Gehl Forage Harvesters CB1060 (SN 8501 and Up), CB1065 Operators Manual 907051A - PDF DOWNLOAD

Form No.

1060/1065

907051

(1060 After SN8500 and All 1065’s)



Forage Harvesters

OPERATOR’S MANUAL

GEHL AGRICULTURE NEW AGRICULTURAL EQUIPMENT WARRANTY GEHL AGRICULTURE DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl agricultural equipment, skid loaders, Gehlmax articulated loaders and attachments, to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the Warranty Start Date, except as set forth below: The following parts are warranted for a period of ten (10) years from the Warranty Start Date for replacement only, labor and freight excluded, unless defect occurs during initial twelve (12) month warranty period: MANURE SPREADER sides on box spreaders or tank on Scavengerr spreaders against perforation (rust through) and Clad-Tuffr floor against delamination.

BU970 SELF-UNLOADING FORAGE BOX metal sides, end panels and roof against perforation (rust through) and platform against delamination.

GEHL AGRICULTURE WARRANTY SERVICE 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.

1.

GEHL WARRANTY SERVICE DOES NOT INCLUDE: 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; 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 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

CHAPTER 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

CHAPTER 3 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

CHAPTER 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

CHAPTER 5 Controls & Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

CHAPTER 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

CHAPTER 7 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

CHAPTER 8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

CHAPTER 9 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

CHAPTER 10 Preparing for Field Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

CHAPTER 11 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

CHAPTER 12 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85

CHAPTER 13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86

CHAPTER 14 Set-up & Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102

CHAPTER 15 Optional Features & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

121

CHAPTER 16 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

124

CHAPTER 17 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

128 1

CHAPTER 1 INTRODUCTION Thank you for purchasing this piece of Gehl equipment.

We are sure that your decision was strongly considered and that you are looking forward to many years of work from this machine.

We, as a Company, have invested a great deal of time and effort in developing our lines of equipment. The equipment you have purchased is built with a great deal of pride and designed to give you long life, efficient operation, durability and dependability.

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 references. A chart depicting standard hardware torques is located on the inside back cover.

A Manual Pocket is provided on the inside of the Toolbox Cover for storing the Operator’s Manual. After using the Manual, please return it to the Pocket and keep it with the unit at all times! Furthermore, if this machine is resold, Gehl Company recommends that this Manual be given to the new owner.

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

The Gehl dealer organization stands ready to provide you with any assistance you may require and carries genuine Gehl service parts. All parts should be obtained from or ordered through your Gehl Dealer. Give complete information about the part and include the model and serial numbers of your Harvester.

Numbers for this unit are stamped on a plate located on the right side of the Main Frame adjacent to the Cylinder Shaft Bearing.

2

MODEL NO.

106 (Fill In)

SERIAL NO. (Fill In)

COMPANY



WEST BEND, WI 53095 USA

Typical Model & Serial Number Plate

‘‘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’’.

Throughout this manual, information is provided which is set in italic type and introduced by the word NOTE. 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.

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.

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

to pinpoint characteristics which, if NOT properly followed, can create a safety hazard.

When you see this symbol in this manual or on the machine itself, you are reminded to BE ALERT! Your personal safety is involved!

CHAPTER 2 SPECIFICATIONS All Dimension are in Inches (Millimeters) Unless Otherwise Noted Model & Description . CB1060/1065 Forage Harvester Power requirement . . . . . . . . . Up to 200 PTO hp (149 kw) Tractor with 1–3/8 or 1–3/4 Diameter PTO Shaft operating at 1000 RPM Cutting Cylinder Characteristics:

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 (533) Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 (457) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM Quantity of Knives . . . . . . . . . . . . . . . . . . . . . Eight Length-of-Cut: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4″ Optional . . . . . . . . . . . . . . . . 3/16″, 5/16″ & 3/8″ Blower Characteristics:

Fan Diameter . . . . . . . . . . . . . . . . . . . . . . . . 36 (914) Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 750 RPM Quantity of Paddles . . . . . . . . . . . . . . . . . . . . . . Four Spinner Characteristics:

Fan Diameter . . . . . . . . . . . . . . . . . . . . . . . . 24 (609) Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 566 RPM Quantity of Paddles . . . . . . . . . . . . . . . . . . . . . . . Six Overall Dimensions:

Width (with Standard Single Wheel Axle Retracted) . . . . . . . . . . . . 116–3/4 (2965) Height (to top of Cap) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . 128 (3250) Available . . . . . . . . . . . . . . . . 116–164 (2946–4165) Length (to end of Cap) . . . . . . . . . . . 219–3/4 (5582) Throat Area . . . . . . . . . . . . . 120 sq. in (770 sq. cm) Typical Weight . . . . . . . 3950 lb (1793 kg) for Shear Bolt Unit or 4000 lb (1816 kg) for Torque Sensor Unit Standard Features:

Tungsten Carbide–faced Knives Tungsten Carbide–faced Reversible Cutterbar Single Station Cutterbar Adjustment

Feed Rolls & Attachment Engaged by an Electro– magnetic 12″ Diameter Clutch Driving a Solenoid–reversed Shifter Transmission with Sealed Roller Bearings Running in Oil Lower Feed Rolls & Spinner Protected by Shear Bolts Impact Pin-protected Main Drive 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 Attachment Lift System has Adjustable Lift Height and Down-Stop Adjustable Tongue Hitch with Four Operating and One Transport Position Hydraulically–powered Knife & Cutterbar Sharpener Overrunning Clutch on Main Drive Replaceable Blower Wear Liner Replaceable Spout Wear Liner 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 PTO Connection Optional (Factory-installed ONLY) Features:

Shear Bolt Model - Shear Bolt Protection on Upper Feed Rolls Torque Sensor Model - Automatic Disengagement of Feed Rolls and Attachment whenever the Feed Rolls are Overloaded, the Attachment is Overloaded, or the Blower Speed is Too Low Metal Detector Model - Automatic Disengagement of Feed Rolls and Attachment Whenever Ferrous Metal is Detected, the Feed Rolls are Overloaded, the Attachment is Overloaded, or the Blower Speed is Too Low

3

Optional Axle and Tire Selections:

Accessories:

Single Wheel Axle Set Options: (2) 14 x 8.00 D.C. Wheels (less Tires) or (2) 14 x 8.00 D.C. Wheels with Mounted 11L x 14 6–Ply Rated Implement Tires or (2) 15 x 10.00 D.C. Wheels (less Tires) or (2) 15 x 10.00 D.C. Wheels with Mounted 12.5L x 15 8–Ply Rated Implement Tires

Hydraulically-controlled Tongue with Pin-latched Transport Position Requiring a Second Hydraulic Output on Tractor Length–of–Cut Sprockets Long Cut Kit 1–ft or 2–ft Vertical Spout Extensions Kit for Relocating Cap Motor when Factory-installed 1–ft Vertical Spout Extension is Removed 3–1/2–ft or 5–1/2–ft Horizontal Spout Extension Kits Spout Tripod Kit (for use with any Extensions) Reversible Square–holed Screens in Sizes from 3/4″ through 4″ Wet Crop Deflector Offset Wagon Hitch Tunnel Switch Kit (for Water Tank Option on Shear Bolt Models) Wiring Harness for a Second Tractor Wiring Harness Extension Safety Tow Chain

Flotation Axle Set: (2) W11C x 16.1 Wheels with Mounted 16.5L x 16.1 8–Ply Rated Implement Tires Tandem Axle Set: (4) 15 x 8.00 D.C. Wheels with Mounted 27 x 9.50 x 15 6–Ply Rated Implement Tires

4

Remove Dealer’s File Copy at Perforation

CHAPTER 3 CHECKLISTS PRE-DELIVERY 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.

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

Dealership Name

Check that: Harvester has been assembled correctly according o Forage to instructions in the Set–up & Assembly chapter of this

Dealer Representative’s Name

manual.

Grease Fittings have been properly lubricated, Chains o All oiled and the Transmission and Gearbox have been filled

Date Checklist Filled-out

to the proper operating levels; see Lubrication chapter of this manual for specific details.

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 chapter. adjustments are made to comply with the settings givo All en in the Adjustments chapter of this manual.

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

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

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, Spout and Cap Cono The trol Mechanisms are operating smoothly and properly.

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 refo Attachment erence in the separate Operator’s Manual for the Attach-

Serial Number

DELIVERY 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.

Operator’s Manual, which is stored in a Comparto Give ment on the underside of the Toolbox Cover, to the Cus-

tomer and instruct Customer and all operators to be sure to read and completely understand its contents BEFORE operating the unit.

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

and review the Service chapter of this manual. o Explain Remind customer about Rim Sheet Take-up Nut torque. the Length–of–Cut topic in the Adjustments o Explain chapter. how to use the Knife Sharpener and the imporo Explain tance of sharp Knives and correct adjustment to Cutterbar. the importance of correct tractor hook–up and o Explain Drive Line alignment. with him the Preparing for Field Operation chapo Review ter.

Customer’s Signature

ment.

Lift system is correctly adjusted for the Attacho Harvester ment. o Operator’s Manual for the Attachment is provided.

Date Delivered (Dealer’s File Copy) 5

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

6

CHAPTER 3 CHECKLISTS PRE-DELIVERY 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.

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

Dealership Name

Check that: Harvester has been assembled correctly according o Forage to instructions in the Set–up & Assembly chapter of this

Dealer Representative’s Name

manual.

Grease Fittings have been properly lubricated, Chains o All oiled and the Transmission and Gearbox have been filled

Date Checklist Filled-out

to the proper operating levels; see Lubrication chapter of this manual for specific details.

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 chapter. adjustments are made to comply with the settings givo All en in the Adjustments chapter of this manual.

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

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

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, Spout and Cap Cono The trol Mechanisms are operating smoothly and properly.

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 refo Attachment erence in the separate Operator’s Manual for the Attach-

Serial Number

DELIVERY 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.

Operator’s Manual, which is stored in a Comparto Give ment on the underside of the Toolbox Cover, to the Customer and instruct Customer and all operators to be sure to read and completely understand its contents BEFORE operating the unit.

Customer on how to use the Index of this manual o Direct as a quick page number locating guide. and review with Customer the SAFETY chapter o Explain of this manual. and review with Customer the Controls & Safety o Explain Equipment chapter of this manual. that regular lubrication is required for continued o Explain proper operation and long life. Review with Customer the Lubrication chapter of this manual. and review the Service chapter of this manual. o Explain Remind customer about Rim Sheet Take-up Nut torque. the Length–of–Cut topic in the Adjustments o Explain chapter. how to use the Knife Sharpener and the imporo Explain tance of sharp Knives and correct adjustment to Cutterbar. the importance of correct tractor hook–up and o Explain Drive Line alignment. with him the Preparing for Field Operation chapo Review ter.

Customer’s Signature

ment.

Lift system is correctly adjusted for the Attacho Harvester ment. o Operator’s Manual for the Attachment is provided.

Date Delivered (Pages 5 and 6 have been removed at perforation)

7

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.

BEFORE YOU ATTEMPT TO OPERATE THIS EQUIPMENT, READ AND STUDY THE FOLLOWING SAFETY INFORMATION. IN ADDITION, MAKE SURE THAT EVERY INDIVIDUAL 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 its machinery and guards exposed moving parts for his/her protection.

However, some areas can NOT be guarded or shielded in order to assure proper operation. In addition, this Operator’s Manual and Decals on the machine, warn of further danger and should be read and observed closely.

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

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

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

8

MANDATORY SAFETY SHUTDOWN PROCEDURE BEFORE unclogging, cleaning, adjusting, lubricating or servicing the unit: 1.

Disengage the tractor PTO.

2.

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

3.

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

4.

Wait for all movement to stop and remove the Telescoping PTO Drive and ALL power connections from the tractor.

5.

Turn the Control Box Keyswitch Lock to ”OFF”, remove the Key and take it with you.

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.

ADDITIONAL SAFETY REMINDERS 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 Harvester is used without a properly mounted GEHL Attachment.

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.

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

BE SURE to review and comply with ALL Safety recommendations set forth in the tractor operator’s manuals.

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

SAFETY (Continued) ALWAYS wear safety glasses with side shields when while operating the Knife Sharpener. In addition, ALWAYS wear safety glasses with side shields when striking metal against metal. It is further recommended that a softer (non-chipable) material be used to cushion the blow. Failure to heed could lead to serious injury to the eye(s) or other parts of the body.

Good safety practice dictates that you NEVER tow an implement (without brakes) unless the towing vehicle weighs at least one-and-one half (1-1/2) times the weight of the towed implement and its load. 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. Do NOT tow a loaded wagon behind the Harvester on a highway unless the wagon has operational brakes.

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.

ALWAYS follow state and local regulations regarding use of a safety chain and transport lighting when towing farm equipment on public highways. Restrict highway towing speeds to 20 mph (32 kmh) maximum. BE SURE to check with local law enforcement agencies for your own particular regulations. Unless otherwise prohibited, use a Slow–moving Vehicle 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.

Our Company does NOT sell replacement tires. In addition, tire mounting, service or inflation can be dangerous. Whenever possible, trained personnel should be called to service and/or mount tires, following the tire manufacturer’s instruction. 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 directive given in the Service chapter of this manual.

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

A Harvester that has a factory–installed Metal Stop system will automatically sense the presence of ferrous metal in the Feed Roll area. A metal detection activates a Declutch 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 and reset the detection system, perform the following steps in the sequence given:

Signaling Device Shut–off, Metal Location & Removal, and System Resetting Procedure 1.

Move the Feed Roll Switch to “Neutral”

2.

Back the Harvester up (15 to 20 feet) so that there is NO crop under the Attachment.

3.

Reverse the crop out of the Feed Roll area and return the Feed Roll Switch to “Neutral”.

4.

Disengage the tractor PTO, shut the tractor engine ”Off”and remove the Starter Key.

5.

Turn the Control Box Keyswitch to ”Off”, remove the Key and take it with you.

6.

Wait for ALL parts to stop moving.

7.

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

To safely locate the metal and remove it from the crop, once it has been detected, 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.

NEVER attempt to hand–feed the crop into the Attachment.

9

SAFETY (Continued)

093202

091444

10

SAFETY (Continued)

093378 093376

11

SAFETY (Continued)

093365

12

SAFETY (Continued)

093373 093367

13

SAFETY (Continued)

093374

093381

14

SAFETY (Continued)

093379

093204

093439

Torque Sensor or Metal Detector Model Control Box

Shear Bolt Model Control Box

15

SAFETY (Continued)

093645

093653

1-3/4″ PTO Tongue Extension 093380

16

CHAPTER 5 CONTROLS & SAFETY EQUIPMENT This Harvester is provided with several features for operator safety and convenience.

CAUTION Become familiar with and know how to use ALL Safety Devices and Controls on the Harvester (and tractor) BEFORE attempting to operate 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.

1

1 – Lift Cylinder/Knife Sharpener Selector Valve

Fig. 2

CAP CONTROL (Fig. 3) The Spout Cap is spring-returned to the raised (up) position. Lowering the Cap (to distribute the forage from the back to the front of the forage box) is accomplished by activating the appropriate tractormounted Control Box Switch which operates the Cap Control Gearmotor.

1

2

3

SPOUT CONTROL (Fig. 3) The Spout can be rotated (to distribute the forage across the width of the forage box) by activating the appropriate tractor-mounted Control Box Switch which operates the Spout Control Gearmotor.

1

1 – Lift Cylinder Fully Extended 2 – Down Stop Bolt 3 – Down Stop Pin Locked in Highest Hole Position

Fig. 1

2

ATTACHMENT POSITIONING (Figs. 1 & 2) Mounted Attachment positioning is accomplished by the standard 8” stroke, 3” bore, double-acting hydraulic cylinder provided. A Lift Cylinder/Knife Sharpener Selector Valve enables convenient switching between the Attachment Lift and Knife Sharpener systems.

1 – Capmotor 2 – Spout Control Gearmotor

Fig. 3

17

TONGUE POSITIONING (Figs. 4 & 5)

Transport Latch mechanism should be locked in the deactivated position.

The Harvester Tongue can be repositioned manually by operating the Latch Mechanism which is linked by a Control Cord routed to the operator on the tractor seat.

CAUTION When transporting the Harvester, the Latch Mechanism MUST be locked in the “transport” position, as shown in Fig. 4.

4

LIFT SYSTEM LOCK (Fig. 6 & see Fig. 1)

1 3

2 5 1 – Control Cord 2 – Latch Lock Clip 3 – Tongue Latching Mechanism in “Transport” Position 4 – Pivot Pin Secured with 1/4 x 2 Cotter Pin 5 – Tongue

The hydraulically operated Lift System can be lockedup 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 the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) and install the Down Stop Pin into the “highest” possible (1 of 3) holes in the Lift Mechanism.

BE SURE to lock the Pin in this position with the Cotter Pins provided. Then, turn the Down-Stop Bolt fully downward into contact with the Down Stop Pin. 1

Fig. 4: Manual (Control Cord) Tongue Control

2 1

3

2

4 3 1 – Tongue Latching Mechanism (Locked-out) 2 – Latch Lock Clip 3 – Transport Lock Decal on Tongue 4 – Notch Cover Plate

Fig. 5: Hydraulic Tongue Kit (Installed)

The Tongue can be remotely repositioned by obtaining and installing a Hydraulically-operated Tongue Kit. When this Kit is installed and for field operation, the 18

1 – Lift Cylinder Fully Extended 2 – Down Stop Bolt 3 – Down Stop Pin Locked in Highest Hole Position

Fig. 6

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.

WARNING Read and thoroughly understand ALL Warnings on the unit BEFORE operating it. Do NOT attempt to operate this equipment unless ALL factory installed Guards and Shields are properly secured in place.

2 1

3

Implement Drive Line Guards (Fig. 7) The Telescoping PTO Drive connection to the tractor is equipped with rotating Shields.

1 – Rear Shield 2 – Knife Sharpener Cover 3 – Spinner Cover

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

Fig. 8

A Guard is provided over the entire fixed-length portion of the Implement Drive Line, from the Front Bearing Support back to the Bevel Gearbox Input Shaft.

Miscellaneous Guards (Figs. 7 & 8) 2 3

1

Various latched and hinged Guards and Covers are provided on the Harvester to protect access points for service and/or adjustment.

CAUTION 4 1 – Drive Chain Guard 2 – Toolbox 3 – Telescoping PTO Drive Rotating Shield 4 – Guard Over Fixed-length Drive Line

BEFORE proceeding to perform 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.

Fig. 7

19

HITCHJACK (Fig. 9) A Hitchjack (Jack) is furnished with the Harvester to support the machine when the tractor is disconnected as well as to facilitate aligning the Harvester Hitch Clips with the tractor Tongue during hookup.

2

Fig. 10: Hydraulic Knife Sharpener Assembly

3

OVERRUNNING CLUTCH (Fig. 11)

1 1 – Bolt-locked 1000 RPM 1-3/4″ Coupler 2 – Telescoping PTO Rotating Shields 3 – Hitchjack in “Supporting” Position

1

Fig. 9

WARNING BE SURE the Lockpin is properly seated through the holes in the Jack Tube and the Tongue Hub of the Harvester, BEFORE the disconnecting the Harvester from the tractor.

