and the spout and cap gearmotors through wiring harnesses with sealed plug connectors. Refer to the wiring diagrams, provided at the end of this chapter, for circuit wiring and troubleshooting references.

A: Voltage Checks To determine if the electrical system is in proper operating condition, perform the following D.C. voltage checks:

NEVER inflate beyond 35 PSI (240 kPa) to seat the beads. If beads have not seated by the time the pressure reaches 35 PSI, deflate the assembly, reposition the tire on the rim, relubricate both parts and re-inflate it. Inflation pressure beyond 35 PSI with unseated beads may break the bead or rim with explosive force sufficient to cause fatal or serious injury.

WARNING Remove the telescoping PTO drive coupling from the tractor PTO shaft before servicing this unit.

With the control box attached to the 12-volt D.C. power from the tractor, the tractor connected to the Harvester and the telescoping drive disconnected, start the tractor engine and take the following readings while operating the control box switch in “Reverse.”

After seating the beads, adjust the inflation pressure to the recommended operating pressure listed.

Test #1 - Battery voltage MUST be 12 to 15-1/2 volts.

Check the Harvester tire pressure after every 50 hours of operation. Tires should be inflated to appropriate pressure listed in the table. Wheel bolt torques should also be checked after every 50 hours of operation and tightened with 90 lb.-ft. (125 Nm) of torque.

908156/CP0205

Size & Description

Test #2 - A minimum of 8-1/2 volts MUST exist across the electric clutch wires.

If the voltage readings of tests 1 and 2 are NOT obtained, check all plugs and connections.

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Chapter 6 - Care & Maintenance (Service)

The wiring system in some tractors is too light to obtain and maintain the required voltages. The battery power supply harness (optional on early models) should be installed directly to the 12-volt D.C. battery.

If a tractor is not available to check out the Harvester electrical system, proceed as follows: 1. Use a battery power supply harness to connect the control box to a 12-volt D.C. battery, and add a battery charger if necessary.

2. Perform the preceding Test #1 and Test #2.

IMPORTANT: The service procedures related to the shifter transmission, solenoids and torque sensors are restricted to wiring connection checks.

Actual service, repairs or replacements of these components and their electrical circuitry should only be performed by (or under the direction of) an authorized Gehl dealer. These mechanisms require special tools and training to repair. Only your Gehl dealer has the facilities and trained personnel to provide this service.

1.

Shut off the tractor engine and detach the telescoping PTO drive.

2.

Clean the contact surfaces of the clutch electromagnet and armature with safety solvent.

3.

Remove the attachment drive chain and remove the length-of-cut drive chain.

4.

Install the 37-tooth length-of-cut sprocket and install the clutch reburnishing tool. Secure the tool to the 37-tooth sprocket with a 5/16 x 1-3/4″ Grade 5 cap screw and hexagon nut.

5.

After reconnecting the telescoping PTO drive in the normal operating location, run the Harvester at full tractor PTO RPM and engage the electric clutch in “Reverse’’ for 10-12 seconds.

WARNING After slipping the clutch for 10-12 seconds, it will be smoking and very HOT. DO NOT TOUCH THE CLUTCH!

B: Reburnishing Electric Clutch (Fig. 85) NOTE: A reburnishing tool can be obtained from your local Gehl dealer.

WARNING Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) before servicing this unit.

6.

Allow the clutch to cool off; this should take approximately one hour. DO NOT attempt to expedite cooling by using water, as this may cause warpage.

7.

If the clutch did NOT smoke when step 5 was carried out, repeat steps 5 and 6.

8.

With the PTO running at a speed as close to idle as possible without activating the speed monitor, engage and disengage the electric clutch in “Forward” in short bursts until the Grade 5 cap screw in the reburnishing tool shears.

In the event that the electric clutch does not provide adequate torque due to having oil or grease on the surface of the clutch, the proper torque can be restored by performing the following procedure:

WARNING

2

Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) before servicing this unit.

1 3

9.

Remove the reburnishing tool, install the desired length-of-cut sprocket and reinstall the attachment drive chain.

1 - Clutch Reburnishing Tool 2 - 37 Tooth Sprocket 3 - 5/16 x 1-3/4″ Grade 5 Bolt & Nut

Fig. 85

Printed in U.S.A.

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Chapter 6 - Care & Maintenance (Service)

C: Electrical Schematics

Fig. 86: Harvester electrical schematic for 1085 after SN14149 and 1285 after SN20899

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Chapter 6 - Care & Maintenance (Service)

Fig. 87: Harvester electrical schematic for 1085 before SN14150 and 1285 before SN20900

Printed in U.S.A.

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Chapter 6 - Care & Maintenance (Service)

Fig. 88: Transport Lights Electrical Schematic

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Chapter 6 - Care & Maintenance (Service)

3 1 - Hydraulic cylinder 2 - Quick disconnect (male) at tractor end 3 - Elbow fitting hydraulic

1

2

Fig. 1: Hydraulics Diagram (for attachment lift system and tongue swing system)

3

1 - Quick disconnect (male) at tractor end 2 - Quick disconnect (female) remote hydraulic outlet

2

1

Fig. 2: Remote hydraulic outlet kit

3

4 1 - Hydraulic attachment lift cylinder 2 - Quick disconnect (male) at tractor end 3 - Elbow fitting hydraulic 4 - Tee fitting hydraulic 2 5 - Union fitting hydraulic 6 - Lubricator pump

1

Fig. 3: Chain oiler option

6 3 5

3

Fig. 89: Harvester Hydraulic Schematic

Printed in U.S.A.

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CHAPTER 7 STORAGE 5.

Clean and oil all drive chains and sprockets.

6.

Paint all the parts from which the paint has been worn to prevent rust.

7.

Replace any worn or damage parts so the Harvester will be ready to operate the next season. For your safety and continued proper operation, use only genuine Gehl service parts.

8.

Store the Harvester in a dry place where it is neither exposed to weather nor livestock.

IMPORTANT: If a pressure washer is used to

9.

clean the harvester, do NOT aim water stream directly at electrical devices such as the metal detector, or at bearings. Water will enter the electrical components and damage them. Water will enter the bearings and cause them to corrode during storage.

Release tension on the blower and Crop Processor roll drive belts if the Harvester is going to be out of operation for more than a month.

Protection of Unpainted Surfaces Apply a rust preventative oil or grease to the following unpainted surfaces:

3.

1.

The front telescoping drive yoke hub at the PTO drive end.

2.

The front bevel gearbox shaft splines.

3.

The length-of-cut sprocket splined shaft.

4.

The entire surface of both Crop Processor rolls.

At the end of the harvesting season it is suggested that the following steps be performed: 1.

2.

4.

The electrical control box should be stored in a dry place. Install the dust caps, where provided, over the ends of the wire harness plug connectors.

Clean the Harvester thoroughly of all dirt, trash, excess grease and any other material that will absorb water and cause rust. If a pressure washer was used to clean the Harvester, all bearings should be lubricated after cleaning.

The Crop Processor MUST be thoroughly cleaned inside the housing. Rotting forage will cause severe corrosion damage to the Crop Processor rolls.

Thoroughly lubricate the Harvester as indicated in the Lubrication section.

908156/CP0205

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Printed in U.S.A.

CHAPTER 8 TROUBLESHOOTING NOTE: This Troubleshooting guide presents problems, causes and suggested remedies beyond the extent of loose, worn or missing parts and it was developed with the understanding that the machine is in otherwise good operating condition. Refer to the index at the back of this manual for Chapter and Topic page references. For additional assistance, BE SURE to contact your local Gehl dealer.