When the Jack is NOT being used to support the Tongue, remove the Lockpin and swing the Jack into its “storage” position. Wrap the Lockpin Chain around the Jack Handle (to hold it up) and then insert the Lockpin through the holes in the Jack Tube and Tongue Hub to secure it.

HYDRAULIC KNIFE SHARPENER (Fig. 10 & see Fig. 2) The Harvester is equipped with a factory-installed Hydraulic Knife Sharpener for sharpening the Cylinder Knives and the Cutterbar. The Sharpener is powered by the same tractor hydraulic circuit used to operate the Attachment Lift Cylinder. A Selector Valve is provided to conveniently switch between the Lift Cylinder and Knife Sharpener.

20

1 – Overrunning Clutch

Fig. 11

The Harvester is provided with an Overrunning Clutch assembly on the input to the Bevel Gearbox. The Overrunning Clutch isolates the tractor PTO from the Harvester Drive Line and therefore eliminates torque loading and strain on the tractor PTO brake.

SHIFTER TRANSMISSION CONTROL The Shifter Transmission (and Electric Clutch) is used to stop the Feed Rolls and the Attachment, to run them forward (to bring the crop into the Cutting Cylinder), or to run the Feed Rolls backwards (to reverse plugging material out of the Feed Roll area). Shifting the Transmission is accomplished by activating Switches on the tractor-mounted Control Box. Refer to the Operation chapter in this manual for specific details.

CAUTION

highways. Refer to the Optional Features & Accessories chapter for ordering information. The safety chain should be attached to the tractor and Harvester as shown.

BEFORE leaving the tractor, ALWAYS turn the Control Box Keyswitch to OFF and remove the Key and take it with you for your own safety and to avoid unnecessary drain on your tractor battery.

TELESCOPING PTO COUPLER LOCK (See Fig. 9) The standard 1-3/8″ Telescoping PTO Drive is equipped with a Spring-loaded Locking Device to positively lock it onto the tractor PTO shaft. Depress the Locking Device against the Spring tension and slide the Yoke onto the tractor PTO shaft. Release the Locking Device and move the Yoke ahead or back until the Lock engages in the groove on the tractor PTO shaft. The optional 1-3/4″ Telescoping PTO Drive is provided with two Bolts for securing the Yoke onto the tractor PTO shaft.

WARNING BE SURE the Telescoping PTO Connection is properly secured to the tractor PTO shaft BEFORE starting the tractor. Also BE SURE that the Telescoping Drive Shields rotate freely BEFORE starting the tractor.

SAFETY CHAIN & TRANSPORT LIGHTING (Fig.12) As required or when desired, the Harvester should be equipped with a safety chain for operation on public

2

1

3 1 – Locking Hitchpin 2 – Clevis Bolted to Tractor Drawbar 3 – 30,000 Pound Accessory Safety Chain

Fig. 12

CAUTION ALWAYS follow state and local regulation 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 machines, 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 Emblem.

21

CHAPTER 6 OPERATION NOTE: This chapter is divided into four separate sections. The first section pertains to all Harvester models. The second section only pertains to a Shear Bolt model Harvester. The third section only pertains to a Torque Sensor model Harvester. The fourth section only pertains to a Harvester with Metal Detector system.

ALL HARVESTER MODELS GENERAL INFORMATION

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

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.

Start-up

BE SURE ALL Guards and Shields are properly secured in place BEFORE starting the tractor engine and operating the Harvester.

ALWAYS engage the tractor PTO at idle speed when starting-up the Harvester. The first time the Harvester is being operated, shift the Feed Roll Transmission through its three positions to make sure that all mechanisms are operating properly. In addition, operate the Lift System and the Spout and Cap control systems to verify proper operation.

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

22

When any part of the Harvester other than the Feed Rolls or Attachment becomes plugged, stop Harvester operation IMMEDIATELY by moving the Feed Roll & Attachment Selector Switch to NEUTRAL or OFF. Then, disengage the tractor PTO and wait for ALL movement to STOP. Then, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8). BEFORE leaving the tractor seat to remedy the plugging problem, turn the Control Box Power Keyswitch to OFF, remove the Key and take it with you.

Entering the Crop

WARNING

NOTE:

WARNING

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 Cutterbar adjustment will provide for more efficient Harvester operation and will reduce horsepower waste.

Leaving the Crop 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 can be disengaged or the tractor throttled down.

UNPLUGGING

2.

WARNING When any part of the Harvester other than the Feed Rolls or Attachment becomes plugged, stop Harvester operation IMMEDIATELY by moving the Feed Roll & Attachment Selector Switch to NEUTRAL or OFF. Then, disengage the tractor PTO and wait for ALL movement to STOP. Then, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (as described on page 8). BEFORE leaving the tractor seat to remedy the plugging problem, turn the Control Box Power Keyswitch to OFF, remove the Key and take it with you.

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.

Reinstall and secure the Cylinder Cover and Guards.

c.

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 Impact Pins.

d.

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

e.

Inspect the Main Drive Impact Pins (and replace them, if necessary) following the procedure as described under the “OVERLOAD PROTECTION - Main Drive Line” topic, later 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).

2.

Before cleaning-out the Blower, wait for the Cylinder to stop turning. Observe the Blower Shaft to determine if the Blower is still rotating.

NOTE: Even if the Blower Outlet is plugged, the Fan could continue to rotate.

3.

The Spinner Chute can be removed to help gain access to the bottom portion of the Blower.

4.

After the forage has been cleaned-out of the Blower and the Fan turns freely, check the Blower Outlet to insure that it is NOT also plugged.

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 Chute and Cleanout Covers. Close the Belt Guard Shield and latch it.

Cylinder If the Cutting Cylinder becomes plugged with forage, proceed as follows: 1.

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

WARNING After the Cylinder is freed and cleaned-out and the Impact Pins have been inspected (and replaced), reinstall all Guards and Covers BEFORE resuming Harvester operation.

3.

Insert the Control Box Key, turn the Power On, start and idle the tractor, engage the PTO, bring the tractor up to rated operating speed, shift to “Forward” and resume harvesting.

Spout If the Spout becomes plugged with chopped forage, proceed as follows: 1.

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

2.

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).

23

4.

Check and, if necessary, unplug the Blower and Cylinder areas. Refer to the information under the Blower and/or Cylinder topics, earlier in this chapter, to unplug these areas.

NOTE:

For highest achievable efficiency, keep the Feed Rolls full and keep the Knives sharp and set up to a sharp Cutterbar.

Table of Harvesting Capacities

Spinner & Spinner Chute The Spinner and Spinner Chute might become plugged if the tractor PTO RPM is NOT maintained. To clean-out the Spinner and Chute, proceed as follows: 1.

2.

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

Remove the Spinner Cover, open the Blower Belt Guard and remove the Spinner Chute. To remove the Chute, first unlatch it. Next, shift the Chute about 3/4″ (19 mm) to the right. Then, pull the left end away from the Blower Housing and shove the Chute to the left while removing it.

3.

Remove the forage which is built-up in the Chute and on the Spinner.

4.

Slowly rotate the Spinner (by hand) to insure that it turns freely.

5.

6.

Check also that the Blower turns freely and make sure that the Spout is unplugged. Refer to the information under the Blower and Spout topics earlier in this chapter to unplug these areas.

Replace the Spinner Cover and Chute and close and secure the Blower Belt Guard before resuming operation.

HARVESTING CAPACITY The accompanying Table is intended as a guide to help the customer anticipate his machinery requirements in order to achieve his harvesting program. The figures are based on actual field tests conducted by the Gehl Company in corn yielding 10 Tons to the acre at 50% moisture. These figures may also be used to calculate hay harvesting at 50% moisture and yielding 4 Tons to the acre.

These figures represent an uninterrupted run and most customers should multiply them by 0.7 to account for time spent changing wagons, traveling headlands and any other non-harvesting activities.

“Tractor Horsepower” is the PTO dynamometer rating.

From it was subtracted a suitable amount for pulling the tractor itself, the Forage Harvester and a half-loaded wagon across the ground at a speed appropriate for the listed capacity.

24

Length of Cut in Inches

3/16

1/4

5/16

3/8

Horsepower (hp) per Ton per Hour

3.0

2.9

2.7

2.6

Tractor hp

Capacity in Tons/Hour

80

19

19

20

21

90

21

22

23

24

100

23

24

25

26

110

25

26

27

28

120

28

28

30

31

130

30

30

32

33

140

32

32

34

35

150

34

34

36

37

160

36

36

38

39

170

37

38

40

41

180

39

40

42

43

190

41

42

44

45

200

43

44

46

47

OVERLOAD PROTECTION Main Drive Line (Fig. 13) The Main Drive, which is connected through an Overrunning Clutch assembly to the Input Shaft of the Bevel Gearbox, is protected from “sudden start” impact damage by a flanged connection and Impact Pins. The Flange is secured to the Overrunning Clutch with (2) Impact Pins (5/16 x 3-1/4 Grade 5 Cap Screws) with double-Nuts (two 5/16 Hexagon Nuts per Pin). These Pins are capable of transmitting approximately 675 hp and are designed to break only under a high impact caused by the engagement of the tractor PTO while the tractor is running at a high RPM. 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 Impact Pins are provided in the Toolbox.

NOTE:

ALWAYS use double-Nuts (Two 5/16 Hexagon Nuts) on each Impact Pin to prevent them from loosening.

2

3

1

Spinner Drive (Fig. 15) The Spinner Drive is protected by two (2) 5/16 x 1 Grade 2 Shear Bolts which are installed in the Spinner Disc.

BE SURE to remove the cause of the overload BEFORE attempting to resume operation. The sheared-off portion of the Shear Bolt will be found in the material laying on the Spinner Disc and should be removed.

4

1 – Main Drive Joint 2 – Double Nuts on 5/16 x 3-1/4 Grade 5 Cap Screw (Impact Pin) 3 – Flange 4 – Pilot Area Grease Fitting

Fig. 13

Lower Feed Roll Drive (Fig. 14) The Lower Feed Roll Drive is provided with a Shear Flange for overload protection and uses a 1/4 x 1-1/2 Grade 8 Shear Bolt.

2 1 1 – Spinner Disc Paddles 2 – 5/16 x 1 Grade 2 Shear Bolts & Lock Nuts (2 each)

Fig. 15

1 2

Hydraulic Knife Sharpener A Hydraulic Fuse is included in the Knife Sharpener pressure line.

This Fuse prevents over-speeding the Sharpener Motor by limiting the oil flow to a maximum level. Refer to the Knife Sharpener topic in the Service chapter for additional resetting information.

3

Control Boxes (See Figs. 17 & 18)

1 – Attachment Drive Torque Sensor 2 – Upper Feed Roll Drive Torque Sensor 3 – Lower Feed Roll Drive Shear Flange

Fig. 14

The entire electrical system is protected by Circuit Breakers within the appropriate Control Box. To reset a Breaker, clear the trouble in the system first. Then, depress the Breaker Button.

NOTE: After a Breaker is tripped-out, it takes about 10 seconds before the Breaker can be reset.

25

HARVESTER WITH SHEAR BOLT-PROTECTED FEED ROLL & ATTACHMENT DRIVES OPERATING FEED ROLLS & ATTACHMENT (Fig. 17) The Electric Clutch and Shifter Transmission combination is used to stop the Feed Rolls and the Attachment, to run them forward (to bring the crop into the Cutting Cylinder) or, to run the Feed Rolls backwards (to reverse plugged material back out of the Cutting Cylinder area).

Shifting the Transmission is accomplished by appropriate activations and settings of Switches on the Control Box which is mounted on the tractor.

To feed material into the Harvester, set the Feed Roll toggle Switch to the “Forward” position. The Transmission will continue operating in the “Forward” mode until the Feed Roll Toggle Switch is reset to the “Off” position.

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.

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 Transmission into reverse.

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.

OVERLOAD PROTECTION (Fig. 16)

To stop the Feed Rolls and the Attachment, turn off the power to the system by placing the Feed Roll Toggle Switch to the “Off” position.

1

CAUTION BEFORE leaving the tractor, ALWAYS turn Control Box Power Keyswitch OFF and remove the Key and take it with you for your own safety and to avoid unnecessary drain on your tractor battery.

To back material out of the Feed Rolls and Attachment, set the Feed Roll Control Toggle Switch to the “Reverse” position and hold it there momentarily while observing the crop as it reverses-out of the Feed Rolls and Attachment; this process should only take 3 to 4 seconds. If the “Reverse” position is held continuously for more than 12 seconds, the Circuit Breaker will trip-out to protect the Shifting Solenoid. To reset the Breaker, wait at least 10 seconds and then, depress the Button to reset the Breaker.

UNPLUGGING THE FEED ROLLS By design, the Feed Rolls allow various mat thicknesses to pass between them. If however, the mat thickness

26

3 2

1 – Upper Roller Drive One-way Shear Bolt Protective Device 2 – 1/4 x 1-1/2 Grade 8 Shear Bolt & Hexagon Lock Nut 3 – Lower Roller Drive Shear Flange

Fig. 16

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.

4

3

5

2

6

9 1 1 – Connect to Harness from Tractor Battery 2 – Feed Roll Selector Toggle Switch 3 – Connect to Water System Harness 4 – Water Tank Equipped Units Only

8

7

5 – Spout Gearmotor Control Switch 6 – Connect to Wiring Harness Extension Inside Tractor Cab 7 – Capmotor Control Switch 8 – 20 Ampere Circuit Breaker 9 – Power Keyswitch

Fig. 17: Control Box for Shear Bolt Harvester Model

HARVESTER WITH TORQUE SENSOR-PROTECTED FEED ROLL & ATTACHMENT DRIVES OPERATING FEED ROLLS & ATTACHMENT (Fig. 18) The Shifter Transmission is used to stop the Feed Rolls and the Attachment, to run them forward (to bring the crop into the Cutting Cylinder) or, to run the Feed Rolls backwards (to reverse plugging material back out of the Cutting Cylinder area). Shifting the Transmission is accomplished by appropriate activations and setting of Switches on the Control Box which is mounted on the tractor.

Move the “AUTO-OFF-MANUAL” Mode Switch to “AUTO” and leave it there. With the Power Keyswitch ON, the Feed Rolls and Attachment are controlled by the FEED ROLLS & ATTACHMENT “SELECTOR” Switch. Toggling the Switch to “FWD” (forward) will

immediately cause the Electric Clutch to close and, if the PTO is engaged, the Feed Rolls and Attachment will run to feed crop into the Knives. Toggling into “NEUTRAL” will open the Clutch and stop all Feed Roll and Attachment motion. To back material out of the Harvester, move the Toggle Switch to “REV” (reverse) and, in addition, rotate and hold the springloaded “HOLD FOR REVERSE” Handle to the right (counterclockwise); release the Handle to automatically open the Clutch and stop reversing.

The reversing process should only take 3 or 4 seconds.

If the “Hold-to-Reverse” Switch is continuously held for more than 12 seconds, the Circuit Breaker will trip-out to protect the Shifting Solenoid. To reset the Breaker, wait at least 10 seconds and then, depress the Button to reset the Breaker.

27

6

5

7

8

9

10

11

4

12

3

13 2

1

14

1 – Connect to Harness from Tractor Battery 2 – Power Outlet Plug for Water System 3 – Power Keyswitch 4 – Feed Roll & Attachment Reversing Switch 5 – Feed Roll Selector Toggle Switch 6 – Indicator Light “On” When “AUTO-OFF-MANual” Toggle Switch is in “AUTO” Position 7 – 18 Ampere Circuit Breaker

8 – “AUTO-OFF-MANual” Toggle Switch 9 – Indicator Light “On” When “AUTO-OFF-MANual” Toggle Switch is in “MANual” Position 10 – 20 Ampere Circuit Breaker 11 – Spout Gearmotor Control Switch 12 – Capmotor Control Switch 13 – Connects Control Harness (Going to Implement) 14 – Connects Control Harness (Going to Implement)

Fig. 18: Control Box* with Metal Stop Decal * Control Box for Torque Sensor Harvester does NOT have extra Decal in lower right-hand corner of Box.

NOTE:

Except for the brief time that the “HOLD FOR REVERSE” Handle 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.

The “MANUAL” and “OFF” positions of the Mode Switch are used only when there is a problem with the Automatic circuit. In this mode, the Clutch closes and runs the Feed Rolls and Attachment Forward, when the Switch is toggled to “MANUAL” and the Clutch opens when the Switch is toggled to “OFF” to stop Feed Rolls and Attachment. While operating in MANUAL condition, there is NO Reverse capability NOR will the Speed Monitor, Metal Stop system or Torque Sensors operate.

28

CAUTION BEFORE leaving the tractor, ALWAYS turn the Control Box Power Keyswitch to OFF, remove the Key and take it with you for your own safety and to avoid unnecessary drain on your tractor battery. If any of the Control Box Indicators are still “ON” (lighted), the Keyswitch is NOT off.

NOTE:

When operating in the “MANUAL” mode, be extra cautious to avoid plugging the Feed Rolls or the Attachment because the reversing function is inoperative in this mode.

CONTROL BOX (Figs. 18 & 19) Place the “Auto-Manual” Switch into the “Auto” position and LEAVE IT THERE. This will allow the Auto-Maxr system to protect the Harvester. No AutoMaxr Shut-Off systems will operate with the “AutoManual” Switch in “Manual”. The “Manual” Switch position allows the Feed Roll and attachment Drive Load Sensors to ratchet when they are overloaded. The Load Sensors may ratchet only a few seconds at a time, but the total accumulative ratcheting life is less than 7 minutes. The “Manual” Switch position should be used as little as possible to avoid damaging the Load Sensors.

The Load Sensors should never ratchet while the “Auto-Manual” Switch is in “Auto”.

If the Metal Stop system malfunctions and can NOT be repaired immediately, disconnect the Wiring Harness Plug inside the Feed Roll Drive Frame, move the Stop Pawl Spring to the “bypass” position, and keep the “Auto-Manual” switch in “Auto”. Refer to the Metal Stop section in this chapter.

1

1 – Plug (Tape Ends of Plugs to Prevent Shorting-out Against Frame)

Fig. 19

NOTE: Using electrician’s tape, cover the ends of the Plug and Socket to keep dirt out of both parts.

If the Speed Monitor system malfunctions and cannot be repaired immediately, disconnect the Speed Monitor Plug at the side the Spinner Gearbox and keep the “Auto-Manual” Switch in “Auto”.

If disconnecting the Metal Stop system and the Speed Monitor does NOT allow the Auto-Maxr system to operate and it can NOT be repaired immediately, proceed as follows. Operate Harvester with the “AutoManual” Switch in “Manual” and shut-off the Feed Rolls and Attachment by moving the “Auto-Manual”

Switch to “Off”. The “Manual” Switch position should only be used as a means to finish the day’s work before making repairs. DO NOT use “Manual” Switch all season long.

UNPLUGGING THE FEED ROLLS 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 Load 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.