BLOWER PROBLEM Forage is NOT being blown adequately or spout is plugging.

Blower belt is coming off.

Blower fan blades are striking blower side sheets.

Printed in U.S.A.

CAUSE

REMEDY

Tractor PTO RPM is dropping too low.

Reduce the ground travel speed to keep the PTO speed up to 1000 RPM.

Blower rim sheet and/or spout is gummed up.

Remove gum and dirt by either scraping it out or by running very wet forage or freshly cut crop through it; consult with your dealer for information on a water applicator kit.

Blower belt slipping.

Check belt for wear and/or oil contamination and check for proper Idler alignment and tension.

Blower paddles are NOT set out to the rim sheet.

Adjust paddles.

Blower rim sheet liner is worn through.

Replace liner.

Spout liner is worn through.

Replace liner.

Spout horizontal extension is interfering.

Correct the extension mounting, as required.

Cap is being tipped down too far.

Operate the cap in a higher position.

PTO is being engaged at too high an RPM.

Always engage the PTO at tractor idle.

Blower fan is obstructed.

Check the fan to see if it turns freely.

Belt idler is tipped and/or NOT in line.

Position idler perpendicular and in line with belt.

Locking collars on blower bearings are loose.

Center the fan and tighten the bearing lock collars.

Blower arms are bent.

Replace arms.

Rim sheet is loose.

Tighten rim sheet take-up after cleaning and greasing the rim sheet grooves.

Bolts in side sheets are loose.

Tighten bolts.

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Chapter 8 - Troubleshooting

CUTTING CYLINDER PROBLEM Crop will NOT feed into cutting cylinder.

Knives wearing out rapidly.

Stems are too long.

Long cobs in corn silage when Crop Processor is not used.

Knives are striking the cylinder side sheet tie and/or shear bar when knives are moved out.

908156/CP0205

CAUSE

REMEDY

Knives are too dull.

Sharpen the knives and readjust their positions, as required.

Upper rear feed roll is packed between the flutes.

Clean out the material between the roller flutes.

Smooth feed roll scraper is NOT against the feed roll.

Clean out the area between the roll and the scraper and lower the scraper.

Soil or sand being picked up by the mounted attachment.

Operate the attachment higher off the ground.

Shear bar is NOT set up to knives.

Correct the shear bar setting.

Knives are NOT sharp.

Sharpen the knives and readjust their positions, as required.

Shear bar is NOT sharp.

Remove and rotate or replace the shear bar.

Shear bar is NOT straight and/or set up to the knives.

Check if shear bar is straight and correctly set it up to the knives.

NOT enough material depth into the feed rolls to hold stems.

Increase the ground speed or windrow size and/or reduce the length-of-cut.

Length-of-cut is too long.

Reduce the length-of-cut.

Stem guides NOT correctly set to the knives.

Set the guides 1/32-1/16″ (0.8-1.6 mm) from the knives.

Knives are NOT sharp.

Sharpen the knives and readjust their positions, as required.

Shear bar is NOT sharp.

Remove and rotate or replace the shear bar.

Shear bar is NOT straight and/or set up to the knives.

Check if shear bar is straight and correctly set it up to the knives.

NOT enough material depth into the feed rolls to hold stems.

Increase the ground speed and/or reduce the length-of-cut.

Tractor PTO RPM is dropping too low.

Reduce the ground travel speed to keep the PTO speed up to 1000 RPM.

Knives are moved out too far.

Reset the knives with the set-up rod.

Shear bar is NOT moved fully forward.

Clean out the material from in front of shear bar before it is moved forward.

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Chapter 8 - Troubleshooting

SPOUT PROBLEM Spout turns hard.

CAUSE

REMEDY

Spout flange is dry.

Properly grease spout flange.

Spout worm gear is dry.

Grease worm gear.

Spout worm gear drive chain is dry.

Lubricate worm gear drive chain.

Cap pivot spacers are binding.

Oil the pulleys and pivot spacer holes.

Forage wedged between cap and spout.

Remove material buildup.

Spout turns hard with a horizontal extension installed.

Spout is tipped in relation to the blower outlet.

Adjust the tripod to eliminate the binding.

Cap motor or spout gearmotor operates slowly.

Binding in a joint.

Lubricate all joints and check for incorrect joint alignment.

Voltage too low.

Check voltage at tractor. Install battery power supply harness to increase voltage.

Fuse(s) in tractor control box harness blown.

Check wiring and replace 30-Amp and/or 10-Amp fuse(s).

Fuse in battery power supply harness blown.

Check wiring and replace 30-Amp fuse.

Fuse to tractor 3-pin power outlet blown.

Check wiring and replace 30-Amp fuse in tractor.

Plugs or wires have separated.

Check the wiring and the plugs.

Cap moves hard.

Entire electrical control is dead and does NOT function.

CHAIN DRIVES PROBLEM Drive chains are jumping.

Drive chains are NOT releasing from sprocket and are noisy.

CAUSE

REMEDY

Chain tension idler is NOT correctly positioned.

Correctly align and/or adjust tension.

Sprockets or chains are worn excessively.

Lubricate chains or replace them, as required.

Chains are lacking lubrication and/or are worn excessively.

Lubricate chains or replace them, as required.

Sprocket teeth worn and/or bent backwards.

Replace sprocket.

FEED ROLLS & ATTACHMENT CONTROLS PROBLEM Feed roll drive overloads frequently.

Printed in U.S.A.

CAUSE

REMEDY

Smooth feed roll scraper packed with forage or raised above the feed roll.

Remove the scraper, clean it and the feed roll, then reposition the scraper against the feed roll.

A bearing has failed.

Replace the bearing.

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Chapter 8 - Troubleshooting

FEED ROLLS & ATTACHMENT CONTROLS (Cont.)

PROBLEM Feed roll drive overloads frequently.

(Cont.)

Feed rolls will run forward but NOT in reverse.

Reverse solenoid shifts but the clutch does NOT engage in the “Reverse” position.

Electric clutch does NOT engage when switch is moved to “Forward.” Horn is silent and alert lights are off.

Electric clutch does NOT engage when switch is moved to “Forward.” Horn sounds and one or more alert lights are on.

908156/CP0205

CAUSE

REMEDY

Material is being pulled down between the lower front and rear feed rolls.

Remove burrs from the rolls. If cutting straw, reduce the ground travel speed.

Feed roll interference with the attachment.

Check the throat sheets clearance. If necessary, lower the maximum “up” position of the lift rollers.

Harvester wheel spindles are positioning the unit too high for the hay attachment, when installed.

Adjust the spindles to lower the Harvester.

Feed rolls are running at maximum capacity.

Reduce the ground travel speed and/or increase the length-of-cut.

Upper rear feed roll is packed with material.

Remove or otherwise clean out the material between the roller flutes.

Slugs are entering the feed rolls.

Force the slug through by operating back and forth between the “Forward” and “Reverse” operation of the shifter transmission control switch.

A plug or wire is loose on reverse solenoid or transmission switch.

Check wiring and plug connections; repair as necessary.

The reverse switch may have to be activated after a pause.

Check for proper switch operation. If still NOT working, contact your Gehl dealer.

A plug or wire is loose or corroded on transmission switch.

Check wiring and plug connections; repair as necessary.

Transmission switch is misadjusted or otherwise malfunctioning.

Contact your Gehl dealer.

Power switch is “Off.”

Turn power switch “On.”

A fuse has blown.

Check wiring and replace fuse(s).

Low voltage at electric clutch.

Check voltage at clutch. Install battery power supply harness to increase voltage.

Clutch coil is open.

Have the total circuit checked out by your Gehl dealer.

Open contacts within the brush holder.

Have the total circuit checked out by your Gehl dealer.

Control box has not been reset.

Reset the control box.

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Chapter 8 - Troubleshooting

FEED ROLLS & ATTACHMENT CONTROLS (Cont.)

PROBLEM Electric clutch does NOT engage when switch is moved to “Forward.” Horn sounds and “Speed” light is on.

CAUSE

REMEDY

Tractor PTO is not running.

Tractor PTO speed must be above 400 RPM.

PTO speed dropped below 400 RPM.

Tractor PTO speed must be above 400 RPM.

Auger drive shear bolt has sheared.

Clean out auger and replace auger drive shear bolt.

Wiring to the torque sensor contacts is loose or disconnected.

Re-secure wire or check plug connections.

Torque sensor switch contacts are set farther than 0.060″ (1.5 mm) from face of sprocket.

Readjust the contact gap.

Sprocket or contact points are coated with a material which does NOT conduct electricity.

Clean the sprocket and contact points with a safety solvent.

The insulation on the torque sensor wires is damaged or broken.

Tape the damaged insulation and cover any bare wire(s).

Torque sensor switch contacts are set closer than 0.030″ (0.8 mm) from face of sprocket.

Readjust the contact gap.

Torque sensor sprocket is wobbling excessively.

Sprocket is loosely secured or otherwise deformed. Tighten the sprocket or replace it.

Switch contacts are touching the sprocket bolt lock strip.

Make sure that the torque sensor switch does NOT make contact with anything which is grounded to the machine.

The feed rolls and attachment are stopping Horn is stopping. sounding and “Speed” light is on.

PTO speed dropped below 400 RPM.

Tractor PTO speed must be above 400 RPM.

Auger drive shear bolt has sheared.

Clean out auger and replace auger drive shear bolt.

Feedrolls will run and “Head” or “Rolls” alert light is on, but dim.

Wet foreign material is on torque sensor switches.

Clean torque sensor switches.

The torque sensor does NOT open the electric clutch but instead ratchets when overloaded.

The feed rolls and attachment are stopping under a very light load right after they start to operate.

FIELD OPERATION PROBLEM

CAUSE

High horsepower required.

Knives are NOT sharp.

Printed in U.S.A.

REMEDY Sharpen the knives.

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Chapter 8 - Troubleshooting

FIELD OPERATION (Cont.)

PROBLEM High horsepower required. (Cont.)

Harvester is sidetracking.

Row crop stubble is too long.

CAUSE

REMEDY

Shear bar is worn excessively.

Rotate shear bar to the second sharp edge or replace the shear bar. Then resharpen knives.

Shear bar is NOT set up to knives.

Correctly adjust shear bar to knives.

Blower is gummed up.

Remove the gum and dirt by either scraping it out or by running very wet forage or freshly cut crop through it or obtain, install and use an accessory water applicator kit.

Length-of-cut is too short for the power available.

Increase the length-of-cut.

Crop Processor rolls set too close together.

Use largest gap between rolls that still cracks the kernels.

Wagon hitch plate is positioned too far to the right.

Move the hitch plate to the left.

Row crop attachment shoes are dragging or plowing.

Raise the downstop position on the Harvester lift to keep shoes off the ground.

Tires are sinking into the soil.

Obtain and install flotation tire axles.

Tires are sliding sideways with single wheel axles.

Obtain and use tandem axles.

Harvester is being operated with the tongue too far to the left.

Move the tongue closer to the row.

Harvester and/or wagon tires are running on top of the row.

Reposition the tires and wagon hitch plate to move tires between rows.

Tires are running on the rows.

Reposition the tires.

Harvester downstop position is set too high.

Adjust the downstop position.

Harvester frame is set too high.

Lower the frame by moving the wheel spindles up.

KNIFE SHARPENER PROBLEM Knife width uneven.

908156/CP0205

CAUSE

REMEDY

Sharpener is grinding more on one side of knife than other.

Level sharpener carriage to cylinder.

Knives not set to adjustment rod properly.

Readjust knives.

Uneven stone travel speed.

Pull stone across cylinder at even speed.

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Chapter 8 - Troubleshooting

KNIFE SHARPENER (Cont.)

PROBLEM

CAUSE

Knife width uneven.

(Cont.)

Clearance on rear rail not properly set.

Set slide block to attain 0.010″ (0.25 mm) clearance.

Stone breaks.

Stone not held tight in sharpener.

Install stone properly.

Advance rate of stone too high.

Reduce advance rate.

Improper cylinder RPM.

Operate tractor PTO at or above 900 RPM.

Ratchet pawl not properly positioned.

Adjust pawl.

Adjusting screw threads rusty or damaged.

Repair or replace threaded components.

Rotating torque of adjusting screw too high.

Remove shims as necessary to attain a rotating torque range of 50-120 lb-in (5.7-14 Nm).

Sharpener carriage not traveling far enough.

Clear obstructions on rails or right-side mounting brackets.

Rotating torque of adjusting screw too low.

Add shims as necessary to attain a rotating torque range of 50-120 lb-in (5.7-14 Nm).

Sharpener stone does not advance.

Sharpener stone advances too easily.

REMEDY

LIFT SYSTEM PROBLEM Attachment lift height is NOT correct.

CAUSE

REMEDY

Attachment is raising too high or dropping too low.

Adjust the the lift height cam.

Row attachment lowers too far.

Adjust the downstop properly.

Attachment will NOT lower.

Check for transport pin interference. Too much tension exists on lift spring.

METAL STOP

NOTE:

The speed monitor MUST be disconnected to do all metal stop system tests.

PROBLEM Nothing happens when Harvester control box switches for the feed rolls are moved.

Printed in U.S.A.

CAUSE

REMEDY

Power switch is “OFF.”

Turn power switch “ON.”

A fuse has blown.

The power wire MUST be connected to the “POS” and the black wire MUST be connected to the “NEG” battery connections. The tractor MUST have a negative ground system. Check all plugs and replace fuses or contact your Gehl dealer for additional help.

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Chapter 8 - Troubleshooting

METAL STOP (Cont.)

NOTE:

The speed monitor MUST be disconnected to do all metal stop system tests.

PROBLEM With PTO off, horn sounds and “Metal” light comes on when switch is moved to “Forward”.

908156/CP0205

CAUSE

REMEDY

Metal stop system is NOT on.

Reset system by shifting feed rolls into reverse. “Metal” light will stay off when system is reset.

Stop pawl is stuck in ratchet wheel.

Engage PTO with tractor running at idle.

Reset system by shifting feed rolls into reverse until rolls move. “Metal” light will stay off when system is reset.

Fuse is blown (on early models).

Check fuse in amplifier box. Replace with a 1-Ampere type AGC fuse only.

DO NOT use slow-blow type fuses.

Stop pawl can NOT travel freely on pivot.

Disconnect spring and let it hang from pawl. Pawl should move easily with the touch of a finger. If it does NOT, clean pivot shaft and pawl bore. Pack pawl bore with lithium grease. Coat pivot shaft with lithium grease. Reassemble and check for freedom of movement.

Low voltage at the pawl solenoid.

Manually hold the stop pawl away from the ratchet wheel. Shift into reverse to reset. If the “Metal” light stays off, and everything else works, the voltage is too low for the pawl solenoid to retract. The voltage across the pawl solenoid terminals on the Harvester MUST be NO less than 7.5 Volts. A lower voltage could be caused by one of the following:

84

1.