When an overload condition does occur, reset the Clutch by setting the Feed Roll & Attachment Selector Switch to NEUTRAL (center position) and then, return it to FWD (forward) position. Do NOT idle the tractor when shifting the Feed Rolls. If the overload condition is NOT cleared by merely resetting the Electric Clutch, move the Feed Roll & Attachment Selector Switch to the REV (reverse position) and rotate the HOLD-FOR-REVERSE Switch to reverse the material back out about 6” (152 mm). Then, reset the Feed Roll & Attachment Selector Switch to the FWD (Forward position).

NOTE:

Special care should be taken so as 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 Sidesheets; although it should NEVER need to be backed up that far.

WARNING NEVER attempt to hand feed crop into the Feed Rolls as the crop will feed faster than you can react to let go.

OVERLOAD PROTECTION The Upper Feed Roll Drive and the Attachment Drive have Torque Sensors. The Torque Sensors close a Switch when the driving torque is too high. The Switch then disengages the Electric Clutch, stopping the Feed Rolls and Attachment. The Cutting Cylinder, Spinner, and Blower continue to operate to clean out cut material.

When the Torque Sensor stops the intake of material, an Alarm Horn signals in the Control Box. The Alarm is turned off by moving the “FWD-NEUTRAL-REV” 29

Switch to NEUTRAL. This also resets the Electric Clutch so that FORWARD or REVERSE can be selected.

There is a Speed Monitor on the Spinner Gearbox. It measures the Harvester operating speed and closes a Switch if the speed is too low. The Switch disengages the Electric Clutch, stopping the Feed Rolls and Attachment. The Cutting Cylinder, Spinner, and Blower continue to operate to clean out cut material.

The Speed Monitor sounds the Alarm Horn in the Control Box when it stops the Feed Rolls and Attachment. The Alarm is turned OFF by moving the “FWD-NEUTRAL-REV” Switch to NEUTRAL. This

also resets the Electric Clutch so that FORWARD or REVERSE can be selected.

The Speed Monitor is controlled by the Tunnel Switch.

The Tunnel Switch senses the flow of material in the Spinner Chute (Tunnel). If material is in the Tunnel, the Speed Monitor will shut OFF the Feed Rolls whenever the Harvester speed is too low (approximately 70% of operating speed). This helps prevent plugging in the Blower and Spinner. If the Tunnel has NO material in it, then the Speed Monitor is bypassed. This allows starting an empty Harvester at tractor idle speed.

METAL DETECTOR MODELS ONLY

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) NOTE: Metal Detector models contain all of the features included on the Torque Sensor models.

Review all information in the section labeled “Harvester with Torque Sensor-protected Feed Roll and Attachment Drives” and the information in this Metal Detector section.

The Metal Detector model Harvester contains a Metal Stop system which is designed to prevent ferrous metal (containing iron) objects from entering the Forage Harvester Cutting Cylinder. It can be used with all 30

mounted Attachments, except those which use a steel Cover over the Lower Front Feed Roll, such as the Snapper Attachment. A “bypass” procedure is provided for use with these 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 Amplifier Box which is mounted on top of the Feed Roll Housing. When the signal reaches the Amplifier Box, 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: —

hitchpins

—

scrap iron

—

bolts

—

wrenches

—

rake teeth

—

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: —

aluminum

—

stainless steel

—

wood

—

tile

—

cement

—

stones

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 on a daily basis.

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 the 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 causes most of the ferrous metal objects to descend to the bottom of the incoming crop material.

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 can NOT and MUST NOT be expected to be 100% effective at detecting iron objects.

GENERAL INFORMATION (See Fig. 18) The Metal Stop system is operated from the tractor seat with the Harvester Control Box. A ferrous metal detection causes the Amber Signal Light on the Harvester to “flash” and the Control Box Buzzer to sound.

NOTE: Sounding of the Control Box Buzzer also signals maximum capacity or “low speed”.

The flashing Amber Light only signals for a metal detection. The Harvester can NOT be operated until after the Metal Stop system is reset.

To turn off the signaling devices, safely locate and remove the metal and, restore the detection system to be able to resume harvesting, perform the steps in the sequence given on the Control Box Decal or detailed in the Safety chapter.

SYSTEM START-UP (Figs. 21 & 22 & see Fig. 18) To initially start-up the Metal Stop system or reset it, after metal has been detected and removed, perform the “Start-up or Reset Procedure” given, with the tractor PTO disengaged.

If the Amber Light on the Harvester does NOT go out and remain “off”, the Stop Pawl is probably stuck in the Ratchet Wheel., as shown in the illustration provided.

When the Pawl sticks, it causes the Circuit Breaker , in the amplifier Box to open.

Wait about 10 to 15 seconds for the (heat activated) Breaker to cool. Then, idle the tractor, engage the PTO and reverse the Feed Rolls until the Rolls move. The Amber Light should go out and remain. “off”. Now, the Metal Stop system is ready to use. After the preceding steps are performed, idle the tractor and engage the PTO and start (resume) harvesting.

31

2

2 3 3 1

1

4

1 – Lower Front Feed Roll With Detection Magnet 2 – Amplifier Box 3 – Amber Signal Light

1 – Stop Solenoid 2 – Stop Pawl 3 – Ratchet Wheel 4 – Spring

Fig. 22

Fig. 21

Start-up or System Reset Procedure

ACTION

REASON

1.

Move Mode Switch to AUTO and leave it there.

Metal Stop system does NOT operate with Mode Switch in MANual position. Refer to System Bypass topic in this chapter.

2.

Move the FEED ROLL Switch to “Neutral”.

If the Switch is in “Forward”, Buzzer will sound when Keyswitch is turned “ON”.

3.

Turn Keyswitch “ON”.

Control Box is energized and ready but, Amber Light goes “ON”.

4.

Move the FEED ROLL Switch to “Reverse” posi- Metal Stop system is set (reset) and ready for operation tion and momentarily activate the HOLD FOR RE- when the Amber Light is “OFF”.

VERSE Switch (Harvester Amber Light will go off).

NOTE: The Harvester will NOT operate with the Control Box FEED ROLL Switch in the “Forward” position while the Amber Light on the Harvester is flashing. If, after attempting to reset the system, the Amber Light does NOT remain “OFF”, refer to appropriate information in the Troubleshooting chapter.

1.

Move the Control Box FEED ROLL Switch to the “Neutral” position.

2.

Turn the Power Keyswitch to “OFF” and remove the Key before leaving the tractor seat.

STOPPING HARVESTER

DETECTION

The Harvester and Metal Stop system should be switched OFF when the Harvester is NOT being used.

This will avoid unnecessary drain on the tractor battery.

The following sequence should be carried-out to turn the system OFF:

When a ferrous metal detection occurs, the Solenoid will release the Spring-loaded Stop Pawl into the Ratchet Wheel. Simultaneously, the Electric Clutch will receive a signal to open and thus, immediately stop the Feed Rolls and Attachment.

32

Detection Reaction Procedure

ACTION

REASON

1.

Move FEED ROLL Switch to “Neutral”.

This stops the Buzzer.

2.

Stop forward travel and back-up the tractor.

This separates crop in the Feed Rolls from the crop on the ground.

3.

Reverse the Feed Rolls.

This remove the crop (Containing the metal) from the Feed Rolls.

4.

Shut-off the tractor PTO and engine.

This keeps the Harvester from running unnecessarily.

5.

Shut the Power Keyswitch OFF, remove the Key To prevent undesired or unexpected system activation. and take it with you.

6.

Wait for ALL parts to STOP moving.

To avoid being injured by moving parts.

7.

Remove the metal from the crop.

This should be done with the portion of the crop, containing the metal, on the ground.

The preceding action also occurs when the Mode Selection Switch is turned “OFF” as well as when Power is interrupted to the Metal Stop system.

1.

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

A ferrous metal detection is indicated by the Amber Light on the Harvester flashing and the Control Box Buzzer sounding. If the Amber Light is NOT flashing, the Control Box Buzzer is indicating a Load Sensor or Speed Monitor activation..

2.

With NO one near the Harvester, reset the Metal Detector system and start-up the Harvester. Slowly move forward and harvest the windrow.

3.

The ferrous metal object will be detected a second time.

4.

Repeat the following standard procedure to remove the metal.

When a ferrous metal detection occurs, carry-out the procedure detailed in the “Detection Reaction Procedure” given.

WARNING 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.

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 can NOT be discovered through an initial search, continue the search after exercising the proper precautions in the following manner:

a.

Stop forward travel and back-up the tractor

b.

Reverse the Feed Rolls

c.

Shut off the tractor PTO and engine

d.

Shut the Power Keyswitch “Off”, remove the Key and take it with you

e.

Wait for ALL parts to stop moving

f.

Remove the metal from the crop

WARNING NEVER attempt to hand feed crop into the Feed Rolls as the crop will feed faster than you can react to let go.

33

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.

tion” mode cancels ALL automatic Shut-off Devices of the Harvester’s electrical system, including the Metal Stop system. Furthermore, the system can NOT be used on an Attachment using a steel Cover over the Lower Front Feed Roll, such as the Snapper Attachment.

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

It may be desirable or otherwise necessary to bypass the Metal Stop system for the reasons mentioned in the previous paragraph or, if a malfunction occurs that can NOT be remedied quickly. After the Metal Detector system is bypassed, the Harvester can be operated in the same manner as a unit without the Metal Detector system. Bypassing the system allows you to operate in either the “OFF-MANual” or “AUTOmatic” mode and, if desired, use a Snapper Attachment.

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 Amber Light, on top of the Harvester Feed Roll Drive Frame, to continue flashing. Reset the system by shifting to reverse to make the Light go off.

BYPASSING THE METAL DETECTOR SYSTEM (Figs. 23 & 24)

1

1

1 – Plug (Tape Ends of Plugs to Prevent Shorting-out Against Frame)

Fig. 24: Plug in Feed Roll Drive Frame

2

Procedure To bypass the Metal Detector system, refer to the illustrations provided and proceed as follows:

1 – Stop Pawl in “Bypassed” Position 2 – Pawl Spring in “Bypassed” Position

Fig. 23: Stop Pawl Spring in “Bypassed” Position

Reasons Why The Metal Detector system can NOT be used with the Harvester Control Box Mode Selector Switch in the “OFF-MANual” position. The “OFF-MANual” posi-

34

1.

Move the Pawl Spring from the “Operating” position to the “bypassed” position, as shown. After the Spring is moved, make sure that the Stop Pawl is away from the Ratchet Wheel.

2.

Disconnect the Plug inside the Feed Roll Drive Frame, as shown. Using electrical tape, cover the ends of the Plugs to keep dirt out of the Plug sockets. Also, fasten disconnected Plugs where they can NOT rub on Upper Feed Roll Drive Shaft.

To restore the Metal Detector system, return the Spring and Plugs to their original operating positions and return the Control Box Switch to the “AUTOmatic” mode.

DAILY SYSTEM INSPECTIONS (See Fig. 18 & 21)

1.

Since the Metal Stop System is factory installed, the unit has been checked-out for proper operation before leaving the factory. The following inspections should be made on a periodic basis to maintain proper operation: 1.

Check the Wiring Harnesses, Wires and Plugs to determine their condition and electrical continuity.

2.

Check the Stop Solenoid for correct adjustment and proper Ring alignment.

3.

Check that the Metal Stop System is operating properly by carrying-out the following “System Test” procedures.

SYSTEM TEST

CAUTION BEFORE proceeding to perform any test or adjustment on the Metal Detector Stop system, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

2.

With the Mode Switch in “AUTOmatic”: a.

Move the FEED ROLL Switch to “NEUTRAL”.

b.

Turn Control Box Keyswitch “ON”.

c.

Move the FEED ROLL Selector Switch to the “REVERSE” position and momentarily activate the “HOLD FOR REVERSE” Switch. Harvester Amber Light will go off unless the Pawl is stuck in the Ratchet Wheel.

d.

Move the FEED ROLL Selector Switch to the “FORWARD” position.

e.

Pass a ferrous metal object between the Upper and Lower Front Feed Rolls (the Solenoid should release the Stop Pawl into the Ratchet Wheel, the Amber Light should flash and, the Control Box Buzzer should sound signifying a metal detection).

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).

35

CHAPTER 7 ADJUSTMENTS

CAUTION

3

1

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

4 2 5

ATTACHMENT POSITIONING 6

CAUTION Operate the tractor and the hydraulic lift controls yourself. 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.

1 – Lift Spring 2 – Spring Adjusting Bolt 3 – Lift Cylinder Fully Extended 4 – Lift Link 5 – Down Stop Bolt 6 – Down Stop Pin Locked in Highest Hole Position

Fig. 25

4.

Axles & Wheels The Harvester Axles and Wheel Spindles have several mounting hole positions for adjusting the Wheels and Axles in or out and 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 & Spindles topic (beginning on page 48) for appropriate positions related to the different Attachments.

Adjust the Downstop Stud against the Downstop Pin. If the Stud will NOT go down and touch the Square Pin, retract the Stud enough to allow moving the Square Pin upwards one hole. Then, adjust the Stud down against the Square Pin. The Downstop adjustment will vary with different Row Crop Attachments.

Lift Height (Figs. 25 & 26)

Downstop (Fig. 25) 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: 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.

36

4

1 2

3

1 – Lift Cylinder Link 2 – Lift Height Adjustment Cam 3 – Left Wheel 4 – Lift Assembly Plates

Fig. 26

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 Feeder Attachment. The Cam requires readjustment anytime the mounted Attachment raises too high and strikes the Harvester Feed Roll Housing.

To adjust the Cam, retract the Lift Cylinder and loosen the 3/4I 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 3/4I Bolt to lock the Cam in the position selected.

Slowly raise the Attachment and recheck the Attachment clearance to the Feed Roll Housing. Also check for ample clearance between the Feed Roll Sidesheets and the Attachment. If the Attachment, when raised, is still found to be striking the Harvester, readjust the Cam to reduce the maximum height of Attachment travel.

Lift Spring (See Fig. 25) 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.

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.

NOTE: Raise the Attachment to reduce the spring Torque on the Spring Adjusting Bolt which will make it easier to turn the Bolt . Then, lower the Attachment again to gauge the float effect of the Spring.

For a Hay Attachment, the Spring tension should be adjusted to counterbalance the Attachment. It should take approximately 50 lb (22.5 kg) of lift at the Hay Hold-down Bar to raise the Attachment.

If a Water Tank option is being used on the Hay Attachment, adjust the Lift Spring to provide maximum tension. Maximum tension can be adjusted whenever a Row Crop Attachment is mounted, provided the Row Crop Attachment still lowers all the way to the

Downstop without assistance. However, many users leave the Spring set in the hay attachment position.

BLOWER Belt Idler (Fig. 27)

5 4 1 2

3

1 – Blower Drive Sheave 2 – Idler Support 3 – Blower Drive Belt 4 – Blower Driven Sheave 5 – Belt Idler

Fig. 27

The Blower Drive Belt links the Blower Driven Sheave to the Drive Sheave on the output of the Bevel Gearbox.

Belt tension is maintained by a Spring-loaded Belt Idler.

Access to the Belt and Idler is obtained by unlatching and swinging-up the Blower Belt Cover on the left rear of the Harvester. Tension on the Belt is factory set and requires NO further readjustment.

Drive Belt (Fig. 27) The Drive Belt can be removed, for service or replacement, by first removing six (6) Bolts and detaching the Blower Belt Guard. Raise the Idler above the Belt, push the slack Belt toward the Blower and then, lower the Idler until the Spring is loose. Use an appropriate length of 1″ (25 mm) diameter pipe, or equivalent handle, for additional leverage.

Fan Paddles (Fig. 28) Over long periods of Harvester use, the tips of the six 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.

Each Paddle Tip should be approximately 1/32I to 1/16I (0.8 to 1.5 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: 37

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, if you do NOT have an accessory Water Tank.

CAUTION BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding.

2.

Check the Rim Sheet for dents and holes; replace if necessary.

3.

Check to see if the Blower Paddle Arms are bent; replace or straighten, as required.

4.

Loosen the four 1/2I Hexagon 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 Spinner Chute opening in the rear Sidesheet. Align the Paddles over their full 4-3/4I (121 mm) width so that the Tips are 1/32 to 1/16I (0.8 to 1.5 mm) away from the Rim Sheet.

1 3

4 2 1 – Cleanout Cover 2 – Paddle Arms 3 – Spinner Tunnel Opening 4 – Fan Paddle

Fig. 28

38

NOTE:

If after several adjustments of the Paddles, they cannot be moved any closer to the Rim Sheet, replace them according to the procedure outlined under the Blower Fan Paddle topic in the Service Chapter of this manual.

5.

Check the screws and nuts which secure the Paddle Arm to the Blower Disc to see that they are properly secured.

6.

After all Paddles are adjusted and the attaching hardware is tightly secured, rotate the Fan again (by hand) to insure that it turns freely; if NOT, check and remove the obstruction.

7.

Replace the Blower Covers, Chute and, close all 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.

CUTTERBAR (Figs. 29, 30 & 31) NOTE: The two routine maintenance procedures which have the most significant effect on the quality of cut and fuel efficiency are Knife sharpening and Cutterbar adjustment. Frequent sharpening of the Knife edge accompanied by the proper Cutterbar adjustment, will significantly increase the life of the Knives and the Cutterbar 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 Cutterbar to the Knives will be sufficient. However, in areas where the soil is abrasive, more frequent Knife sharpening and Cutterbar adjustment may be necessary.

After sharpening the Cylinder Knives, the Cutterbar requires a slight amount of adjustment toward the Knives. All Cutterbar 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 Keyswitch OFF and removing the Key, proceed to adjust the Cutterbar as follows:

NOTE:

It is NOT necessary to loosen the Cutter bar Hold-down Bolt on the right end of the Cutterbar while adjustments are being made. Also, the Spring-Torqued Hold-down Pin on the left side should NEVER be loosened, even when removing the Cutterbar.

1

2

4.

Again, bring the right side of the Cutterbar to tick and then, back it off enough to stop the ticking.

The Cutterbar is now setup all the way across and backlash toward the Knives has been removed.

NOTE: When the cutting edge of the reversible Cutterbar NO longer stays sharp, the Cutterbar can be removed and changed (end-for-end) to place a new sharp edge toward the Knives. When one or both edges of the Cutterbar are NO longer sharp, one or the other can be renewed with the Knife Sharpener; refer to the Service chapter for details. After both edges are worn-down and can NO longer be renewed, the Cutterbar MUST be removed and replaced with a new Cutterbar.

1

8

2

3

4

10

5 1 – Hold-down Pin Assembly (Do NOT Loosen) 2 – Lockstrip

6

Fig. 29

Setting the Cutterbar requires listening for the Knives to tick the Cutterbar but, it is possible for the Knives to hit the right side of the Cutterbar when you are adjusting the left side and vice-versa, thus giving a wrong indication of the closeness of a Knife to the Cutterbar.

If you follow the method given here, the Knife will always tick the Cutterbar on the side that is being adjusted.

1.

Move the left side of the Cutterbar away from the Cutting Cylinder two full turns of the Left Remote Adjusting Shaft.

2.

Move the right side of the Cutterbar towards the Cutting Cylinder until a ticking sound is heard.

Back the right side away from the Cylinder until the ticking stops and then 1/6 (one flat of the Nut) turn of the Nut further.