Low battery voltage.

2.

The power cable is connected through the tractor wiring harness rather than directly to the battery. Install battery power supply harness to increase voltage.

3.

Corrosion in any of the plugs between the battery and the pawl solenoid.

Contact your Gehl dealer for a complete system checkout.

Printed in U.S.A.

Chapter 8 - Troubleshooting

METAL STOP (Cont.)

NOTE:

The speed monitor MUST be disconnected to do all metal stop system tests.

PROBLEM With PTO off, horn sounds and “Metal” light comes on when switch is moved to “Forward”.

(Cont.)

CAUSE

REMEDY

Shorted pull coil in pawl solenoid.

Disconnect wire #19 from solenoid. Shift into reverse. If the “Metal” light stays off, everything else works except pawl solenoid. If none of the preceding steps correct the problem, contact your local Gehl dealer.

Declutch circuit is grounded inside the metal detector module (amplifier box on early models).

Disconnect 12 pin plug from metal detector module (amplifier box on early models). Move feed roll switch to “Forward”. If control box, horn, and “Metal” light stay off, the problem is in the metal detector module (amplifier box on early models). Contact dealer for complete system checkout.

With PTO engaged, horn sounds and “Rolls” light comes on when switch is moved to “Forward.” Stop pawl solenoid is not retracted.

Open wire to pawl solenoid.

Check for corroded or loose connections at pawl solenoid.

Metal detector does NOT reset. “Metal” light is still on after releasing reverse switch.

Foreign material and/or water on terminals on right side of amplifier box (on early models).

Thoroughly clean and dry terminals.

Make sure terminal cover is installed.

Metal is NOT being detected during testing (after metal stop system is turned on).

Test object does NOT contain iron.

Use steel or iron test object.

Test object is being moved too slowly.

Move the test object past the top of the lower front feed roll rapidly. Move object in the same direction that the crop moves (NOT sideways).

Broken wire in detector shielded cable or faulty detector.

Inspect cable for breaks. Repair cable.

Check resistance of magnets. 1085 should be about 1000 to 1220 ohms.

1285 should be about 1250 to 1520 ohms. If system still does NOT operate, contact your Gehl dealer for complete system checkout procedures.

Feed roll switch is NOT in “Forward” position.

Move feed roll switch to “Forward” position to do this test. Horn does NOT operate in “Neutral” or “Reverse.”

Horn does NOT come on during testing. Stop pawl moves and “Metal” light comes on.

Printed in U.S.A.

85

908156/CP0205

Chapter 8 - Troubleshooting

METAL STOP (Cont.)

NOTE:

The speed monitor MUST be disconnected to do all metal stop system tests.

PROBLEM Metal stop system false alarms when Harvester is NOT running.

CAUSE

REMEDY

Power or ground wire momentarily opens.

Reset system. Wiggle wire and plugs to find a loose connection in the wire between control box in tractor and metal detector module (amplifier box on early models) on Harvester. Repair the wire or plug connections.

Two-way radio interference.

System may be tripped by a transmitting radio depending on the distance and strength of the signal.

Loose or incorrect connection of shielded cable to amplifier box (on early models).

Check connections marked “Black” and “Clear” at the right end of the amplifier box. The cable should be on the correct screws and be tightly secured.

Open cable to detector.

Inspect cable for breaks. Repair cable.

Water in amplifier box (on early models).

Replace amplifier box.

Metal stop system false alarms when Harvester is running without crop in it.

Steel foreign object wrapped around or wedged into feed rolls.

Inspect feed rolls and remove steel foreign object. Check everything listed with problem “Metal stop system false alarms with Harvester NOT running”.

Metal stop system false alarms when Harvester is running with or without crop in it.

Metal filings on feed rolls from sharpening knives.

Wash filings off feed rolls with water.

Loose wire on stop pawl solenoid.

Check wires and tighten screws at stop pawl solenoid.

Loose brush holder on electric clutch.

Check inner half to see if it is loose at end of clutch shaft. Carefully, re-tighten against end of clutch shaft. Check outer brush holder housing to see if it is loose on its bearing. If loose, replace brush holder.

The metal stop system is receiving false signals.

To determine if metal stop is receiving false signals, proceed as follows:

908156/CP0205

86

1.

Disconnect the 12 pin plug from the metal detector module (amplifier box on early models).

2.

Disable the stop pawl by connecting the pawl spring to the rear. If problem NO longer exists, then problem is in the metal stop system, which MUST be handled by your Gehl dealer.

Printed in U.S.A.

Chapter 8 - Troubleshooting

METAL STOP (Cont.)

NOTE:

The speed monitor MUST be disconnected to do all metal stop system tests.

PROBLEM

CAUSE

REMEDY

False alarms caused by rear feed rolls.

Incorrect upper rear or lower rear feed rolls.

The demagnetized upper rear and lower rear (smooth) feed rolls have a letter “D” stamped on both ends of their shafts. If there is NO letter “D” on the ends of the shaft, replace the feed roll(s). NOTE: This marking does NOT appear on the upper front or lower front feed rolls.

False alarms caused by lower front feed roll.

Worn or loose components in lower front feed roll.

Make sure that the Harvester is stopped and the tractor engine is off. Disconnect the chain that drives the lower front feed roll. Reset the system. Spin the lower front feed roll. It should turn freely without any noise. If the system trips, contact your Gehl dealer for repair on the lower front feed roll.

Bent drive shaft or roll at lower front feed roll.

Visible flexing of the feed roll side sheets while the feed rolls are running indicates excessive shaft runout on the lower front feed roll. Contact your Gehl dealer for checking the lower front feed roll.

Incorrect repair welds on lower front or upper front feed rolls.

Almost all welding electrodes (including many stainless steel electrodes) contain too much iron. Welds that contain iron will trip the detector. Repair welds should be done by a qualified welder under dealer direction.

Badly damaged/deformed feed roll.

Replace feed roll.

Metal filings or loose hardware on top of detector magnet inside lower front feed roll.

Contact your Gehl dealer for checking inside the lower front feed roll.

Printed in U.S.A.

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908156/CP0205

Chapter 8 - Troubleshooting

PTO DRIVE PROBLEM

CAUSE

Main drive shear bolts are failing.

Tractor PTO is being engaged at too fast an engine speed.

Engage the PTO at a slower engine speed.

Shear bolts are too loose.

Tightly secure with lock nuts.

Incorrect shear bolts.

Replace with correct shear bolts.

Transmission shaft is bent.

Straighten the shaft to within 0.015″ (0.38 mm) or replace shaft.

Telescoping drive spline, attaching to tractor PTO shaft, is worn.

Replace the splined yoke.

Entire driveline timing is out of phase.

Correct timing so that 1st, 4th & 6th yokes are in phase.

Tubular driveline is bent.

Tubular driveline MUST be straight or it must be replaced. See your Gehl dealer for assistance.

Tractor drawbar hitch pin hole NOT correct distance from end of PTO.

Correctly adjust tractor drawbar and install drawbar extension if necessary.

Tractor drawbar is NOT correctly centered.

Move drawbar in line with PTO shaft.

Tractor drawbar free to swing from side to side.

Fasten drawbar to keep side-to-side movement to an absolute minimum.

Undersized hitch pin.

Use 1-1/4″ diameter hitch pin, supplied.

Bent pedestal (front bearing stand).