3.

Adjust the left side of the Cutterbar towards the Cutting Cylinder until a ticking is heard and then, back the left side away from the Cylinder only enough to stop the ticking sound.

11

7

12

9

1 – 076964 Hardened Washer 2 – Frame 3 – 076965 Spring Washers (4) 4 – 076963 Nut 5 – 076962 Adjusting Nut 6 – 1/2 x 5 Cap Screw 7 – 076967 Rounded Key (1 of 2) 8 – 076966 Retaining Ring 9 – 0.05 to 0.08I (1.3 to 2 mm)* 10 – Cutterbar 11 – 076968 Stud 12 – 1/2 Lock Nut * NOTE: As required, add or remove 076964 Hardened Washer(s) to obtain dimension.

Fig. 30: Cutterbar Right Side Adjustment Component Replacement Detail

39

1 4

2

6

3

7 5 9 8 10 1 – Stem Deflector Mounting Bolts (Both Sides) 2 – Cutterbar Right Adjustment Nut 3 – Tie Bolt 4 – Cutterbar Clamp Bolt 5 – Stud Assembly

6 – Tie Bolt Nut 7 – Smooth Feed Roll Scraper 8 – Cutterbar Support 9 – Right End of Cutterbar 10 – Left Side Cutterbar Remote Adjustment

Fig. 31

SPOUT (Fig. 32) 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.

40

WARNING Properly support the Spout whenever it becomes 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.

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 [ 181-1/12I (4610 mm)]

A C E

B

F

D

All Dimensions are in Inches (Millimeters) Unless Otherwise Noted

A

Spout

B

C

D

E

Without Vert. Ext.

38 (970)

116 (2946)

STD. 1 ft. Vert. Ext.

38 (970)

128 (3251)

w/ 2 ft. Vert. Ext.

38 (970)

140 (3556)

w/ 3 ft. Vert. Ext.

38 (970)

152 (3861)

w/ 4 ft. Vert. Ext.

38 (970)

164 (4166)

Without Vert. Ext.

w/ 3-1/2 ft. Horz. Ext.

79 (2010)

123 (3134)

STD. 1 ft. Vert. Ext.

w/ 3-1/2 ft. Horz. Ext.

79 (2010)

135 (3439)

w/ 2 ft. Vert. Ext.

w/ 3-1/2 ft. Horz. Ext.

79 (2010)

147 (3744)

w/ 3 ft. Vert. Ext.

w/ 3-1/2 ft. Horz. Ext.

79 (2010)

159 (4049)

w/ 4 ft. Vert. Ext.

w/ 3-1/2 ft. Horz. Ext.

79 (2010)

171 (4354)

Without Vert. Ext.

w/ 5-1/2 ft. Horz. Ext.

103 (2630)

129 (3292)

STD. 1 ft. Vert. Ext.

w/ 5-1/2 ft. Horz. Ext.

103 (2630)

141 (3597)

w/ 2 ft. Vert. Ext.

w/ 5-1/2 ft. Horz. Ext.

103 (2630)

153 (3901)

w/ 3 ft. Vert. Ext.

w/ 5-1/2 ft. Horz. Ext.

103 (2630)

165 (4246)

w/ 4 ft. Vert. Ext.

w/ 5-1/2 ft. Horz. Ext.

103 (2630)

177 (4511)

NOTE: Actual Measurements vary on the basis of Tire size and adjusted Wheel Spindle positions.

Fig. 32

TONGUE (Figs. 33 & 34) NOTE:

When the Harvester is transported on the highway, the Lock Mechanism MUST be locked into the “Transport” position.

The Tongue of the Harvester can be manually repositioned in any one of four operating positions or into the “Transport” position, as desired. Select the appropriate position for operation with the least amount of offset in

41

order to extend the Universal Joint life and to reduce vibration.

To reposition the Tongue, first remove and store the Lock Pin in the Latch Lever. Then, from the tractor seat, pull the Latch Release Cord and drive forward or back, as required to move the Tongue to a different notch position in the Frame. After the desired position is reached, release the Cord to allow the Lever to slip into and engage a notch in the Frame.

When this Kit is installed and ready for field operation, the Transport Lock Mechanism should be locked in the de-activated position, as shown in Fig. 34. When transporting the Harvester, the Latch Mechanism MUST be locked in the “Transport” position.

DRIVE CHAINS The various Drive Chains of the Harvester are provided with appropriate adjustable-position or self-tensioning mechanisms.

2

Length of Cut Drive Chain (Fig. 35)

3

Unlock the Chain Adjustment Knob on the Length-ofCut Frame and adjust the Chain tension with the Knob for a slack of 1/4 to 3/8I (6 to 9.5 mm) in the strand of Chain between the Upper Feed Roll Drive Sprocket and the Length-of-Cut Drive Sprocket. After proper Chain tension is adjusted, BE SURE to lock the Knob.

1

1 2

1 – Control Cord 2 – Latch Lock Clip (Stored in Top Hole) 3 – Tongue Latching Mechanism

Fig. 33: Manual (Control Cord) Tongue Control

3

2 1

3

1 – Adjustment Knob Lock 2 – Length of Cut Chain Adjustment Knob 3 – Length of Cut Drive Chain (Check slack here)

Fig. 35: Length-of-Cut Frame 1 – Transport Lock Mechanism (Locked in “De-activated” Position) 2 – Latch Lock Clip 3 – Transport Lock Decal on Tongue

Fig. 34: Hydraulic Tongue Control Kit (Installed)

NOTE: For added convenience, a hydraulicallyoperated Tongue Kit is available for field installation to automatically reposition the Tongue from the tractor seat. Refer to the Optional Features & Accessories chapter for ordering information.

The Tongue can be remotely repositioned by obtaining and installing a Hydraulically-operated Tongue Kit. 42

Attachment Driver (Fig. 36) 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 to 3/8I (6 to 9.5 mm) in the strand of Chain between the Attachment Drive Shaft Sprocket and the Lower Drive Sprocket.

NOTE: When re-tightening the Idler Sprocket mounting bolt, make sure the Idler Sprocket linesup with the Chain. Also, too much Chain tension can result in excessive Chain and Sprocket wear; avoid applying too much tension.

1 1 2

3

4 1 – Attachment Driver Chain Idler Sprocket Bolt

Fig. 36 1 – Cover Mounting Bracket (Each Side) 2 – Cylinder Tie 3 – Wet Crop Deflector 4 – Self-adjusting Spinner Drive Chain Idler

Lower Feed Rolls (Fig. 37)

Fig. 38

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 5/16I (8 mm) deflection on the strand of Chain opposite the Slide.

Upper Feed Rolls (Fig. 39) 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.

2 1 1

1 – Lower Feed Roll Drive Chain Tension Adjustment Slide 2 – Remove Spring Looseness; then, Turn Bolt (at Bottom of Spring) One More Revolution. Tighten Nut Against Spring Nut Casting

Fig. 37

1 – Upper Feed Roll Drive Chain Roller Slides

Fig. 39

Shifter Transmission & Spinner Drives (Fig. 38 & see Fig. 35) The Shifter Transmission Drive Chain and the Spinner Drive Chain each have self-adjusting Idlers which require NO further readjustment.

FEED ROLL SPRINGS (See Fig. 37) 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)

43

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.

Tension on each Spring can be readjusted by tightening each Spring Tensioning Bolt until there is no looseness and then one additional revolution 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.

FRONT PTO BEARING HOUSING The Front PTO Bearing Housing MUST be adjusted vertically in order to position the Drive Shaft and Telescoping Drive in a straight line. This adjustment is extremely important to minimize vibration. Refer to the Preparing for Field Operation chapter for details.

KNIVES (Fig. 40) The Cutting Cylinder Knives will have to be readjusted whenever 1/4I (6 mm) or more is ground-off through repeated sharpening because the Cutterbar has only 1/4I (6 mm) of actual adjustment.

To adjust the Knives, proceed as follows:

CAUTION BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE attempting to adjust the Knives.

1.

Remove and retain the Spinner and Cylinder Covers and the Recutter Screen (if present).

2.

After cleaning-out the space between the Cutterbar and the Scraper, move the Cutterbar forward to the end of its travel.

3.

Install the Knife Set-up Rod (which is stored in the Toolbox) through the access holes in the Cylinder Sidesheets.

4.

Loosen the (3) Knife Bolts just enough to permit the Knife to be tapped into position.

5.

Adjust the Knife to just clear or just touch the Setup Bar along the entire length of the Knife.

6.

Tighten all (3) Knife Bolts to 220/240 ft-lb of torque and then recheck the clearance.

7.

Repeat steps 4, 5 & 6 for all of the Knives.

After all the Knives have been sharpened and adjusted to obtain a round Cylinder, readjust the Cutterbar following details in this chapter. Refer to the Service chapter for directives on sharpening the Knives. BE SURE to remove the Knife Set-up Rod and store it in the Toolbox. Then, reinstall the Spinner and Cylinder Covers and the Screen (if used) before resuming harvesting.

LENGTH OF CUT (See Fig. 35) 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.

Refer to the Length of Cut chart provided for Sprocket and Knife combinations. Refer to the Service chapter for Knife removal and replacement details.

To change the Length of Cut Sprocket, proceed as follows:

1

Length of Cut Chart in Inches (millimeters) Number of Knives Used Sprocket 8

4

2

20 Tooth *

3/16 (5)

3/8 (10)

3/4 (19)

25 Tooth

1/4 (6)

1/2 (13)

1 (25)

30 Tooth *

5/16 (8)

5/8 (16)

1-1/4 (32)

37 Tooth

3/8 (10)

3/4 (18)

1-1/2 (38)

2

* Optional (order separately) 1 – Knife Set-up Rod 2 – Spinner

1.

Fig. 40

44

Unlock the Chain Adjustment Knob on the Length of 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. To properly adjust the slack, rotate the Knob by hand until Chain is tight. Then, rotate the Knob counterclockwise 1/4 turn, to provide the correct slack. After the Chain slack is adjusted, BE SURE to reset the Knob Lock.

To reduce the amount of long pieces of hay or to crack kernels of corn, optional Recutter Screens can be ordered and installed; refer to the Screen Adjustment topics in this chapter, for further details. A Screen recommendation table is also provided to aid in proper Screen selection.

Drive) MUST be maintained with a 0.036 to 0.060″ (0.9 to 1.5 mm) gap between the Sensor Contact Point and the adjacent Sprocket. A lesser gap causes the Contact Point to make contact with the Sprocket due to Sprocket wobble or under lighter loads. A greater gap causes the Torque Sensing device to ratchet without releasing the Electric Clutch.

NOTE: The Torque Sensing device has a relatively short ratchet life.

1 4

NOTE: To minimize the increased horsepower requirements, BE SURE to use the Sprocket which gives the longest acceptable Length of Cut in conjunction with the Screen. It should also be understood that the use of a Recutter Screen increases horsepower requirements and reduces harvesting capacity.

NOTE: To reduce the shelled corn loss from the Lower Feed Rolls, use a shorter Length of Cut Sprocket.

Screen Recommendations Material

Screen Size

Haylage

4I Square

Corn Silage

4I or 3I Square

TORQUE SENSOR CONTACT POINTS (Fig. 41) NOTE:

The following information applies ONLY to Harvesters which are equipped with Torque Sensors for overload protection.

To operate with maximum capacity sensing capability, the Torque Sensor Contact Points for each Sensor (one on the Feed Roll Drive and one on the Attachment

2 3

1 – Contact Point 2 – Chrome-plated Sprocket 3 – 0.036 to 0.060I (0.9 to 1.5 mm) gap 4 – Gap Adjustment Screw & Locknut

Fig. 41

METAL STOP SOLENOID & STOP PAWL (Fig. 42) NOTE: The following information applies ONLY to Harvesters which are equipped with Metal Detectors.

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 (3) Bolts in the Solenoid Mount and slide the Mount towards or away from the Ratchet Wheel. After the 1/8″ (3 mm) clearance is obtained, tightly secure the (3) Bolts.

45

SCRAPER (See Fig. 31) 1

2

CAUTION BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE attempting to adjust the Scraper.

6 3

4 5

7

1 – Solenoid Mount Attaching Bolts 2 – Stop Pawl 3 – Solenoid 4 – Eyebolt 5 – 3 Rings 6 – 1/8″ (3 mm) 7 – Ratchet Wheel

Fig. 42

The (3) 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.

After the preceding adjustments are made, recheck the Solenoid operation to insure that the Stop Pawl moves freely.

REAR CYLINDER TIE (See Fig. 38) The Rear Cylinder Tie is provided as a stabilizer to maintain the position of the Cylinder Sidesheets. When desired or otherwise as necessary, the Tie can be removed for additional clearance to install a Recutter Screen or to adjust the Cylinder Knives.

CAUTION The Cylinder Tie MUST ALWAYS be in place BEFORE operating the Harvester.

The Cylinder Tie is attached with the same hardware which secure the Cylinder Cover Mounting Brackets.

After the Tie and Cover Mounting Brackets are loosely attached, align the Cover Mounting Brackets following details provided under the Cutting Cylinder topic in the Service chapter.

46

NOTE:

The Scraper MUST ALWAYS be set within 0.010I (0.25 mm) from the Smooth Feed Roll in order to prevent excessive wear on the Length of Cut Sprocket and to help prevent excessive horsepower consumption.

The Scraper, for the Rear Lower Smooth 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 1/2I 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 Cutterbar Support.

NOTE: Raise the Stem Deflectors, above each end of the Scraper, 1/4I (6 mm) to provide clearance for removing the Scraper.

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 1/2I 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.

NOTE: When the Scraper is reset, BE SURE to set the Stem Deflectors down against the Cutterbar and 1/32I (0.8 mm) forward of the cutting edge of the Cutterbar on its lower end. Carefully rotate the Cutting Cylinder (by hand) to make sure the Knives do NOT strike the top of the Stem Deflectors. 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.

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 Sidesheet, between the Scraper and Feed Roll. It is build-up in this area that

causes higher Torques which wear the Sprockets and increase horsepower consumption.

SQUARE HOLE SCREENS (Fig. 43) Square Hole Screens are available in hole sizes from 3/4 to 4I (19 to 100 mm). Refer to the Setup & Assembly chapter for installation details.

2

1

6.

Replace the Cylinder and Spinner Covers and tightly secure them.

7.

Reinstall the Telescoping Drive and start the Harvester. Some ticking will probably occur; this is permissible and even desirable since operating the Harvester will eventually eliminate it.

NOTE:

Slightly ticking Knives are acceptable (and even desirable) but, if the Harvester can NOT be easily started or if the Knives are making loud noises, the Screen MUST be readjusted.

High spots on a Screen can be beaten-down with a heavy bar, if they are NOT too close to the Screen Flanges. The Screen can only be moved about 1/4I (6 mm) inward from its initial position, with the Knives set out to a 9I (228 mm) radius. If the Screen can NOT be moved into the Knives far enough, the Knives will have to be reset and sharpened.

NOTE: Screens are also reversible so that, when the edges of the Screen holes become rounded, the Screen can be removed, rotated and replaced with the sharp edges facing the Knives.

1 – Square-holed Screen 2 – Screen Adjustment Cam (2 of 3 each side)

Fig. 43

After the Screen is installed or after the Knives are sharpened, the Screen MUST be properly adjusted so that harvesting capacity is NOT decreased or so that power is NOT wasted due to hairpinning of the crop at the edges of the holes.

To adjust the mounted Screen, proceed as follows: 1.

Remove the Spinner Cover and Cylinder Cover.

2.

Loosen the Cam Bolts just enough so that the Cam Nuts can be rotated.

3.

Turn the Spinner Disc (by hand) and, starting with the forward, then the middle and then, the rear Cams, turn each Cam Nut counterclockwise on the right side and clockwise on the left side until the Screen stops the Cutting Cylinder. Then, backoff the Nuts slightly. Repeat this process for all of the Cam Nuts.

4.

5.

After all of the Cam Nuts are adjusted, repeat the adjustment because the last adjusted Cams will affect the position of the Screen with respect to the first adjusted Cams. Adjust the Screen as close as possible to the Knives; a slight ticking is permissible.

Retighten the Cam Bolts.

STEM DEFLECTORS (See Fig. 31) Right and Left Stem Deflectors are located above the Cutterbar at each end. These Deflectors prevent forage stems from moving around the ends of the Knives. The bottom Deflector edges should be set down against the Cutterbar and the curved rear edges should be positioned about 1/32 to 1/16I (0.8 to 1.6 mm) from the Knives.

To adjust the Deflectors, loosen the two 3/8I Hexagon Head Cap Screws which are threaded into the Deflectors. Move the Deflector by tapping the 3/8I Screws.

When the Deflectors are properly positioned, retighten the two Screws.

NOTE: 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.

TIRES, WHEELS & AXLES (Figs. 44 & 45) The Harvester can be obtained with either Standard Single Wheel, Flotation Tire or Tandem Axles.

All Axle options fit into the Harvester Frame in the same manner. Once the Axle Extensions are installed, the Axle Spacers (“L”-shaped Brackets) can be secured and remain in place.

47

requirements of the Attachment and field conditions.

Each Spindle is secured to the Axle Extension with (4 each) 1/2 x 1-1/2I Cap Screws, Lock Washers and Nuts.

1

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.

2

3

1 – Axle Extension 2 – 1/2 x 6″ Cap Screw Securing Axle Extension 3 – Axle Spacer Mounting Bolt (1 of 2)

Fig. 44

The various positions for the Spindles are illustrated.

BE SURE to set both Spindles to the same height. 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, readjust the Axle Extensions or Spindles and resecure the attaching hardware.

Flotation Tire Axles, Wheels & Spindles (Figs. 44 & see Figs. 46 & 47) 2 1

3

1 – Axle Extension 2 – Axle Spacer 3 – Left Tandem Axle Beam

Fig. 45

Standard Single Wheel Axles, Wheels & Spindles (Figs. 44 & see Figs. 46 & 47) 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.

A single 1/2 x 6I 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 48

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.

A single 1/2 x 6I Bolt, Lock Washer and Hexagon Nut are used to secure the Extension to the Frame.

The Flotation 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 (4 each) Cap Screws, Plain Washers, Lock Washers and Nuts.

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.

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 resecure the attaching hardware. To change the Spindle height, temporarily loosen (but do not remove) the 4 Capscrews in each

Spindle. Then, Slide the Spindle up or down and resecure the Spindle attaching hardware. BE SURE to set both Spindles to the same height.

Tandem Wheel Axles, Spindles, Wheels & Tires (Fig. 45, 46 & see Fig. 48) 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 6I Bolt, Lock Washer and Nut are used to secure each Extension to the Harvester Frame.

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. The Spindles are secured with a total of (6 each) 1/2 x 1-1/2I 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.

NOTE:

The topmost Spindle Mounting Bolts require only to be temporarily loosened when the Spindle positions are readjusted.

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 resecure the hardware.

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:

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

Two metal doughnut-shaped Spacers (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.

NOTE: The following information applies only to equipping Tandem Axles with other than the Tires furnished with each factory provided assembly.