Replace pedestal. BE SURE that the tractor three-point hitch arms do NOT come in contact with PTO pedestal.

Joint bearings are worn excessively.

Replace the cross and bearing.

Main drive shaft vibrating excessively.

Universal joint is noisy.

REMEDY

AUGER PROBLEM Auger is plugged with forage.

908156/CP0205

CAUSE

REMEDY

Blower is plugged.

Clean out blower and auger.

Auger is gummed with crop material.

Remove gum by scraping it out or by running very wet forage or freshly cut crop through Harvester.

88

Printed in U.S.A.

Chapter 8 - Troubleshooting

CROP PROCESSOR PROBLEM High horsepower required.

Crop particles too small.

Crop particles too large.

Belts slip when engaging tractor PTO.

Processor rolls are getting chipped teeth or teeth are rounding quickly.

Printed in U.S.A.

CAUSE

REMEDY

Rolls set too close together.

Open rolls as far as possible and still process the corn kernels.

Length-of-cut is too short.

Use longest length-of-cut that produces desired particle size.

Rolls set too close together.

Open rolls as far as possible and still process the corn kernels.

Length-of-cut is too short.

Use longest length-of-cut that produces desired particle size.

Rolls set too far apart.

Move rolls closer together.

Length-of-cut too long.

Use shorter length-of-cut.

Belt tension not applied.

Make sure belt idler spring is properly adjusted. Adjust spring to its correct length.

Spring is not correctly set due to belt wear (including break-in).

Adjust spring to its correct length.

Forage pinched between rolls.

Clean out forage. It only takes a very small amount of forage to prevent the rolls from starting. ALWAYS let Harvester completely clean out before stopping PTO.

Forage frozen to processor rolls and housing.

Thaw out processor rolls. Completely clean out forage from processor before parking machine in freezing weather.

Operating with row crop too close to ground, picking up soil and stones.

Lift row crop higher from ground and use downstop to maintain this height.

Harvesting hay.

Remove Crop Processor to harvest hay.

Running an iron object through rolls when metal detector is disconnected.

Have metal detector repaired and operating.

Rolls touching each other.

Adjust roll stops to attain minimum roll clearance of 0.020″ (0.5 mm).

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CHAPTER 9 OPTIONAL FEATURES & ACCESSORIES TRIPOD

Accessories are shipped with separate instructions to install. Refer to your Gehl “Farm Equipment Price List” for stock numbers and ordering information.

A tripod kit is available when additional spout support is desired or needed.

TELESCOPING PTO DRIVES

VERTICAL EXTENSIONS

The Harvester can be ordered and obtained with either a 1-3/8″ or a 1-3/4″ telescoping PTO drive.

Vertical spout extensions are available in 6-inch (152 mm), 1-foot (305 mm) and 2-foot (610 mm) sizes. A maximum of 4 feet (1220 mm) of vertical extensions can be installed. A tripod kit is required when a total of more than 2 feet (610 mm) of vertical extensions is installed. The tripod will NOT accept 2-1/2 feet (762 mm) of vertical extensions.

QUICK-ATTACH DRAWBAR 4″ (102 mm) EXTENSION A quick-attach drawbar 4″ (102 mm) extension is available for tractors without an extendable drawbar to obtain the required 20 inch (508 mm) dimension from the end of the PTO shaft to the hitch pin.

HORIZONTAL EXTENSIONS

AXLES, WHEELS & TIRES

Horizontal spout extensions are available in 3-1/2 foot (1067 mm) and 5-1/2 foot (1677 mm) lengths. A tripod kit is required.

The Harvester can be obtained with several choices of axles, wheels and tires. The various choices are: 1.

2.

A water applicator system is available which will apply fluids into the blower or auger areas at various rates.

Reasons for applicator use are:

Single axle set with two 11L-14, 6-ply rating implement tires (NOT FOR USE WITH CROP PROCESSOR ATTACHMENT OR 1285).

3.

Single axle set with two 10.00-20, 12-ply rating recapped truck tires with ribbed implement tread.

4.

Single axle set with two 16.5L-16.1, 8-ply rating implement tires (NOT FOR USE ON 1285 WITH TWO ROW NARROW ROW CROP ATTACHMENT).

5.

WATER APPLICATOR

Single axle set with two 14 x 8.00 DC wheels (without tires) (NOT FOR USE WITH CROP PROCESSOR ATTACHMENT OR 1285).

To reduce gum build-up in the blower, auger and spout which will increase harvesting efficiency and reduce frictional heating.

•

To apply crop preservatives or biological inoculants to the chopped material.

The applicator system is pressurized by an electrical pump. It can be operated constantly, or be set to automatically come on and off with the feed roll transmission electric clutch. The tank is mounted on the tongue and holds 80 gallons (303 L).

Tandem axle set with four 11L-15, 8-ply rating implement tires (NOT FOR USE ON 1285 WITH TWO ROW NARROW ROW CROP ATTACHMENT).

SAFETY CHAIN

CROP PROCESSORS

NOTE:

If the Harvester is going to be transported on a public highway, a safety chain should be obtained and installed per details in the Transporting chapter.

A 1005 Crop Processor is available for the 1085 Harvester.

A 1205 Crop Processor is available for the 1285 Harvester.

A 30,000-pound rating safety chain kit is available to accommodate the potential weight of the Harvester and a forage box.

Both processors include a storage carriage.

908156/CP0205

•

90

Printed in U.S.A.

Chapter 9 - Optional Features & Accessories

EXTENDED CONTROL BOX WIRING HARNESS

of hoses and couplers. One or two kits can be installed on the Harvester.

An extended control box wiring harness is available for tractors with the cab forward of the rear axle. Installation information is provided in the Set-up & Assembly Manual.

LIFT SPRING A lift spring kit is available to provide additional flotation to the crop heads. It is recommended for use with the HA1240 Hay Attachment.

ADDITIONAL TRACTOR CONTROL BOX WIRING

SPOUT LINER The Harvester is designed with a replaceable wear liner for the spout. A replacement spout liner kit is available by part number 112182.

An additional tractor control box wiring kit is available for adapting the same control box to another tractor.

Installation information is provided in the Set-up & Assembly Manual.

BLOWER RIM SHEET LINER

SPOUT LIGHT

The Harvester is designed with a replaceable wear liner for the blower rim sheet. A replacement rim sheet liner kit is available by part number 155201.

A spout light kit is available. It mounts onto the side of the spout to illuminate the spout discharge and forage wagon interior.

MAIN DRIVE SHEAR BOLTS Replacement 5/16 x 2″, Grade 8 shear bolts and lock nuts are available by Gehl part number 153753. One package contains eight bolts and eight lock nuts.

CHAIN OILER A chain oiler kit is available to oil four chains, with four additional ports available.

FEED ROLL SHEAR BOLTS (1085)

OILER BRUSH

Replacement 1/4″ x 1-1/2″, Grade 8 shear bolts and lock nuts are available by Gehl part number 080079. One package contains eight bolts and eight lock nuts (NOT USED ON THE 1285).

An oiler brush kit includes one oiler brush with tubing to adapt to chain oiler ports. Up to four additional brushes can be added to the base chain oiler, for a maximum of eight brushes.

AUGER DRIVE SHEAR BOLTS

REMOTE HYDRAULIC OUTLET

Replacement 1/4 x 1″, Grade 5 shear bolts and lock nuts are available by Gehl part number 904400. One package contains eight bolts and eight lock nuts.

The remote hydraulic outlet kit provides hydraulic power to the rear of the Harvester. It includes one pair

Printed in U.S.A.

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908156/CP0205

CHAPTER 10 DECAL LOCATIONS GENERAL INFORMATION

Ref. Part No. No. 1 080739 2 080745

Decal locations information is provided to assist in the proper selection and application of new decals, in the event the original decals become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the kit. Refer to the appropriate illustrations for replacement locations.

3 4 5 6 7

To ensure proper selection for correct replacement decals, compare all of the various close-up location illustrations of the machine before starting to refinish the unit. Then circle each pictured decal, applicable to your machine, while checking off its part number in the listing. After verifying all the decals needed for replacement, set aside any unneeded decals for disposal.

NOTE:

Refer to the SAFETY Chapter of this manual for specific information on the safety decals in the decal kits.

NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new decal. To apply a solid-formed decal, remove the smaller portion of the decal backing paper and apply this part of the exposed adhesive backing to the clean surface while maintaining proper position and alignment. Slowly peel the other portion of the backing paper while applying hand pressure to smooth out the decal surface.

CAUTION

10 11

093373 093374

12

093378

13

093379

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

35 36 37 38

093381 093653 094912 094913 094951 122288 122433 143007 145216 145217 145218 145234 145316 145847 153799 154226 154281* 158060 154185 158168* 158390 158391 158664 158665 158749* 158778 163941 163957

39 40

163962 173972

32 33

ALWAYS follow safety precautions on decals.

Replace the decals if they are damaged, or if the unit is repainted. If repainting, BE SURE that all applicable decals are affixed to your unit.

34

PAINT NOTICE Use this list to order paint for refinishing: 906315 One Gal. AG Red 902872 One Qt. Light Grey 906316 6 (12 oz. Spray Cans) AG Red 902874 6 (12 oz. Spray Cans) Light Grey

41

* See 1005/1205 Crop Processor Manuals for Decal Locations

NOTE:

Order part number 126757 for a 10-ft. roll of replacement striping.

The decal kit number for the 1085 is 155734 and for the 1285 is 155737. The kits include the following: 908156/CP0205

8 9

091444 093020 093202 093209 093211 074490 093366 093367

Description & Quantity Fuse (Auto-Max Units, Early Models Only) Terminal (Auto-Max Units, Early Models Only) DANGER - Rotating Driveline Lubrication Symbol (9 Places) DANGER - Avoid Electrocution Place Edge Shearbar Removal & Replacement (1085) Shearbar Removal & Replacement (1285) IMPORTANT - Store Manual Here WARNING - Owner’s Responsibility & Read Manual WARNING - General Safety WARNING - Towing Implement Without Brakes DANGER - Rotating Components (2 Places) WARNING - Wear Goggles When Using Knife Sharpener WARNING - Use Drawbar Transport Lock WARNING - Rotating Driveline Colorbar 12″ (2 Places) GEHL (2 Places) Made in USA GEHL GEHL DANGER - Shield Missing Red Reflector Strip (3 Places) Amber Reflector (4 Places) Orange Marker (3 Places) SMV Marker Length Of Cut Chart Knife Sharpener Instructions 1000 RPM CAUTION - Hitchpin alignment Belt Routing (Not Shown) 1085 (2 Places) 1285 (2 Places) Roll Adjustment (Not Shown) Shearbar Adjustment (1085) Shearbar Adjustment (1285) Shearbolt Chart (1085) Shearbolt Chart (1285) Crop Processor (Not Shown) Lubrication WARNING - To Avoid Injury or Death Decal/Warn Hands Out (3 Places on harvester) (*1 Place on crop processor, not shown) DANGER - Keep Hands Out Auto-Max/Metal Stop (Auto-Max units) For early models use top portion of 173972 for Auto-Max and bottom portion for Metal Stop Metal Stop (Auto-Max units, Early Models Only). See note for 173972.

92

Printed in U.S.A.

Chapter 16 - Decal Locations

4

6

Cylinder Shaft Guard

12 READ

READ

Sharpener Cover Under Shield

TYPICAL BOTH SIDES

4

4 19 7

23

40 41 16 31 23

5 11 4 READ

38

14 23 17 Both Sides

26

READ

34

15 READ

READREAD

28

READ READ READ

Shield Door Open

READ

3

Printed in U.S.A.

READ

29

READ

21

Beneath Shield

9

93

10

37

908156/CP0205

Chapter 16 - Decal Locations

NOTE:

20 21 22 23 24 25 26 27 28 29 30 31

The decal list has been duplicated for your convenience when selecting decals from the following page.

The decal kit number for the 1085 is 155734 and for the 1285 is 155737. The kits include the following:

Ref. Part No. No. 1 080739 2

080745

3 4 5 6 7 8 9

091444 093020 093202 093209 093211 074490 093366 093367

10 11

093373 093374

12

093378

13

093379

14 15 16 17 18 19

093381 093653 094912 094913 094951 122288

908156/CP0205

Description & Quantity Fuse (Auto-Max Units, Early Models Only) Terminal (Auto-Max Units, Early Models Only) DANGER - Rotating Driveline Lubrication Symbol (9 Places) DANGER - Avoid Electrocution Place Edge Shearbar Removal & Replacement (1085) Shearbar Removal & Replacement (1285) IMPORTANT - Store Manual Here WARNING - Owner’s Responsibility & Read Manual WARNING - General Safety WARNING - Towing Implement Without Brakes DANGER - Rotating Components (2 Places) WARNING - Wear Goggles When Using Knife Sharpener WARNING - Use Drawbar Transport Lock WARNING - Rotating Driveline Colorbar 12″ (2 Places) GEHL (2 Places) Made in USA GEHL

35 36 37 38

122433 143007 145216 145217 145218 145234 145316 145847 153799 154226 154281* 158060 154185 158168* 158390 158391 158664 158665 158749* 158778 163941 163957

39 40

163962 173972

32 33 34

41

GEHL DANGER - Shield Missing Red Reflector Strip (3 Places) Amber Reflector (4 Places) Orange Marker (3 Places) SMV Marker Length Of Cut Chart Knife Sharpener Instructions 1000 RPM CAUTION - Hitchpin alignment Belt Routing (Not Shown) 1085 (2 Places) 1285 (2 Places) Roll Adjustment (Not Shown) Shearbar Adjustment (1085) Shearbar Adjustment (1285) Shearbolt Chart (1085) Shearbolt Chart (1285) Crop Processor (Not Shown) Lubrication WARNING - To Avoid Injury or Death Decal/Warn Hands Out (3 Places on harvester) (*1 Place on crop processor, not shown) DANGER - Keep Hands Out Auto-Max/Metal Stop (Auto-Max units) For early models use top portion of 173972 for Auto-Max and bottom portion for Metal Stop Metal Stop (Auto-Max units, Early Models Only). See note for 173972.

* See 1005/1205 Crop Processor Manuals for Decal Locations

NOTE:

Order part number 126757 for a 10-ft. roll of replacement striping.

94

Printed in U.S.A.

Chapter 16 - Decal Locations

READ

4 36

Under Cover Underside of Sharpener Cover 25

20

22

24 22

24

22

4

39

Rear View 12

READ READ

Under Cover

Top of Auger Cover 38 4

READ

8 READ

Rear View of Blower

Printed in U.S.A.

95

908156/CP0205

Chapter 16 - Decal Locations

NOTE:

20 21 22 23 24 25 26 27 28 29 30 31

The decal list has been duplicated for your convenience when selecting decals from the following page.