A Tire, with larger than a 27I outside diameter, can NOT be used on the right front Wheel if the Harvester is going to be operated with an HA1100 or HA1110 Hay Attachment. A larger Tire will interfere with the HA1100 or HA1110 Attachment Flotation Wheel and the right sidesheet of the Attachment will cut the Tire while passing-over an object which raises the right front Tandem Wheel as the Attachment drops below the normal ground position.

WAGON HITCHPLATE (Fig. 49) Two Wagon Hitchplates are provided on the Harvester.

One of the Plates is attached in the “Transport” position and is designed to locate the trailing forage box as far to the right as possible for viewing traffic behind the box while traveling on a public highway. The other Hitchplate can be mounted in any one of many positions to align the forage box tires between the crop rows, as required. A “mud’’ position is also provided, on the far left end of the Frame, for use in helping to reduce Harvester side draft when operating in muddy or soft fields. Suggested Wagon Hitchplate positions, relative to the various Attachments, are identified in the illustrations provided.

49

A - Tandem Axle Wheel B - Single Axle Wheel C - Wagon Hitch Plate D - 48 (1211) Min. to 72 (1821) Max. E - 78 (1981) Min. to 98 (2489) Max. w/Standard Tires 80-1/2 (2045) Min. to 98 (2489) Max. w/Flotation Tires F - 83 (2118) Min. to 98 (2494) Max. G - Centerline of Cutting Cylinder

H - 27-13/16 (706) Min. to 51 (1295) Max. w/Standard Tires 30-5/16(770) Min. to 51 (1295) Max. w/Flotation Tires J - Transport Hitch Plate K - 50 to 100 (1270 to 2540) L - 33 (838) Min. to 51 (1300) Max. M - Tongue N - 20 (508)

All Dimensions are in Inches (Millimeters) Unless Otherwise Noted

L

F

A

K

M G

B

J C

N

D

H

E Fig. 46

50

A - Standard Axle Extension (Top Surface) B - Axle Extension C - Spindle Plate D - Wheel E - High Harvester Spindle Position F - Low Harvester Spindle Position

A

E

C

A

B

F D NOTE: Flotation Axle NOT Shown

Attachment

Row Width in Inches (mm)

Left Axle Hole

Right Axle Hole *

Harvester Height

Hay

–

2

1

Low

28 (710)

3

1

30 (760)

4

S=2/ F=1

32 (810)

6

S=2/ F=1

34 (860)

6

S=3/ F=2

36 (910)

2

3

38 (960)

2

3

40 (1020)

2

4

28 (710)

6

4

30 (760)

2

5

32 (810)

2

5

34 (860)

3

6

36 (910)

4

6

38 (960)

5

6

40 (1020)

6

6

2-Row

3-Row

High

High

* S = Standard Axle, F = Flotation Axle Fig. 47: Single Wheel and Flotation Axle & Spindle Positions

51

A D D

H

B 5

4

3

2

1 F C D G

A - Right Front Wheel B - Axle Extension C - Spindle Plate (Typical) D - Beam (Top Surface) E - Right Rear Wheel F - Spindle Plate Assembly in “High” Harvester Position G - Spindle Plate Assembly in “Low” Harvester Position H - Spindle Bolt (1 of 6)

H E

Attachment

Row Width in Inches (mm)

Left Axle Hole

Right Axle Hole

Harvester Height

6-ft Hay

–

2

4

Low

7-ft Hay

–

2

3

Low

28 (710)

2

1

30 (760)

4

1

32 (810)

5

1

34 (860)

5

1

36 (910)

5

2

38 (960)

2

3

40 (1020)

2

3

28 (710)

5

4

30 (760)

5

4

32 (810)

2

5

34 (860)

2

5

36 (910)

4

5

38 (960)

5

5

40 (1020)

5

5

2-Row

3-Row

Fig. 48: Tandem Wheel Axle & Spindle Positions

52

High

High

1

2

C

B

A

3

4

5

6

7

F E

8

A - Left Side B - Main Frame C - Right Side D - Wagon Hitch Plate

D

Attachment

Row Width in Inches (mm)

Wagon Hitch Plate Holes

Highway Transport

–

E&F

Hay

–

4&5

28 (710)

1&2

30 (760)

4&5

32 (810)

3&4

34 (860)

2&3

36 (910)

1&2

38 (960)

1&2

40 (1020)

1&2

28 (710)

5&6

30 (760)

4&5

32 (810)

7&8

34 (860)

6&7

36 (910)

5&6

38 (960)

4&5

40 (1020)

4&5

–

1&2

2-Row

3-Row

Wet Ground

FE

Fig. 49: Wagon Hitch Plate Positions

53

CHAPTER 8 LUBRICATION GENERAL INFORMATION

CAUTION

1 2

NEVER attempt to 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 proceeding to lubricate this equipment.

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

TRANSMISSION LUBRICATION (Figs. 50 & 51) 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.

1 – Reverse Delay Switch 2 – Front Reservoir Breather Plug

Fig. 51

NOTE: Do NOT remove the Reverse Delay Switch; this Switch MUST be precisely set for proper operation of the ’’reverse engagement’’ cycle.

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.

1

2

2 1

1 – Rear Reservoir Breather Plug and Plate 2 – Rear Reservoir Oil Level Plug

Fig. 52

1 – Front Reservoir Oil Level Plug 2 – Rear Reservoir Breather Plug and Oil Level (Accessed from Rear of Drive Frame)

Fig. 50

54

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 which 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.

NOTE:

Do NOT overfill either assembly; only fill them to the bottom of their Level Plug holes.

SPINNER GEARBOX The Spinner Gearbox requires 1 U.S. Quart (1 liter) of lithium-base grease. The Gearbox is packed at the factory and requires NO further attention unless service is performed on the Gearbox requiring removal and replacement of the grease.

NOTE: 1 U.S. Quart (1 liter) of lithium-base grease will fill about 1/2 of the Gearbox volume.

Overfilling the Gearbox will cause grease to be forced out around the Shafts and Bearings.

DRIVE CHAINS Lubricate all Drive Chains every 6 to 8 hours of operation using a good grade of foaming aerosol lubricant such as NAPA Chain and Cable Lubricant.

This type of lubricant increases the life of the Chain 3 to 4 times over those lubricated at 8 hour intervals with new or used 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.

NOTE:

To minimize wear on the Sprockets, the Chains should be replaced after they become worn 3% longer than their original length or otherwise when the Tightener (where provided) has reached the end of its adjustment.

AMMONIA SILAGE ADDITIVE NOTE: Gehl Company does NOT recommend running ammonia silage additives through any part of the Harvester because of their damaging effects on Bearings.

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

It should only be introduced at the Blower in the top portion of the Blower Outlet, in order to keep the ammonia away from the 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 which are exposed to ammonia vapor.

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

Lubricate Every 10 Hours (or Daily) The Rotating Telescoping PTO Drive Guard

Lubricate Every 50 Hours Torque Sensor Contact Pivot Points (Torque Sensorequipped models ONLY) Blower Belt Idler Pivot Points Rear Feed Roll Guides (both sides) Knife Sharpener Guide Bearings (10 places)

Lubricate Every 100 Hours (or Annually) Drawbar Pivot Pin All Hinged-Cover Hinges Feed Roll Spring Strap Pivots (both sides) Feed Roll Stabilizer Pivots (both sides) Spout Control Worm Bearings

HYDRAULIC CIRCUITS The Harvester can be equipped with one or two hydraulically-powered control systems; the standard Attachment Lift Cylinder/Knife Sharpener system and an optional 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. Only the Knife Sharpener Hydraulic system is primed at the factory.

GREASING NOTE:

Grease all fittings on a prescribed basis, at the intervals of operation listed, before and after storing the unit, and as otherwise listed. Use a good grade of lithium-base grease.

Wipe dirt from the fittings before greasing to prevent dirt from being forced into the Bearing or pivot. Replace any missing fittings when noticed. Force grease into the fitting until it comes out at the Bearing Seal or the Shaft.

To minimize dirt build-up, avoid excessive greasing.

NOTE:

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 the Spout Worm and Gear. Periodically, lubricate the Telescoping Drive Shaft and Tube.

55

Grease Fitting Locations

12.

Overrunning Clutch (2 places)

Grease Every 10 Hours (or Daily)

13.

Electric Clutch Hub

1.

Telescoping Drive (2 places for 1-3/8 Drive or 3 places for 1-3/4 Drive)

14.

Attachment Drive Cross

2.

Main Drive Cross

3.

Right Feed Roll Stabilizer Bar Bearing

4.

Left Feed Roll Stabilizer Bar Bearing

5.

Grease Every 50 Hours 15.

Blower Outlet Flange* (2 places)

16.

Remote Rear Blower Bearing

Right Feed Roll Guide Bearing

17.

Spinner Drive Bearing

6.

Left Feed Roll Guide Bearing

18.

Right Cylinder Bearing Housing

7.

Upper Feed Roll Drive (3 places)

8.

Lift Tube Cast Bearing

9.

Cylinder Drive Crosses (2 places)

10.

Right Lift Tube Sleeve Bearing

* To distribute the grease over the entire Flange area, first grease both fittings at one position. Then, rotate the Deflector 90° and grease both fittings again. Then, rotate the Spout back-and-forth a couple of times to spread the grease.

11.

Left Lift Tube Sleeve Bearing 13 31

30

9 9 28

2

12 Rear Master

15 25

4 16

17

56

3

19.

Right Lower Rear Feed Roll Bearing

Grease Every 100 Hours (or Annually)

20.

Right Lower Front Feed Roll Bearing

30.

Knife Sharpener Torque Arm

21.

Right Upper Front Feed Roll Bearing

31.

Knife Sharpener Motor Adjustment Screw

22.

Right Upper Rear Feed Roll Bearing

32.

Left Quick-switch Attachment Drive Hub

23.

Remote Left Lower Front Feed Roll Bearing

Grease Each Time a Bolt is Sheared or At Lease Once a Year

24.

Remote Left Lower Rear Feed Roll Bearing

33.

25.

Left Cylinder Bearing Housing

26.

Remote Left Upper Front Feed Roll Bearing

27.

Remote Left Upper Rear Feed Roll Bearing

28.

Front Blower Bearing

29.

Feed Roll Input Chain Idler Arm Pivot

Feed Roll Shear Flange (Shear Bolt-equipped models ONLY)

Grease Each Time an Attachment is Changed or At Lease Once a Year 34.

Left Lift Roller

35.

Right Lift Roller

7

8 27

6

26 32

5

21

29 33

22

19 20

18

Front Master

24

23 35

1

10

11 14

1

1 1

34

1-3/8″ Drive

1 1-3/4″ Drive

57

CHAPTER 9 SERVICE

CAUTION

bolts. These (2) bolts require adjustment to restore the Idler Pulley alignment.

BEFORE proceeding to perform all Service routines on 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 Motors, Hoses and Fittings should be routinely checked after every 100 hours of operation for leaks and secure attachment.

BEVEL GEARBOX NOTE:

Internal Bevel Gearbox component repairs and replacements should only be attempted by (or under the direction of) an authorized Gehl equipment dealer. The Bevel Gearbox is a mechanism which requires special tools and training to attempt repairs; only your Gehl dealer has the facilities and trained personnel to provide this service.

BLOWER

1 – Blower Drive Shield Mounting Bolts (2 of 6)

Fig. 53

To install a new Belt, reverse the removal process. Make sure that the new Belt is completely into the Grooves of the Sheaves before restoring Idler tension. After the Belt is replaced and if the Idler Support was removed, BE SURE to replace and tightly secure the (4) Idler Support bolts.

3

4

1

6 5

2

Drive Belt (Fig. 53 & 54) The Blower Drive Belt should be checked for cracks, tears and evidence of oil after every 50 hours of operation. To remove the Belt, first remove the (6) Bolts which secure the Blower Drive Belt Guard assembly and remove the assembly. Then, lift the Idler, push the slack Belt towards the Blower and, lower the Idler until the Spring is loose. With tension released, slip the Belt off the Drive and Driven Sheaves. If the Belt does NOT clear the Idler Pivot, loosen the (4) bolts at the bottom of the Idler Support and tilt the Support rearward to obtain more clearance. Loosening the (4) bottom Support bolts will NOT disturb the factory set Idler Pulley alignment. Do NOT loosen the (2) top Support 58

1 – Blower Drive Sheave 2 – Idler Support 3 – Tension Spring 4 – Belt Idler 5 – Blower Drive Belt 6 – Blower Driven Sheave

Fig. 54

Drive Sheave (Fig. 54) To remove the Drive Sheave from the Output Shaft of the Bevel Gearbox while the Gearbox is on the machine, remove the Sheave Retaining Bolt from the end of the Shaft and retain all washers, used as spacer shims, for replacement, in the same amount and order, when

Sheave is replaced. The Sheave can NOT be removed from the Shaft without removing the Belt Idler Pivot Stand. When reinstalling the Sheave, place an Internal and External Tooth Lock Washer onto the 1/2 Bolt between the Shaft and heavy Retaining Washer; tighten the 1/2 Bolt with 60 to 70 ft-lb.

1 3

Blower Driven Sheave (Fig. 54) To remove the Blower Driven Sheave from the Harvester, first remove and retain the (6) fasteners which secure the Blower Belt Guard assembly and remove the assembly. Next, release Drive Belt tension and remove the Belt from the Blower Driven Sheave. Then, remove and retain the Bolt and Washer from the end of the Blower Shaft. The Driven Sheave can now be slid-off the Blower Shaft. When reassembling the Sheave onto the Blower Shaft, the Toothed Lock Washer is reinstalled onto the Retaining Bolt between the Blower Shaft and the heavy Retaining Washer. Tighten the Bolt with 60 to 70 ft-lb torque.

4 2 1 – Cleanout Cover 2 – Paddle Arms 3 – Spinner Tunnel Opening 4 – Fan Paddle

Fig. 55

1

Rim Sheet Wear Liner (Figs. 56 & 57)

2 4

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 Sidesheets.

NOTE: If the Blower Fan requires removal for service and/or the Rim Sheet Wear Liner has to be removed and replaced, the following suggested procedure should be carried-out. In addition, do NOT attempt to transport the Harvester without securing the Rim Sheet in place; doing so could result in damage to the Blower Outlet and/or Sidesheets.

Rim Sheet Removal 1.

Remove and retain the (6) fasteners which secure the Blower Belt Guard assembly and remove the Guard assembly.

3

5

6 7

2.

Release the Drive Belt Idler tension by lifting the Idler, pushing the slack Belt towards the Blower and lowering the Idler until the Spring is loose.

Then, detach the base of the Idler Support by removing the (4) mounting bolts.

1 – Rim Sheet Assembly 2 – Wear Liner* 3 – 5/16 x 1 Plow Bolts, Lock Washers & Nuts (3 each) 4 – 5/16 x 3/4 Plow Bolts, Plain Washers, Lock Washers & Nuts (8 each)* 5 – 5/16 x 3/4 Flat Head Socket Cap Screws, Lock Washers & Nuts (3 each)* 6 – Spacer 7 – Removable Rim Shell

3.

Remove the three 5/16 Plow Bolts from the bottom of the Outlet at the point where the Rim Sheet assembly is attached to the Outlet.

* Included in Rim Liner Kit 094948.

Fig. 56: 3-piece Rim Sheet & Liner Assembly

59

3

2

1

7

1

5

3 4

2

6 8

1 – Blower Outlet Attachment End

2 – Rim Sheet Liner

3 – Rim Sheet

Fig. 57: Rim Sheet Liner Tightening Sequence Detail (Tighten in Order 1 through 8)

4.

To loosen the Rim Sheet assembly, a 2 x 4 wooden block MUST be used through the Spinner Chute Inlet hole and the access hole in the rear Sidesheet.

While striking against the Rim Sheet assembly with the wooden block, rotate and slide the Rim Sheet down so that the end with the (3) holes can be freed from between the Outlet and the Blower Side Sheets.

NOTE: The block of wood is recommended to help prevent denting a reusable Rim Sheet. If the Rim Sheet is worn out and being replaced, it is NOT necessary to be so careful.

5. After the Rim Sheet is loosened from the base of the Blower Outlet, remove the Jam Nuts and the Take-up Nuts from the Bolts at the top of the Rim Sheet and Blower Outlet.

6. Loosen the top of the Rim Sheet by driving it away from the Blower Outlet. Then, before proceeding, make sure that the entire perimeter of the Rim Sheet is freed from the Blower Sidesheets.

7. Raise the top of the Rim Sheet away from the Blower Sidesheets. Then, pull the Rim Sheet to the rear while rotating it counterclockwise. Continue to pull the Rim Sheet counterclockwise until the 3-hole end of the Rim Sheet clears the right end of Blower Frame.

8. Detach the Wear Liner from the removable Rim Shell.

NOTE: After the Rim Sheet assembly has been removed, clean the outside edges of the front and rear Blower Side Sheets.

60

Wear Liner Installation & Rim Sheet Assembly Replacement 9.

10.

Preassemble the three pieces of the Rim Sheet. a.

Properly position and attach the Removable Rim Shell to the Rim Sheet with the Spacer and (3 each) 5/16 x 3/4 Flat Head Socket Head Cap Screws, Lock Washers and Nuts.

Tightly secure the attaching hardware. If removeable Rim Shell is NOT replaced, disregard this step.

b.

Properly align and loosely attach the Wear Liner to the Rim Sheet Shell Section with (8 each) 5/16 x 3/4 Plow Bolts, Plain Washers, Lock Washers and Nuts; hardware will be tightly secured after Rim Sheet is in position on Harvester (following step 14.).

c.

Clean-out all paint and foreign material from the Rim Sheet grooves. Then, apply a light coating of grease into the grooves around the entire edges of the Rim Sheet assembly.

Properly position and install the 3-piece Rim Sheet in somewhat the reverse manner as the original Rim Sheet assembly was removed. Reinstall the Rim Sheet by starting at the area of the Blower Outlet and placing the 3-hole end of the Rim Sheet back against and around the Sidesheets first.

Guide the Rim Sheet around the Blower in a clockwise direction.

NOTE:

When the Rim Sheet is being installed, it can possibly become hung-up on the material thickness transition point at the base of the Blower Outlet. To facilitate moving the Rim Sheet past this transition; it may be necessary to slide a thin sheet of material past this transition point which can serve as a guide for the end of the Rim Sheet.

11.

Guide the end with the (3) holes between the Blower Side Sheets and the Outlet. Using a drift punch, align the holes in the Rim Sheet and Liner with the holes in the Outlet and tightly secure the three parts with (3 each) 5/16 x 1 Plow Bolts, Lock Washers and Nuts.

12.

Force the Rim Sheet against the Sidesheets around the entire perimeter of the sidesheets. Insert the flanged-end of the Rim Sheet under the lip of the Blower Outlet.

13.

With the Rim Sheet assembly correctly aligned and using a rubber mallet, block of wood or lead hammer, tap along the Side Sheet edges of the Rim Sheet, starting at the Blower Outlet end, to properly seat the Blower Side Sheets into the Rim Sheet grooves.

14.

Reinstall the Takeup Bolts and, in an alternating manner, tighten two Nuts while striking against the Rim Sheet Beads to seat the Rim Sheet assembly. Secure the Takeup Nuts with 40 ft-lb (54 Nm) of torque and tighten the Jam Nuts.

15.

After the 3-piece Rim Sheet is properly installed and secured, tightly secure the Wear Liner hardware in the manner defined by the drawing (Fig. 57).

16.

Rotate the Blower Fan, by hand, to check for interference.

17.

Readjust the Fan Paddles following the details in the Adjustment chapter of your manual

18.

Reinstall the components removed in steps 1 & 2.

NOTE:

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 ft-lb (54 Nm), as necessary

CHAINS & SPROCKETS Sprocket wear is most often caused by an excessively worn Chain. A Chain which has worn 3% (1.03 times the original length) should be removed and replaced.

This Harvester is designed so that when the Chain Tightener reaches the limit of its adjustment, the Chain has reached a condition of maximum wear. To calculate the original Chain length, multiply the number of Links times 3/4” for a #60 Chain or, times 5/8” for a #50 Chain.

CUTTING MECHANISM (Figs. 58, 59, 60 & 61) Cutterbar The edge of the reversible Cutterbar (Shear Bar) will remain sharp provided the Knives are kept sharp and the Cutterbar is properly set up to the Knives. When the cutting edge NO longer stays sharp, the Cutterbar can be removed and sharpened or changed (end-for-end) to place a new sharp edge toward the Knives. To remove and replace the Cutterbar, proceed as follows:

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 Cutterbar.

1

2

3

1 – Proper Wear 2 – Cutterbar (see Proper & Improper Wear Views) 3 – Improper Wear

Fig. 58

61

6.

1

2

From the right side, pull the Cutterbar out from under the left side Cutterbar Hold-down Pin and remove the Cutterbar.

3

1 4

4

2

3 5

7

6

5 6

1 – Hold-down Pin Assembly (Do NOT Loosen) 2 – Cam 3 – Lockstrip 4 – Cutterbar Clamp U-Bolt 5 – Cam Pivot U-Bolt 6 – Slot Baffle 7 – Cutterbar (Left End)

Fig. 59

7

8

1 – Cutterbar Right Adjustment Nut 2 – Cutterbar Clamp Bolt 3 – Tie Bolt 4 – Tie Bolt Nut 5 – Stud Assembly 6 – Smooth Feed Roll Scraper 7 – Left Side Cutterbar Adjustment 8 – Cutterbar Support

Fig. 60

1.

It may be necessary to remove the trash between the Cutterbar and the Feed Roll Scraper before the Cutterbar can be moved. Using the Remote Adjustment Shaft and the Right Adjustment, move the Cutterbar forward until the rear edge of the Cutterbar is flush with the rear edge of the Cutterbar Support Channel.

2.

Remove the Cutterbar Holddown Bolt, Washer and Nut on the right side of the Cutterbar.

3.

Do NOT remove, loosen or alter the position of the Cutterbar Hold-down Pin on the left side.

4.

Loosen and remove the Lock Nuts, Slot Baffle and Cutterbar Cam U-Bolt on the left side; retain all attaching hardware. BE SURE to use new Lock Nuts when Cutterbar is replaced.

5.

Remove and retain the right side (1/2 x 6) Tie Bolt.

Do NOT disassemble the Right Side Adjusting Mechanism.

NOTE: In order to remove the Cutterbar, it may be necessary to loosen both pairs of Stem Guide mounting bolts and move the Stem Guides up to free the Cutterbar. After the Guides are moved, retighten the bolts to keep the Guides away while replacing the Cutterbar.

62

Replacement 7.

Before attempting to replace the Cutterbar or install a new Cutterbar, BE SURE that it is thoroughly cleaned. In addition, clean-off the Cutterbar Support behind the Smooth Feed Roll Scraper.

Apply grease or a lubricant to the entire bottom side of the Cutterbar to facilitate sliding it back into its mounting position and to facilitate adjustment.

8.

Install the Cutterbar with end bevels facing “up”.

Force the left end of the Cutterbar under the Spring-loaded Cutterbar Hold-down Pin on the left side.

9.

Do NOT attempt to loosen the left side Hold-down Pin Sleeve. Make sure however, that the Pin is free to slide in its Sleeve.

10.

After the Cutterbar is properly aligned, reinstall the right side Tie Bolt and Nut.

11.

Apply grease in the Cutterbar Cam groove and reinstall the left side Cutterbar Cam U-Bolt, the Slot Baffle and the Lock Nuts. Torque the Lock Nuts so that the U-Bolt pulls the Cam tightly against the Slot Baffle and Cutterbar.

12.

Retighten the right side Hold-down Bolt and Locking Nut.

Cylinder Cover (Fig. 62) 1

2 3

4

The Cylinder Cover Mounting Brackets are secured with the same hardware which attaches the Rear Cylinder Tie Plate to the Sidesheets. If the Tie Plate is removed for access to the Knives (for removal), the Cylinder Cover Mounting Brackets MUST be properly repositioned and secured. When properly attached, the Brackets MUST be secured with their notches on top and facing towards the rear of the Harvester. The proper method to attach and align the Brackets is as follows: 4

5

6 1

7

8 9

2

3

5

6

1 – Plastic Cover Over Sleeve 2 – Cotterpin 3 – Hold-down Pin Sleeve 4 – Left Cylinder Side Sheet 5 – 3/4″ Locking Nut 6 – Left Side Cutterbar Hold-down Pin 7 – Cutterbar Support 8 – Spring Washers 9 – 5/8″ (16 mm)

Fig. 61: Left Side Hold-down Assembly

Refer to the Cutterbar topic in the Adjustments chapter to make the proper Cutterbar adjustments for operation.

BE SURE to reset the Stem Guide positions if they had been changed. Set the Stem Guides down against the Cutterbar and make sure that they are clearing the Cutting Cylinder by 1/32 to 1/16″, to prevent damage to the Knives. Then, retighten the Stem Guide Bolts.

NOTE:

Loose Stem Guide Mounting Bolts will allow the crop to push the Stem Guides into the Knives and severely damage the Cutting Cylinder.

1 – Cylinder Cover 2 – Spinner Cover 3 – Bolt and Spring Assembly 4 – 1/2 Carriage Bolt and Nut Securing Elevator Position 5 – Rear Rail Height Adjustment Cam 6 – Bracket & Tie Mounting Bolts (2 each side)

Fig. 62

1.

Loosen (but do NOT remove) the Nuts which secure the Brackets to the Rear Cylinder Tie.

2.

Force the Cutting Cylinder Cover tightly against the Front Cylinder Tie Plate.

3.

Install the Spinner Cover and tighten the Holddown Knobs.

4.

Force the Cover Mounting Brackets forward against the Cylinder Rods on both sides of the Cylinder Cover. Then, tighten the (4) Nuts securing the Brackets and Tie Plate.

Knife Replacement (Fig. 63) After numerous sharpenings, Knives will be grounddown 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:

63

6.

CAUTION BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding.

1.

The space between the Cutterbar and Scraper will first have to be cleaned of debris. Then, move the Cutterbar forward to the end of its adjustment slots.

2.

After implementing the proper precautions, remove the Spinner and Cylinder Covers. For better access, remove the (4) Bolts holding the Sidesheet Tie and remove the Tie.

3.

After the Screen (if present) is also removed, loosen the (3) Bolts which secure the Knife to the Cylinder Headers.

Adjust the Cutterbar and Knives following the details given in the Adjustment chapter of this manual.

NOTE: BE SURE to watch 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.

SPOUT (Fig. 64) A replaceable Liner is built into the Spout which can be removed by taking-out (8) Plow Bolts. After the hardware is removed, the Liner can be guided through the Spout and removed from the Cap end, without taking the Spout off the Blower Outlet. To facilitate removal, it may be necessary to temporarily remove a Horizontal Spout Extension, if present. New Liner installation is in reverse of old Liner removal. As necessary, remove any or all of the Cleanout Hole Covers for access to the Liner and Plow Bolts.

2

2

1 1

3 3 4

5 4

1 – Sidesheet Tie 2 – Knife Bolt (1 of 3 per Knife) 3 – Cylinder Header (1 of 3)

6

Fig. 63

4.

Secure the replacement Knife to the Cylinder Headers with the (3) Knife Bolts. Torque each Bolt to 220 to 240 ft-lb.

NOTE:

Knife Bolts are threaded into Special Nuts which are positioned in the Header slots with their thin sides facing the left side of the Harvester.

5.

64

After the Knives and Cutterbar are adjusted, replace the Sidesheet Tie following details under the Cylinder Cover subtopic in this chapter.

7 1 – Liner 2 – Cap 3 – Spout 4 – Cleanout Cover 5 – 5/16 x3/4 Plow Bolt (6 Total) 6 – 5/16 x 1 Plow Bolt (2 Total) 7 – Attaching Hardware

Fig. 64: Spout and Wear Liner Assembly

KNIFE (& CUTTERBAR) SHARPENING

WARNING Because the tractor engine will be running while the Knives or Cutterbar are being sharpened, BE SURE that the Telescoping PTO Drive Connection is removed from the tractor PTO shaft.

NOTE: To facilitate rotating the Cylinder Knives while sharpening them, BE SURE to suspend the Harvester Telescoping Drive with the Spring provided. In addition, make sure that the Electric Clutch is open.

General Information The Knife Sharpener is designed to operate with any tractor capable of delivering a continuous 8 gpm supply of oil at 1500 PSI (10500 Kpa). The hydraulic circuit is equipped with a Check Valve for the Knife Sharpener Motor which prevents running the Motor backwards.

Thus, hydraulic hose hook-up to the tractor has NO particular orientation except to establish which way the tractor Remote Control Lever has to be moved to run the Sharpener Motor. A Hydraulic Fuse is included in the pressure line. This Fuse allows NO more than 9 gpm to flow thru it. Quantities in excess of 9 gpm cause the Fuse to snap shut and stop the Motor, and thus prevent overspeeding the Grinding Stone. If the Fuse snaps shut, it can be reset. This is done by moving the tractor Remote Control Lever momentarily to the position opposite of the running position. Like an electric circuit, if everything is in order and the Motor will NOT turn, the Fuse is tripped-out and MUST be reset to restore Motor operation.

Since few tractors deliver the same quantity of oil (gpm) to the remote circuit and since the gpm determines the RPM of the Hydraulic Motor, the first use (and first use only) with any unproved tractor will require one of two settings to be determined. On Open Center System tractors, the throttle setting will determine the Sharpener Motor RPM while on Closed Center System tractors, the Needle Valve will determine the RPM and thus, require setting.

The type of system used in your tractor will be found in your tractor’s Operators Manual.

Open Center System Tractors NOTE: The Needle Valve is NOT used with this type of tractor and should be left wide open. If it has been closed-down for use on a Closed Center System tractor, open it (counterclockwise).

To determine the tachometer setting at which the unit should always be operated, first, idle the tractor at low idle and engage the remote control lever, starting the Sharpener Motor. Increase the tractor RPM until the Motor cuts out. The Hydraulic Fuse has tripped at around 9 gpm. A tachometer reading of 100 RPM less than this cut-out value is the proper speed at which the Sharpener should be operated with this tractor.

When you are ready to grind the Knives or Cutterbar, set the tractor throttle to this tachometer setting and engage the remote control lever.

Cold hydraulic oil can trip the fuse at your “normal” tachometer setting. BE SURE to run the Sharpener at lower than the rated speed, BEFORE starting to sharpen the Knives or Cutterbar, until the oil is warm. Once the oil is warmed-up, the Sharpener can be operated at the “normal” tachometer setting to grind.

NOTE: DO NOT try to operate above this setting as it will cause frequent tripping-out of the Hydraulic Fuse.

Closed Center System Tractors The throttle will have no control over the gpm on these tractors.

1000 RPM on the tachometer will be a good spot to run while using the Needle Valve to control the oil flow.

To find the proper setting for your tractor, turn the Valve shut (full clockwise) and back it off 2 turns. Engage the remote control lever, to start the Sharpener Motor. Open the Needle Valve slowly until the Motor stops. The Hydraulic Fuse has tripped-out at 9 gpm. Close the Needle Valve 7/8 turn (clockwise) and gently lock it in place with the Jam Nut. Reset the Hydraulic Fuse. Now, the system is permanently set for operation with this Closed Center System tractor.

Most new tractors have a readily accessible flow control of their own and you may prefer to use it. Its setting would be accomplished in a manner similar to the one described above. A scribe mark on the dial of the control, below the ’’Trip-out’’ point, will make it easy to reset without trial and error if it is required to move the control for other operations. Remember, however, that the Gehl Needle Valve and the tractor control are interdependent and a change in either between usages will effect the RPM of the Hydraulic Motor.

65

On some tractors the remote control lever is either spring-loaded to neutral or will kick out under low hydraulic pressures. These levers will have to be tied, with wire or rope, to prevent undesired disengagement.

the Knife to make sure that it travels freely. Then, return the Carriage to the ’’storage’’ side of the Rails.

1

Preparation (Fig. 65) The Selector Valve is mounted on the Attachment Lift Cylinder, near the front of the Toolbox. Switch the Selector Valve to the Knife Sharpener circuit.

Unlatch the Sharpener Cover and tip it forward over the Feed Roll Housing. Remove the Spinner and Cylinder Covers. Clean crop and debris from the undersides of the Knives so the Lower Guide Rollers can operate smoothly. In addition, BE SURE that the top surface of the Sharpener Rails are also clean. Remove the Draw Rod from its storage position.

2

NOTE:

Before operating the Knife Sharpener, make sure the entire unit is properly lubricated; the Sharpener has two Grease Fittings.

Cylinder Knife Sharpening (Fig. 66)

1 – Sharpener Carriage 2 – Drawrod (in “Storage” Hole position)

Fig. 65: Sharpener in Storage Position

1

WARNING BEFORE operating the Knife Sharpener, remove the Telescoping Drive connection from the tractor PTO shaft and turn the Control Box Keyswitch to ’’OFF’’ and remove the Key. ALWAYS wear Safety Goggles (furnished in Toolbox) when operating the Knife Sharpener.

3 5

2

4 With the Carriage at the storage end of the Rails and using a gloved left hand, turn the Cylinder and draw the Carriage toward the Knife until the Knife is caught between the two sets of Roller Guides under the Stone.

One set of Rollers bears-down against the top side of the Knife while the other set of Rollers bears-up against the bottom side of the Knife. A curved ’’lead-on’’ Plate is also provided to help rotate the Knife into position between the Roller Guides. Lower the Stone until it just contacts the Knife. Move the Carriage all the way across

66

6 1 – Stone Adjustment Knob 2 – Rail Height Adjustment Cam 3 – Right Side Upper Guide Spring 4 – Right Side Upper Guide Roller 5 – Guide Block Slotted Mounting Holes 6 – Lower Roller Guide 7 – 3/8 x 3-3/4 Carriage Bolt

Fig. 66

7

Start the Sharpener with the tractor remote control lever and make the first pass with the Stone set according to the information in the preceding paragraph. Make one pass each way on each Knife. Use a 1/8 turn of the Stone Adjustment Knob for each new cut but only after all Knives have been ground with the same number of passes at the previous setting. Totally grinding one Knife at a time will produce cutting edges at various radii which will make a close Cutterbar setting to all of the Knives impossible.

After making a complete circuit of all the Knives with one Stone setting, the Stone itself will have worn away.

This means that the last Knife of the circuit will NOT be ground-down quite as much as the first Knife in the circuit. A good technique for overcoming this problem is to start the second circuit on the last Knife to be ground on the first circuit, i.e. after finishing the last Knife, turn the Stone down 1/8 turn of the Knob and begin grinding on this same Knife to start the next circuit. This Knife now becomes the first Knife on the new circuit and you should then stop and start this time on what was the second to the last Knife on the first circuit. Thus the starting point will work its way around the Cylinder with each succeeding pass. A chalk mark identifying each starting Knife as it comes up will help you to keep yourself straight.

2 1

3 1 – Rear Rail 2 – Front Rail 3 – Cutterbar Installed for Sharpening

Fig. 67

To set-up the Cutterbar for sharpening, proceed as follows: 1.

Place the Sharpener Carriage in ’’storage’’ position at the left side of the Cylinder.

2.

Raise the Stone approximately 3/4” (19 mm) higher than the setting used for Knife sharpening.

3.

Loosen the 1/2” Nut which secures the Elevator so that it is free to move up or down in the slot. Remove the 3/8 x 3-3/4 Carriage Bolt from the right side. Then, place the Cutterbar into the location shown while orienting it in the same position and direction as it was when removed from the Harvester. When properly oriented, the edge to be sharpened will be closest to the Sharpener Stone.

With the Cutterbar correctly oriented, place the innermost of the two left side horizontal Cutterbar holes onto the stub of the Cutterbar Elevator.

4.

While holding the right end of the Cutterbar approximately 2” (51 mm) above the Support as shown, pull the Sharpener Carriage to a position where the Stop Plate on the Carriage is to the right of the Elevator. Make sure one of the Cylinder Knives is in place between the Roller Guides.

If the Cutterbar wears improperly, as shown, where NO sharp edge exists to act as a scissor blade for the Cylinder Knives, the Knife Sharpener can be used to renew the Cutterbar edge.

5.

Lay the Cutterbar on the right side Support and reinstall the 3/8 x 3-3/4 Carriage Bolt and tighten the Nut until the Cutterbar is lifted clear of the Cylinder Knives on the left side.

To understand the function of the Sharpener, realize that the Cutterbar is set at an angle to the incoming crop as shown. To renew the cutting edge, the Cutterbar is sharpened so that it parallels the crop sliding over it.

6.

Move the Carriage over to the right end of the Rails (raise the Stone some more if necessary) and make sure that one of the Cylinder Knives is in place between the Roller Guides.

NOTE: Traverse the Carriage in a smooth movement across the entire length of the Knife to prevent burning and to insure a smooth, uniform grind.

Cutterbar Sharpening (Figs. 67, 68, 69 & 70 & see Fig. 58) A Cutterbar (Shear Bar) does NOT need sharpening just because it is worn but rather, because it becomes improperly worn. The Gehl Company manufactures its Cutterbar so that, if it is set up close to sharp Knives, it will wear ’’sharp’’ and ’’parallel’’ to the crop sliding across it. This is shown in the illustration provided.

As long as the tungsten carbide facing provides a nice sharp lip to the cutting edge of the worn corner, the Cutterbar is as good as ’’brand new’’ (even better than ’’brand new’’).

67

7.

With the Carriage positioned over the right end of the Cutterbar, lower the Stone to a distance of approximately 1/16” (1.5 mm) from the Cutterbar.

8.

With a 1/16” distance established on the right side, move the Carriage to the left end of the Cutterbar.

NOTE: BE SURE that the Carriage is moved over only as far as the Stop Plate will allow. The Stop Plate prevents the Cutterbar from being ground too far to the left end which would result in removing a surface which is contacted by the Adjustment Cam. BE SURE that the Carriage Stop Plate is on the Cylinder Knife side of the Plate which is attached to the Cutterbar Elevator Mechanism or it will NOT be possible to draw the Stone Carriage across the Knives after the left side is set.