The decal kit number for the 1085 is 155734 and for the 1285 is 155737. The kits include the following:

Ref. Part No. No. 1 080739 2

080745

3 4 5 6 7 8 9

091444 093020 093202 093209 093211 074490 093366 093367

10 11

093373 093374

12

093378

13

093379

14 15 16 17 18 19

093381 093653 094912 094913 094951 122288

908156/CP0205

Description & Quantity Fuse (Auto-Max Units, Early Models Only) Terminal (Auto-Max Units, Early Models Only) DANGER - Rotating Driveline Lubrication Symbol (9 Places) DANGER - Avoid Electrocution Place Edge Shearbar Removal & Replacement (1085) Shearbar Removal & Replacement (1285) IMPORTANT - Store Manual Here WARNING - Owner’s Responsibility & Read Manual WARNING - General Safety WARNING - Towing Implement Without Brakes DANGER - Rotating Components (2 Places) WARNING - Wear Goggles When Using Knife Sharpener WARNING - Use Drawbar Transport Lock WARNING - Rotating Driveline Colorbar 12″ (2 Places) GEHL (2 Places) Made in USA GEHL

35 36 37 38

122433 143007 145216 145217 145218 145234 145316 145847 153799 154226 154281* 158060 154185 158168* 158390 158391 158664 158665 158749* 158778 163941 163957

39 40

163962 173972

32 33 34

41

GEHL DANGER - Shield Missing Red Reflector Strip (3 Places) Amber Reflector (4 Places) Orange Marker (3 Places) SMV Marker Length Of Cut Chart Knife Sharpener Instructions 1000 RPM CAUTION - Hitchpin alignment Belt Routing (Not Shown) 1085 (2 Places) 1285 (2 Places) Roll Adjustment (Not Shown) Shearbar Adjustment (1085) Shearbar Adjustment (1285) Shearbolt Chart (1085) Shearbolt Chart (1285) Crop Processor (Not Shown) Lubrication WARNING - To Avoid Injury or Death Decal/Warn Hands Out (3 Places on harvester) (*1 Place on crop processor, not shown) DANGER - Keep Hands Out Auto-Max/Metal Stop (Auto-Max units) For early models use top portion of 173972 for Auto-Max and bottom portion for Metal Stop Metal Stop (Auto-Max units, Early Models Only). See note for 173972.

* See 1005/1205 Crop Processor Manuals for Decal Locations

NOTE:

Order part number 126757 for a 10-ft. roll of replacement striping.

96

Printed in U.S.A.

Chapter 16 - Decal Locations

16

13

2

1 Read

Yellow End 31

Read

33 READ

23

READ

READ

27

Right Side 38

READ

4

READ

Right Side Cover Removed

Printed in U.S.A.

18

97

908156/CP0205

CHAPTER 11: MAINTENANCE LOG SERVICE EVERY 10 HOURS COMPONENT and SERVICE REQUIRED

PROCEDURE and/or SECTION/CHAPTER TOPIC REFERENCE (Check Page No. in Index)

Check rotating telescoping PTO drive guard.

Lubricate with oil and test for freedom of rotation.

Check rear feed roll scraper.

Adjust clearance.

Check all drive chain tensions. Oil chains every 6 to 8 hours with foaming aerosol lubricant.

See Drive Chains topic in the Adjustments and Lubrication sections of the Care & Maintenance chapter.

Lubricate appropriate grease fittings.

Refer to the Lubrication section of the Care & Maintenance chapter.

Date of Service

SERVICE EVERY 50 HOURS Check knives and knife bolt torques.

See Knives topic in the Adjustments section of the Care & Maintenance chapter.

Check blower belt tension.

See Drive Belt topic in the Service section of the Care & Maintenance chapter.

Check Crop Processor drive belt tension.

See Drive Belt Tensioner topic in the Adjustments section of the Care & Maintenance chapter.

Check tire pressure and wheel nut torque.

Inflate tires and torque wheel lugs per details in the Service section of the Care & Maintenance chapter.

Lubricate appropriate grease fittings.

Refer to the Lubrication section of the Care & Maintenance chapter.

Date of Service

908156/CP0205

98

Printed in U.S.A.

Chapter 17 - Maintenance Log

SERVICE EVERY 100 HOURS COMPONENT and SERVICE REQUIRED

PROCEDURE and/or CHAPTER TOPIC REFERENCE (Check Page No. in Index)

Inspect roller chains and drive sprockets.

Replace if stiff, broken or worn excessively.

Check and readjust stem guide positions.

Refer to Stem Guide topic in the Adjustments section of the Care & Maintenance chapter.

Inspect blower rim sheet liner.

See Blower topic in the Service section of the Care & Maintenance chapter.

Check and readjust blower fan paddles.

See Blower topic in the Service section of the Care & Maintenance chapter.

Lubricate appropriate grease fittings.

Refer to the Lubrication section of the Care & Maintenance chapter.

Date of Service

SERVICE EVERY 200 HOURS Check quality and level of transmission oil.

Refer to the Lubrication section of the Care & Maintenance chapter for details.

Inspect all drive joints and bearings.

Replace if worn excessively.

Inspect spout wear liner.

Replace if worn excessively.

Lubricate appropriate grease fittings and repack wheel bearings.

Refer to the Lubrication section of the Care & Maintenance chapter.

Date of Service

Printed in U.S.A.

99

908156/CP0205

Index A

D Decal locations, 92–97 Drive chains adjustment attachment driver, 47 auger drive chain, 48 length -of-cut, 47 lower feed rolls, 48 shifter transmission, 48 upper feed rolls, 48 Drive chains lubrication, 58

Adjustments, 40–57 Alert light operation, 24 Ammonia silage additive use, 59 Attachment positioning adjustments, 40 axles & wheels, 40 downstop, 40 lift height, 40 lift spring, 41 Auger, troubleshooting, 88 Auger drive chain service, 69

E Electric controls alert light operation, 24 cap switch operation, 23 feed roll switch operation, 23 horn operation, 25 identification, 23 instruction reference card, 25 mount location, 25 operation, 23 power switch operation, 23 spout switch operation, 23 Electric controls service, 70 Electrical schematics, 72 Emergency shutdown, 25 Entering the crop, 26

B Bevel gearbox service, 62 Blower, troubleshooting, 77 Blower adjustments, 41 belt idler, 41 drive belt, 41 fan paddles, 42 Blower service drive & driven sheaves, 62 drive belt, 62

C Cap switch operation, 23 Care & maintenance, 40–57 Chain & sprocket service, 62 Chain drives, troubleshooting, 79 Chain length table, 22 Chain oiler Installation, 37 operation, 59 Checklists, delivery, 5–7 Control box alert lights, 24 cap switch, 23 feed roll switch, 23 horn, 25 instruction reference card, 25 mount location, 25 power switch, 23 spout switch, 23 Crop processor, troubleshooting, 89 Crop processor roller mill, 22 adjustments, 48 Cutting cylinder, troubleshooting, 78 Cutting mechanism service knife replacement, 65 shear bar, 63 908156/CP0205

F Feed roll spring tension adjustment, 48 Feed roll switch operation, 23 Feed rolls & attachment controls, troubleshooting, 79 Field operation, troubleshooting, 81

G Grease fitting locations, 60 Greasing, 60 Guards & shields, 17

H Harvester operation crop processor roller mill, 22 general information, 22 Harvester -attachment alignment, 21 Hitchjack, 37 Horn operation, 25 How harvester functions, 17 Hydraulic circuit requirements, 59 Hydraulic schematic, 75

I Identification numbers, 3

100

Printed in U.S.A.

Implement driveline guards, 17 Inflation pressures. See Tire pressures Introduction, 2

J Jack. See Hitchjack

K Knife sharpener, troubleshooting, 82 Knife sharpening cylinder knife sharpening, 67 general information, 66 preparing sharpener, 66 ratchet pawl, 68 ratchet wheel tension, 68 sharpener carriage rails, 68 stone replacement, 67 Knives adjustment, 49

L Leaving the crop, 26 Length -of-cut adjustment, 50 Lift system, troubleshooting, 83 Lift system lock for transport, 35 Lubrication, 58–61

M Maintenance, 98–99 Mandatory safety shutdown procedure, 8 Metal detector bypassing the metal detector system, 33 daily system inspections, 34 general information, 32 introductory information, 31 metal detection, 33 system start-up, 32 system test, 34 Metal stop, troubleshooting, 83 Metal stop solenoid & stop pawl adjustment, 51 Miscellaneous guards, 18 Model/serial number record, 5, 7

O Oiling, 59 Operating optional equipment, water applicator, 22 Operation, 17–39 Optional features & accessories, 90 additional tractor control box wiring kit, 91 axles, wheels & tires, 90 blower rim sheet liner, 91 chain oiler kit, 91 CP1005 Crop Processor, 90 CP1205 Crop Processor, 90 extended control box wiring harness, 91 Printed in U.S.A.

horizontal extensions, 90 lift spring kit, 91 oiler brush kit, 91 Quick -attach drawbar 4 inch (104 mm) extension, 90 remote hydraulic outlet kit, 91 safety chain, 90 shear bolts auger drive, 91 feed roll, 91 main drive, 91 spout light kit, 91 spout liner, 91 telescoping PTO drives, 90 tripod kit, 90 vertical extensions, 90 water applicator kit, 90 Overload protection auger drive, 28 electrical system, 30 feed roll and attachment drive (1085 auto-max model), 29 feed roll and attachment drive (1085 shear bolt model), 29 feed roll and attachment drive (1285), 29 main driveline, 28

P Paint notice, 92 Power requirements, 3 Power switch operation, 23 Preparing harvester for field operation, 18–22 Preparing harvester for operation, 20 Protection of unpainted surfaces, 76 PTO drive, troubleshooting, 88

Q Quick attach drawbar extension, installation, 20

R Reburnishing electric clutch, 71 Remote grease lines, 69 Rim sheet wear liner inspection, 62 Roller mill adjustments drive belt tension, 49 minimum roll spacing, 49 Roll alignment, 49 Roll spacing, 48

S Safety, 8–16 Safety chain, 90 Safety chain & transport lighting, 18 Safety chain & transport lighting for transport, 35 Safety equipment, 17–18 Scraper adjustment, 51

101

908156/CP0205

Service, 62–75 Shear bar position adjustment, 44 Shear bolts auger drive, 91 feed roll, 91 main drive, 91 Shearbar, 59 Shifter transmission service, 69 SMV emblem & reflector for transport, 36 Specifications, 3–4 Speed monitor service, 69 Spout, troubleshooting, 79 Spout adjustments, 45 Spout liner, 68 Spout motor drive chain, adjustments, 47 Spout switch operation, 23 Start -up, 25 Stem deflector adjustment, 52 Stopping harvester, 26 Storage, 76

Towing on highway, 36 Tractor hitch alignment, 19 Transmission lubrication, 58 Transport lighting, 18 Transport lighting connection, 20 Transporting, 35–39 Troubleshooting, 77–89 Typical harvesting cycle, 22–30 preparing crop, 22

T

Vertical driveline alignment, 20 Voltage checks, 70

U Unplugging auger, 27 blower, 26 crop processor, 27 cutting cylinder, 27 feed rolls (1085 shear bolt model), 28 feed rolls (auto-max models), 27 spout, 26

V

Table Of Contents, 1 Tire & wheel service, 70 Tire pressures, 70 Tires, wheels & axles adjustment single wheel axles, 52 tandem wheel axles, 52 Tongue position for transport, 35 Torque sensor contact points adjustment, 50

908156/CP0205

W Wagon hitch plate adjustment, 53 Warranty, 2 Water applicator (optional) operation, 22 Wiring diagrams harvester electrical schematic, 72, 73 transport lights, 74

102

Printed in U.S.A.

NOTES

Printed in U.S.A.

103

908156/CP0205

908156/CP0205

104

Printed in U.S.A.

TORQUE SPECIFICATIONS NOTE: Use these torque values when tightening GEHL hardware (excluding: locknuts and self tapping, thread-forming and sheet metal screws) unless specified otherwise.

All torque values are in Lb-Ft except those marked with an * which are Lb-In (For metric torque value Nm, multiply Lb-Ft value by 1.355 or Lb-In value by 0.113)

Unified National Thread

Grade 2

Grade 5

Dry

Lubed

Dry

Lubed

Dry

Lubed

8-32 8-36

19 19* 20*

14 14* 15*

30 30* 31*

22 22* 23*

41 41* 43*

31* 31 32*

10-24 10-32

27 27* 31*

21 21* 23*

43 43* 49*

32 32* 36*

60 60* 68*

45 45* 51*

1/4-20 1/4-28

66 66* 76*

50 50* 56*

9 10

75 75* 86*

12 14

9 10

5/16-18 5/16-24

11 12

9

17 19

13 14

25

18 20

3/8-16 3/8-24

20 23

15 17

30 35

23 25

45 50

35

7/16-14 7/16-20

32 36

24 27

50 55

35 40

70 80

55 60

1/2-13 1/2-20

50 55

35 40

75 90

55 65

110 120

80 90

9/16-12 9/16-18

70 80

55 60

110 120

80 90

150 170

110 130

5/8-11 5/8-18

100 110

75 85

150 180

110 130

220 240

170 180

3/4-10 3/4-16

175 200

130 150

260 300

200 220

380 420

280 320

7/8-9 7/8-14

170 180

125 140

430 470

320 360

600 660

460 500

1-8 1-14

250 270

190 210

640 710

480 530

900 1000

680 740

Metric Course Thread

Grade 8.8

8.8

Grade 10.9

Grade 8

10.9

Grade 12.9

12.9

Dry

Lubed

Dry

Lubed

Dry

Lubed

M6-1

8

6

11

8

13.5

10

M8-1.25

19

14

27

20

32.5

24

M10-1.5

37.5

28

53

39

64

47

M12-1.75

65

48

91.5

67.5

111.5

82

M14-2

103.5

76.5

145.5

108

176.5

131

M16-2

158.5

117.5

223.5

165.5

271

200

WARNING THIS OPERATOR’S MANUAL IS PROVIDED FOR OPERATOR USE DO NOT REMOVE FROM THIS MACHINE

THANK YOU DO NOT START, OPERATE OR WORK ON THIS MACHINE UNTIL YOU HAVE CAREFULLY READ AND THOROUGHLY UNDERSTAND THE CONTENTS OF THE OPERATOR’S MANUAL. FAILURE TO FOLLOW SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS, POOR OPERATION, AND COSTLY BREAKDOWN. IF YOU HAVE ANY QUESTIONS ON PROPER OPERATION, ADJUSTMENT OR MAINTENANCE OF THIS MACHINE, CONTACT YOUR DEALER OR THE SERVICE DEPARTMENT OF GEHL COMPANY BEFORE STARTING OR CONTINUING OPERATION.



Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. www.gehl.com

908156/CP0205

2005 GEHL Company. All rights reserved.

Printed in U.S.A.