2

1 1 – Elevator Plate 2 – Stop Plate on Carriage (moved outside Elevator Plate for Clarity)

Fig. 69

WARNING 1 2

4

3

BEFORE operating the Knife Sharpener, remove the Telescoping Drive connection from the tractor PTO shaft and turn the Control Box Keyswitch to ’’OFF’’ and remove the Key. ALWAYS wear Safety Goggles (furnished in Toolbox) when operating the Knife Sharpener.

NOTE:

Before operating the Knife Sharpener, make sure the entire unit is properly lubricated; the Sharpener has two Grease Fittings.

12.

Start the Sharpener Motor and lower the Stone into contact with the Cutterbar until sparks appear.

Take the full stroke on each pass across the Cutterbar and crank the Stone down about 1/8 turn after each pass. Continue to make passes across the Cutterbar until NO roundness remains on the cutting edge and until the Tungsten Carbide-facing meets the cutting edge all the way across the entire length of the Cutterbar. It is NOT essential that the ground-down bevel be absolutely straight. However, if the Cutterbar setting was NOT made exactly correct, the bevel can always be adjusted by running the Stone across the least ground portion of the Cutterbar until the bevel is ’’true’’.

13.

Do NOT grind any more than is necessary to restore the sharp edge and do NOT grind more than halfway down. This could cause the Cutterbar to become too weak to support the cutting load.

1 – Cutterbar Elevator Mechanism 2 – Left End of Cutterbar 3 – Stub Engaging Hole in Cutterbar 4 – 1/2″ Elevator Nut

Fig. 68

9.

Tighten the 3/8″ Nut on the Carriage Bolt until the left end of the Cutterbar is brought to a distance of 1/16″ from the Stone and then, stop tightening the 3/8 Nut.

10.

With the Cutterbar levelled below the Stone, tighten the 1/2″ Elevator Nut (above the Front Rail) to secure the position of the Elevator.

11.

Move the Carriage to the center of the Cutterbar and eliminate any downward bow to the Cutterbar (if present) by further tightening the 3/8 Nut on the Carriage Bolt until the center of the Cutterbar is at the same 1/16” distance from the Stone as the two ends were.

68

14.

Sufficient grinding will remove all of the notch in the cutting edge on the right end of the Cutterbar.

This notch acts as a lead-in for the tilted Knives preventing the pointed leading edge of the Knife from driving into the top of the Cutterbar.

NOTE: Always restore the notch on the right end of the Cutterbar (when it has been removed by the Sharpening Stone) before attempting to reinstall and adjust the Cutterbar. Use a benchmounted grinder to restore the notch.

1

longest lasting Knife edges, the Stone be set to provide a clearance of 1/32″ and 1/16″ between the Heel of the Knives (trailing edge of the beveled surface) and the Cutterbar. This is the factory setting. So that you may check this clearance, a Template has been included with the Sharpener and stored in the Toolbox. The drawing provided shows how it is used and what to look for.

Lay the Template across the cutting edges of any two ground Knives and parallel to the Cylinder Side Sheets.

Check the gap between the ground surface and the Template. Best performance will be obtained if the gap on a fully ground Knife measures from 1/32 to 1/16″.

The bevel on a new, unground Knife will measure about 1/16″. Grinding with the factory setting might produce two bevels until the original bevel has been removed.

1

3

1

2

1 – Lead-in Notch in Reversible Cutterbar

Fig. 70

15.

After sharpening Cutterbar, BE SURE to remove it from its sharpening position, replace it into its operating position, lower and secure the Elevator and store the 3/8 x 3-3/4 Carriage Bolt.

4 5

Storing Sharpener (See Fig. 65) After sharpening is finished, return the Carriage to the storage position. Replace the Draw Rod Handle into its storage hole, replace and secure appropriate Guards and Covers and switch the Selector Valve back to the Lift Cylinder circuit.

Make Cutterbar, Knives and Screen adjustments, as applicable, following details given in the Adjustments chapter.

Sharpener Adjustments Stone Angle (Figs. 71 & 72 & see Fig. 66) The Knife Sharpener has a limited adjustment to provide the correct Knife Heel-to-Cutterbar clearance.

We recommend that, for the highest quality cut and the

1 – Improper Heel Contact 2 – Template 3 – Proper Heel Relief 4 – 1/32″ to 1/16″ (0.75 to 1.5 mm) 5 – Knives

Fig. 71: Template (Provided) Being Used to Gage Heel Relief

If adjustment is necessary because of too much Heel gap, the Roller Guide should be moved rearward in its slots. If there is too little gap or heel contact, the Roller Guide should be moved forward in its slots. Moving the Block half the length of the slot will change the Heel gap by about 1/16″ (1.5 mm). BE SURE that both Lower Roller Guides are touching the Knife before retightening the Block Bolts.

69

3

2

1

4 1

3

2

6

5

7

1 – Left Upper Roller 2 – Lower Roller Guide 3 – Carriage 4 – Rear Guide Block Mounting Bolt 5 – Guide Block 6 – Sharpener Stone 7 – Front Guide Block Bolt

Fig. 72

NOTE: After the Roller Guide Block position is relocated, the Upper Roller Spring tension MUST be readjusted.

Guide Arm & Roller Adjustment (Fig. 72) The only requirement for adjustment of the Roller Guide Arm is that both of the Rollers MUST be touching the Knife when both are positioned below the Knife. To get both Rollers to touch, loosen the Front Guide Block Bolt and rotate the Roller Guide assembly. If both Rollers are NOT made to touch the Knife, a jump will be made in the surface of the sharpened Knife when one or the other of the Rollers leaves the Knife, at the end of the stroke, allowing the other Roller to become the guide.

Rail Alignment (Fig. 73 & see Fig. 66) To check Rail alignment, first position the Sharpener Stone over the left corner of a Knife. Using the Motor Position Adjustment Knob, adjust the Stone position for a measured gap of 1/8” (3 mm) from the Knife and position it over the right corner of the Knife. Measure the clearance between the Knife and Stone on this side; it should also be 1/8”. If the clearance is more or less than 1/8”, change the height of the right end of the Rear Rail by rotating the Adjusting Cam on the Right Rear Post supporting the Rail.

70

1 – Bolt & Spring Assembly 2 – Rear Left Post 3 – Cam on Right Rear Post

Fig. 73

The forward and back snugness of the Stone Carriage is controlled by Bolt and Spring assemblies on the Front Right Post and Rear Left Post. Loosen the Locking Nuts on the Bolts which attach the front and rear Rails to their respective Posts. Then, using the Rail and appropriate sized allen wrench, rotate the Rail Attachment Carriage Bolt clockwise to obtain more clearance between the Rollers or counterclockwise to reduce the clearance between the Rail and Carriage Rollers. After the desired clearance is obtained, retighten the Locking Nuts.

Spring Plate, Spring & Upper Roller Adjustments (See Fig. 66) The Upper Roller tension for both Rollers MUST be reset whenever the Lower Roller Guide Block is repositioned. Begin by positioning the Sharpener Carriage at the point on the Rails where the Right Upper Roller is next to (but NOT on) the right end of one of the Knives. Loosen the Adjustment Bolt so that all Spring tension against it is released. Next, move the Spring assembly up or down in its slots to bring the bottom of the Roller flush with the bottom side of the Knife. After tightening the Bolts in the slot, tighten the Adjustment Bolt until the bottom of the Roller is approximately 1/16” (1.5 mm) below the top surface of the Knife.

Lastly, retighten the Locking Nut to fix the Roller position. Repeat this same procedure for the Left Roller on the left end of the same Knife.

Sharpener Carriage Removal (See Fig. 69) It may be desirable to remove the Sharpener Carriage from the Rails to facilitate Stone replacement. To remove the Carriage, first temporarily remove and retain the Stop Plate which is secured with (2 each) Carriage Bolts and Lock Nuts. With the Stop Plate removed, the Sharpener Carriage can be guided-off the right end of the Rails.

REMOTE GREASE LINES Several Remote Grease Lines are provided on the Harvester to facilitate lubrication of otherwise difficult to reach relubeable Bearings. If a Remote Grease Line is damaged or broken, it can be replaced by ordering a Tubing Kit (Gehl #065185).

Drive Chain Idler tension, perform the following steps.

While holding-up on the Latch, force the Idler Sprocket Yoke down until a hole (in the Tube) appears below the Latch. Then, insert a 1/8” diameter pin (such as a nail) thru the hole in the Tube to retain the Yoke in that position. Then, the Drive Chain can be uncoupled and removed.

Procedures for Grease Line replacement are covered in Instructions packaged with the Kit.

SHIFTER TRANSMISSION

2

1

NOTE:

Shifter Transmission component repairs and replacements should only be attempted by (or under the direction of) an authorized Gehl equipment dealer. The Transmission is a mechanism which requires special tools and training to attempt repairs; only your Gehl dealer has the facilities and trained personnel to provide this service.

SPEED MONITOR (Fig. 74) NOTE: The Speed Monitor is NOT used on Shear Bolt models.

3 4

5

The Blower Speed Monitor Module is NOT repairable.

If it is NOT operating properly, your dealer will have to determine if it MUST be replaced.

The Blower Speed Monitor Module is an integral part of the Spinner Gearbox Cover. When replacing the Spinner Gearbox Cover, make sure that the Cover is installed so that the Magnetic Pickup of the Module is directly over the Horizontal Shaft Gear. Also, to prevent damage to the Magnetic Pickup, a Gasket MUST always be present between the Gearbox Housing and the Cover.

6 1 – Drive Chain 2 – Spinner Driven Sprocket 3 – Idler Sprocket 4 – Spinner Drive Sprocket 5 – Idler Sprocket Yoke Tube 6 – Latches

Fig. 75: Spinner Drive Chain Detail

Drive Chain For access to the Drive Chain, Tensioning Mechanism, the Drive and Driven Sprockets, remove the Spinner Drive Guard. Access to the Spinner Disc and Paddles, is gained by removing the Spinner Cover.

1 1 – Spinner Gearbox Cover with Speed Monitor

Fig. 74

SPINNER (Figs. 75 & 76 & see Fig. 63) The Spinner is linked by a direct Chain drive to a Sprocket on the end of the Cutting Cylinder Shaft. When the Drive Chain is uncoupled and removed, the Spinner should be free to rotate (by hand). To release the Spinner

NOTE: The Gearbox is packed at the factory with 1 U.S. Quart of lithium base grease. BE SURE to restore the proper amount of grease after performing service inside the Gearbox. Refer to the Lubrication chapter for additional details.

Disc & Paddles To remove the Spinner Disc, Paddles and Hub, proceed as follows: 71

1.

Detach and remove the Spinner Cover.

1

2

4

3

1 – Cap Screw into Top of Shaft 2 – Spinner Hub 3 – Shear Bolts (2) 4 – Spinner Paddle (1 of 6)

Fig. 76

2.

3.

TIRES & WHEELS

Remove the Spinner Disc assembly, by removing the two Shear Bolts attaching the Disc assembly to the Spinner Hub. Then, lift the Disc away from the Hub. Another method is to remove the Cap Screw from the top end of the Vertical Shaft and lift the Hub and Disc assembly off the Vertical Shaft.

To remove each Paddle from the Disc, remove the (2) fasteners from each Paddle.

WARNING 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 instruction. If you do NOT have such instructions, contact your tire dealer or the GEHL Company. In addition, inflating or servicing tires can be dangerous. Whenever possible, trained personnel should be called to service and/or mount tires. In addition, do NOT place fingers on tire bead during inflation; serious injury or amputation could result! In any event, to avoid possible fatal or serious 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.

•

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.

•

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

TELESCOPING PTO DRIVE

WARNING NEVER attempt to mix the halves of a 1-3/8 Drive with the halves of a 1-3/4 Drive. Each of the halves of the two Drive assemblies are manufactured to different lengths which if mixed, could cause the Drive to separate while it is turning and thus prove to be very hazardous.

NOTE: Besides the personal hazard of intermixing 1-3/8 and 1-3/4 Drive halves, the consequence of incompatible operation of the two improper halves could cause permanent damage to the Drives. To prevent mixing Drive halves, the Male and Female splines and the Rotating Guards on 1-3/4 Drives are manufactured opposite those on 1-3/8 Drives.

72

Check the Forage 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 ft-lb (124.5 N-m) torque.

Tire (Inflation) Pressures

Test #2 - A minimum of 8-1/2 volts MUST exist across the Electric Clutch wires

Inflation Pressure

If the voltage readings of tests 1 and 2 are NOT obtained, check all Plugs and connections and find a source, closer to the tractor battery or starter cables, to move the Control Box Power Supply lead wire connections to.

Size & Description

PSIG

kPa

11 L x 14 6-ply Rating

26

182

12.5 L x 15 8-ply Rating

24

168

16.5 L x 16.1 8-ply Rating

24

168

Because the wiring system in most tractors is too light, it will normally be impossible to connect the Control Box Power Supply leads beyond the starter cables and still be able to obtain and maintain the required voltages.

Tandem 27 x 9.50-15 6-ply Rating

40

280

If a tractor is NOT available to check out the Harvester electrical system, proceed as follows: 1.

Attach the Control Box to a 12 volt D.C. battery and add a battery charger; if necessary.

2.

Attach a battery jumper cable from the Negative (-) terminal of the same battery to the Harvester Frame.

3.

Perform the preceding Test #1 and Test #2.

ELECTRIC CONTROLS (See Figs.

79, 81, 80, 82 & 78) The Control Box is located on the tractor and is linked to the Feed Roll Drive and the Spout and Cap Gearmotors through Wiring Harnesses with Plug Connectors. Refer to the Wiring Diagrams, provided at the end of this chapter, for circuit wiring and troubleshooting references.

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

CAUTION BEFORE proceeding, remove the Telescoping PTO Drive Coupling from the tractor PTO shaft.

With the Control Box attached to the tractor battery, 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 Switches in the ’’Reverse’’ mode.

NOTE: The Circuit Breaker, in the Control Box, will trip-out when the Reversing Switch is held on for approximately 12 seconds.

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

NOTE: 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 attempted by (or under the direction of) an authorized Gehl equipment dealer. These mechanisms require special tools and training to attempt repairs; only your Gehl dealer has the facilities and trained personnel to provide this service.

Reburnishing Electric Clutch (Fig. 77) NOTE: A Reburnishing Tool can be obtained from your local Gehl dealer. In addition, a 37 Tooth Length-of-Cut Sprocket will have to be ordered separately.

WARNING BEFORE proceeding, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

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 carrying-out the following procedure: 73

6.

2

After reconnecting the Telescoping PTO Drive, run the Harvester at full tractor PTO RPM and engage the Electric Clutch in ’’Reverse’’ for 10 to 12 seconds.

WARNING

3 1

After slipping the Clutch for 10 to 12 seconds, it will be smoking and very HOT; DO NOT TOUCH THE CLUTCH! 7.

Allow the Clutch to cool-off; this should take approximately 1 hour. Do NOT attempt to expedite cooling by using water as this may cause warpage.

8.

If the Clutch did NOT smoke when step 6 was carried-out, repeat steps 6 & 7.

9.

With the PTO running at a speed as close to idle as possible while still keeping the tractor running when the Clutch Electric is engaged, continue to engage and disengage the Electric Clutch in short bursts until the Grade 5 Cap Screw in the Reburnishing Tool fails.

10.

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. 77

1.

2.

3.

4.

5.

74

Shut off the tractor engine and detach the Telescoping PTO Drive.

Remove the Clutch Electromagnet and Armature from the Harvester and clean the components with safety solvent.

After the components are cleaned, replace them onto the Harvester.

Remove the Attachment Driven Sprocket Chain and loosen the Length-of-Cut Drive Chain.

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.

(Tractor)

(Harvester)

OFF To Implement Harness on Torque Sensor Models

ON Water System Control Box

This Plug NOT Used

1

7

3

To Outlet Plug of Control Box

Water Solenoid Valve

19

Stop Pawl Solenoid

B

25 26

Flasher

Signal Light Box

3 8

Clear Black

A

Com.

Tunnel Switch Adapter Harness (Shear Bolt Models Only)

19

9

N.O.

1

20

GND

(Hay Attachment)

N.C. 2

GND Harvester Frame

GND

10

Tunnel Switch shown with no Crop in Tunnel

C D E

Detector Lower Front Feed Roll

To Implement Harness 23

10

GND

24 Amplifier Board

10

GND

13

1 Amp Fuse

21

Bat

9

C/B 6A

Aux

14

Amplifier Box

20 3 GND

14 19 8 (This Box is sealed - do NOT open)

Fig. 78: Accessory Water Tank System Controls (Top) & Optional Metal Stop System (Bottom)

75

4

6 2 B C

18

4

10

CH

7

18

8

6

10

3

15

14

D

A

H

7

14

CH

14

GND

4 GND Implement

2

3

CH

8

15

17

Outlet

12 11

16

19

0

Red

White

Battery

12VDC (+) (_ ) Battery Tractor Frame Fig. 79: Control Box for Shear Bolt Model Harvesters

76

Fig. 80: Harvester-mounted Electrical Controls for Shear Bolt Models

77

3

5

2

6

3

2

6

1

GND

1

7

GND

4

Implement Wiring Harness

GND

4

5

1

7

3

3

Control Wiring Harness (On Tractor)

2

5

5

4

GND

2

1

7

1

GND

2

6

5

3

5

Clutch Wiring Harness

3

This Plug NOT Used

3 1

Harvester Frame

GND

2

5

Terminal Block (Inside Feed Roll Drive Frame) 25

7

GND

Black

Green

White White

6

7

7

25

4

4

A

(_ ) (+) Up

Cap Motor

B

3 6 9

Reverse Solenoid

Reverse Relay

Rectifier (Inside Slip Ring)

White (_ )

Green (+)

Clutch & Slip Ring

(_ )

(+)

White ( _)

Green (+)

Black (+) Deflector (_ )Right Motor Red

Black

Red

Shifter Transmission

Forward Spring

Trans.

Switch

0

GND

1 4 7

Rev.

4

Fwd.

CH

6

7

12

CH

2 2

10

18

CH 10 14

CH

14

D

19

9

20

8 1

Outlet

4 19

H 0 4

GND

A

5

20

14 3

2

PINK

PINK 3

17 PINK

PINK 18

100

B

C 15

9

2

13

CAP

8

10

12

PINK

PINK

RELAY

PINK

16

11

A

A

3 6 9

20

6

5

1 4 7

H

B D SPOUT

19 PINK

C

PINK

CH

0

8

5

B

CH

19

4 GND

6

Battery

Red

White

100

12VDC (_ ) (+) Battery Tractor Frame

Fig. 81: Control Box for Torque Sensor and Metal Detector Model Harvesters

78

Fig. 82: Harvester-mounted Electrical Controls for Torque Sensor and Metal Detector Models

79

1

43

5

7

6

1

Gnd

N.O.

N.C.

Gnd Gnd 1 1 2 3 4 5 6 6 7 7 8 9 10

Com.

A B C D E F G H J K L M N P R S

Tunnel Switch shown with no Crop in Tunnel

42

C

C

5

Control Wiring Harness (On Tractor)

GND

3

2

4

7

10

9

2

3

42

5

6

8

1

GND

B

A

3

B

A

42

3

A B C D E F G H J K L M N P R S 7

6

1

Gnd

Implement Wiring Harness

Gnd Gnd 1 1 2 3 4 5 6 6 7 7 8 9 10

To Water System

Speed Monitor

43

Bypass (When Grounded) Power In (+12VDC)

Internal Ground Ground (At Low Speed)

6

7

4

2

1

Red

Red

A

B

A

B

C

(+) (_ ) Right

(_ ) (+) Up

Harvester Frame

GND

GND

Black

8

E

7

9

3

C D

Black

10

B

GND

7

GND

A

To Metal Detector

3

3

8

White

Black

Rectifier (Inside Slip Ring)

White (_ )

Deflector Motor

Reverse Solenoid

Clutch & Slip Ring

(_ )

(+)

Shifter Transmission

Green (+)

Cap Motor

A

B

A

B

C

Forward Spring

Trans.

Switch

2

Attachment Drive Torque Sensor

Feedroll Torque Sensor

Rev.

(Top)

Fwd.

White (_ )

Green (+)

CHAPTER 10 PREPARING FOR FIELD OPERATION TRACTOR HITCH ALIGNMENT (Figs. 83 & 84) 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 the 1″ dia. Hitchpin furnished with the Harvester to help center the Harvester Tongue with the tractor drawbar and reduce the amount of side to side movement. Keeping the Tongue in-line and minimizing side to side movement is essential in eliminating drive-line vibration, especially when maneuvering corners.

The front to rear position of the tractor drawbar hitch hole centerline MUST be correct to insure the proper Universal Joint relationship. The tractor drawbar hole should be 16″ (405 mm) from the rear of the 1-3/8 diameter 1000 RPM tractor PTO Shaft, or 20″ (508 mm) from the rear of the 1-3/4 diameter 1000 RPM tractor PTO Shaft.

2 1 4

3

4 5

2 1 6

4 3

7

5 6

7

1 – Tractor Drawbar* (Top View) 2 – Drawbar Pin Hole In-Line or to Left (as close as possible) of PTO Centerline 3 – 1000 RPM Tractor 1-3/4 PTO Shaft* 4 – 20″ (508 mm) (Center of Hitchpin to End of Shaft)* 5 – 8 to 12″ (203 to 300 mm)* 6 – 13 to 22″ (330 to 560 mm)* (Top of Tongue to Ground) 7 – Tongue Extension

* Tractor MUST comply with ASAE Standard S203 1 – Tractor Drawbar* (Top View) 2 – Drawbar Pin Hole In-Line or to Left (as close as possible) of PTO Centerline 3 – 1000 RPM Tractor 1-3/8 PTO Shaft* 4 – 16″ (405 mm), 1–3/8″ Diameter PTO Shaft* 5 – 15-3/8″ (428 mm) (Center of Hitchpin to End of Shaft)* 6 – 6 to 12″(150 to 300 mm)* 7 – 13 to 22″ (330 to 560 mm)* (Top of Tongue to Ground)

* Tractor MUST comply with ASAE Standard S203

Fig. 83: 1-3/8 PTO 1000 RPM

80

Fig. 84: 1-3/4 PTO 1000 RPM

DRAWBAR HITCH CLIPS (Fig. 84) The Hitch Clips MUST be relocated onto the Tongue Extension to provide a 20″ (508 mm) dimension, between the end of the Splined Drive Shaft and the Hitch Pin Hole in the Clips, to match 1000 RPM 1-3/4 tractor PTO Shaft requirements. This Extension is furnished with the 1-3/4 tractor PTO Telescoping Drive.

DRIVE LINE ALIGNMENT (Fig. 85)

PREPARING HARVESTER

After the Harvester Hitch Clips and Telescoping Drive are connected to the tractor, the Front Bearing Support should be raised or lowered to place the Fixed-length (Main Drive) and Telescoping Drive Shafts in a straight line (when viewed from the side). The straight-line alignment extends joint life by reducing joint vibrations.

To raise or lower Front Bearing Support, temporarily remove the Side Shields on the Front Bearing Stand and remove the (2 each) 3/8 x 5-1/2 Cap Screws and Plain Washers which are securing the Front Bearing Support to the Bearing Support Stand. Next, reposition Bearing Support so that both Shafts are in a straight line. After correct alignment is obtained, line-up the holes in the Bearing Support with appropriate pairs of holes and slots in each side of the Support Stand.

The following points of preparation will have to be made on the Harvester with respect to the Attachment being mounted. Refer to the Adjustments chapter of this manual and, if necessary, the appropriate Attachment Operator’s Manual for specific adjustment details and requirements.

1

6

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 Down–stop Adjustments. Refer to Attachment Positioning topic in the Adjustments chapter.

4.

Adjust the Wagon Hitchplate position, if required.

HARVESTER–ATTACHMENT ALIGNMENT (Figs. 86 & 87)

2 3

7

1.

4

5

1 – Tractor PTO Shaft Connection 2 – Telescoping PTO Drive 3 – Front Bearing Height Adjustment Bolts* 4 – Main Drive Shaft 5 – Bevel Gearbox Input Shaft 6 – Front Bearing Stand 7 – Tractor Drawbar

* Bearing Height MUST be adjusted for the tractor being used so that the Telescoping Drive and Main Drive Shaft form a straight line.

Fig. 85

NOTE: If the Bearing Support holes DO NOT match up when both shafts are in line, move the Support DOWN to the next pair of holes in the Support Stand. After the correct alignment for the Front Bearing is determined, insert and secure the hardware. Then, replace the Side Shields and resecure the attaching hardware.

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 man 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 Throatsheets to match the Harvester Sidesheet opening.

1.

Force the Harvester Lift Arms down to their lowest possible position by inserting the Down Stop Pin (1” Square Bar) into the hole in front of the Cylinder Link and retracting the Lift Cylinder completely. This prevents the Lift Rollers from interfering with the Attachment while it is being mounted.

81

1

1

2

1 – Down Stop Pin Locked in Hole in Front of Lift Link and Cylinder is Fully Retracted

1 – Typical HA1210 Driven Sprocket 2 – Attachment Drive Chain

Fig. 87

Fig. 86

2.

Drive the Harvester into the Attachment and observe that the Attachment Yokes slide over the Harvester Quick–switch Pivots and that the Attachment Throatsheets slide between the Harvester Feed Roll Sidesheets.

3.

Connect the Attachment to the Harvester by first forcing a punch into the Quick–switch Pin mounting holes to align them. Then, insert the Quick– switch Pins (from the Tool box) into the holes and secure them with the Hairpin Cotter Pins.

4.

Slowly extend the hydraulic Lift Cylinder and remove the Down Stop Pin from above the Lift Cylinder Link.

5.

Make the appropriate Attachment positioning adjustments according to the details provided in the Adjustments chapter of this manual.

CAUTION BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding.

82

6.

Align the Attachment Drive Sprocket with the Attachment Driven Sprocket by adding or removing Washers. After proper alignment is obtained, secure the Drive Sprocket with the Cap Screw, Lock Washer and Special Washer.

NOTE: Operating the Harvester with loosely secured Sprockets can cause excessive Shaft Spline wear.

7.

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.

Drive Chain Length Table Model Attachment

Number of Links

HA1100 or HA1110

48

HA1200 or HA1210

58

TR3038 TR330 or TR338

64

CHAPTER 11 TRANSPORTING TONGUE (Fig. 88)

Pins provided. Then, turn the Down–Stop Bolt fully downward into contact with the Down Stop Pin.

The Harvester is provided with a locking Tongue Latch 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 install the Lock Pin ahead of the Latching handle, to prevent the Latch from disengaging the Notch in the Frame.

1

2 1

2 3

3

1 – Lift Cylinder Fully Extended 2 – Down Stop Bolt 3 – Down Stop Pin Locked in Highest Hole Position

Fig. 89 1 – Tongue Latching Mechanism (Locked-in) 2 – Latch Lock Clip 3 – Transport Lock Decal on Tongue

Fig. 88: Hydraulic Tongue Kit (Installed)

LIFT SYSTEM LOCK (Fig. 89)

CAUTION The Attachment Lift system should be locked–up, in the following manner, anytime it is necessary to work under a mounted Attachment.

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 the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) and install the Down Stop Pin into the ”highest” possible (1 of 3) holes in the Lift Mechanism.

BE SURE to lock the Pin in this position with the Cotter

SAFETY CHAIN (Fig. 90) 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:

2

1

3 1 – Locking Hitchpin 2 – Clevis Bolted to Tractor Drawbar 3 – 30,000 Pound Accessory Safety Chain

Fig. 90

83

1.

Chain is sufficiently slack to allow turns and movements of either the tractor or the farm 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.

CAUTION ALWAYS follow state and local regulation 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 machines, 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 Emblem.

SMV EMBLEM & REFLECTORS (Fig. 91)

2 1

NOTE:

Slow–moving Vehicle Emblem MUST be purchased locally.

Because of the variations in the Safety Laws for different states and localities, it may be necessary to change the Emblem Bracket mounting location. Your GEHL dealer can assist you in relocating the Bracket, if necessary.

TOWING ON HIGHWAY(Fig. 91)

WARNING Good safety practice dictates that you NEVER tow an implement (without brakes) unless the towing vehicle weighs at least one-and-one half (1-1/2) times the weight of the towed implement and its load. 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. Do NOT tow a loaded wagon behind the Harvester on a highway unless the wagon has operational brakes.

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 the rear.

TRANSPORT LIGHTING

2 3

1 – SMV (Slow-moving Vehicle) Emblem Mounting Bracket 2 – Red Reflector Strips (2) 3 – Wagon Hitch for Highway Transport

Fig. 91

84

The Harvester is equipped with a Bracket for mounting a Slow–moving Vehicle Emblem (SMV) on the Rear Left Guard. Red Reflector Strips are also provided on the rear corners of the Harvester.

NOTE:

If the Harvester is going to be transported on a public highway, a Transport Lighting Kit should be obtained and installed per details provided with the Kit. An accessory Highway Transport Lighting Kit is available for all Harvester models. The Kit includes Lights, Wiring Harnesses, an Outlet, and installation instructions. The Outlet allows connecting the Transport Lights of a wagon towed behind the Harvester.

CHAPTER 12 STORAGE At the end of the harvesting season it is suggested that the following steps be performed:

7.

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

1.

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.

8.

Release tension on the Blower Drive Belt if the Harvester is going to be out of operation for a long period of time.

2.

Clean the Harvester thoroughly of all dirt, trash, excess grease and any other material that will absorb water and cause rust.

PROTECTION OF UNPAINTED SURFACES

3.

Thoroughly lubricate the Harvester as indicated in the Lubrication chapter.

4.

Clean and oil all Drive Chains.

5.

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

6.

Order and replace any required parts so the Harvester will be ready to operate the next season.

Apply a rust preventative oil or grease to the following unpainted surfaces: 1.

The Front Telescoping Drive Yoke Hub at the PTO drive end.

2.

The Front Bevel Gearbox Shaft Splines.

3.

All Drive Chains and Sprockets.

4.

The Length–of–Cut Sprocket Splined Shaft.

85

CHAPTER 13 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

CAUSE

REMEDY

Forage is NOT being blown adequately or Spout is plugging.

Operating too far below rated PTO speed.

Operate the tractor at the proper PTO speed. Check the Spinner Drive Chain to see if it is on the Sprockets. If a Speed Monitor is present: Check that Speed Monitor is plugged-in.

Check that all electrical Plugs are connected or, if the Speed Monitor is NOT functioning, have the unit checked per the electrical troubleshooting information provided to the dealer.

PTO is being disengaged before the Harvester is cleaned-out.

Disengage PTO only after all forage is cleaned-out.

Blower Rimsheet 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 Tank system.

Blower Paddles are NOT set-out to the Rimsheet.

Adjust Paddles; refer to Adjustments chapter.

Blower Belt slipping.

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

Spout Liner is worn through.

Replace Liner.

Spout Horizontal Extension is interfering.

Correct the Extension mounting, as required; refer to the Set-up & Assembly chapter.

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.

Rimsheet is loose.

Tighten Rimsheet Take-up after cleaning and greasing the Rimsheet grooves.

Bolts in Sidesheets are loose.

Tighten Bolts.

Blower Belt is coming off.

Blower Fan Blades are striking Blower Sidesheets.

86

CUTTING CYLINDER PROBLEM Crop will NOT feed into Cutting Cylinder.

Knives wearing-out rapidly.

Material is hairpinning on the Screen (when being used).

Stems are too long.

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 fluting.

NO Knife heel relief.

Use the Template provided to determine how much to adjust the Knife to Grindstone relationship.

Smooth Feed Roll Scraper is NOT sitting on 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.

Cutterbar is NOT set-up to Knives.

Correct the Cutterbar setting per details in the Adjustments chapter.

All the Knives are NOT at the same radius from center of the Cutting Cylinder.

Repeat the sharpening process making sure a different Knife is used to start the sequence each time the Sharpener Stone is lowered; see Service chapter.

Screen is NOT properly set-up to Knives.

Readjust Screen following details in Adjustments chapter.

Screen is worn excessively.

Remove, rotate or replace Screen.

Knives are worn excessively.

Sharpen the Knives and readjust their positions, as required.

Cutting Cylinder diameter is too small and Screen can NOT be properly set-up.

Adjust the Knife positions outward to increase the Cylinder diameter; see Service chapter.

Knives are NOT sharp.

Sharpen the Knives and readjust their positions, as required.

All the Knives are NOT at the same radius from center of the Cutting Cylinder.

Repeat the sharpening process making sure a different Knife is used to start the sequence each time the Sharpener Stone is lowered; see Service chapter.

Cutterbar is NOT sharp.

Sharpen, remove and rotate or replace the Cutterbar.

Cutterbar is NOT straight and/or set-up to the Knives.

Check if Cutterbar is straight and correctly set it up to the Knives.

NOT enough material depth in 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; see Adjustments chapter.

Stem Guides NOT correctly set to the Knives.

Set the Guides from 1/32 to 1/16″ from the cutting edge of the Cutterbar.

87

CUTTING CYLINDER (continued) PROBLEM

CAUSE

Long cobs in silage.

Knives are NOT sharp.

Sharpen the Knives and readjust their positions, as required.

Knife heel relief is too great.

Resharpen the Knives with a Grindstone to Knife heel relationship of 1/32 to 1/16″.

All the Knives are NOT at the same radius from center of the Cutting Cylinder.

Repeat the sharpening process making sure a different Knife is used to start the sequence each time the Sharpener Stone is lowered; see Service chapter.

Cutterbar is NOT sharp.

Sharpen, remove and rotate or replace the Cutterbar.

Cutterbar is NOT straight and/or set-up to the Knives.

Check if Cutterbar is straight and correctly set it up to the Knives.

NOT enough material depth in the Feed Rolls to hold stems.

Increase the ground speed or windrow size and/or reduce the Length-of-Cut.

Tractor RPM is dropping too low.

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

Knives are moved-out too far.

Reset the Knives with the Setup Bar.

Cutterbar is NOT moved fully forward.

Clean-out the material from in front of the Cutterbar before it is moved forward.

Knives are striking the Cylinder Sidesheet Tie and/or Cutterbar when Knives are moved-out.

REMEDY

DRIVE LINE Overrunning Clutch is NOT driving.

Drive Chains are jumping.

Drive Chains are NOT releasing from Sprocket and are noisy.

88

Clutch Dogs or Clutch Springs are broken.

Replace Dogs and/or Springs; contact your Gehl dealer for assistance.

Clutch Dogs are assembled backwards.

Contact your Gehl dealer.

Chain Tension Idler is NOT correctly positioned.

Correctly align and/or adjust tension per information in Adjustments chapter.

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.

SPOUT PROBLEM

CAUSE

REMEDY

Spout turns hard.

Spout Flange is dry.

Properly grease Spout Flange.

Cap moves hard.

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 and/or Spout Clamp Bracket to eliminate the binding.

Cap Gearmotor operate when Spout Control Switch is activated and vice-versa.

Plugs to the two Gearmotors are reversed.

Plug the wires from the Spout Gearmotor into the Main Harness Plug containing wires #6 & #7. Plug the Cap Gearmotor into the Plug containing wires #4 & #7.

Cap Motor or Spout Gearmotor operates slowly.

Binding in a joint.

Lubricate all joints and check for incorrect joint alignment.

Voltage too low.

Check for corrosion in the Plug connections. Clean the Plugs and, if problem is NOT corrected by this, contact your local Gehl dealer.

20 Ampere Circuit Breaker opens when Cap and Spout Switches are operated simultaneously.

The Control Box is wired such that the Circuit Breaker will trip if the Cap and Spout Switches are operated at the same time.

Operate only one Switch at a time.

Entire electrical control system is dead and does NOT function.

Circuit Breaker has tripped-out on the Control Box.

Reset the main Breaker.

Plug-together terminations or wires have separated.

Check the wiring and the Plugs.

FEED ROLLS & ATTACHMENT CONTROLS - ALL HARVESTER MODELS Feed Rolls will run Forward but NOT in Reverse.

Reverse Solenoid shifts but the Clutch does NOT engage in the “Reverse” position.

A Plug or wire is loose or corroded.

Check wiring and Plug connections; repair as necessary.

The Control Box Toggle Switches are NOT set in their proper positions.

Refer to the procedure for proper Switch operation in the beginning of the Operation chapter. If still NOT working, contact your Gehl dealer.

A Plug or wire is loose or corroded.

Check wiring and Plug connections; repair as necessary.

Transmission Switch is misadjusted or otherwise malfunctioning.

Contact your Gehl dealer.

For Shear Bolt models ONLY, the Reverse Relay on the Harvester is malfunctioning.

Check Harvester Relay wires for looseness, or incorrect installation. Refer to the Wiring Diagram and reconnect wires properly and securely.

89

FEED ROLLS & ATTACHMENT CONTROLS - ALL HARVESTER MODELS (continued) PROBLEM

CAUSE

REMEDY

Electric Clutch does NOT engage when Mode Switch is set to “AUTOmatic” and the Selector Switch is moved to the “Forward” position on Torque Sensor equipped models, or when the Toggle Switch is moved to “FORWARD” on Shear Bolt model.

Circuit Breaker is tripped, a wire is broken, or a Plug or a connection has separated.

Correct wiring and/or reset Breaker.

Check all Plugs and connections in the Main Wiring Harness and Clutch wires.

Clutch Coil is open.

Have the total circuit checked-out by your dealer.

Keyswitch is “OFF”.

Turn on Keyswitch.

Open contacts within the Brush Holder.

Have the total circuit checked-out by your dealer.

An improperly low voltage exists at the Electric Clutch.

On Torque Sensor models ONLY, check that the Mode and Selector Switches are properly set. If they are, check that there is NO less than 10-1/2 volts at the Electric Clutch wire Connecting Screw. If the voltage is “0”, set the Toggle Switch to the “MANual” position and check for a voltage reading.

If there is a voltage present, then the Selector Switch or the Control Box Relay is malfunctioning. Contact your Gehl dealer.

Proper contact is NOT being made between the Control Box and the tractor battery.

Check that White wire is correctly and properly connected to the battery (–) post and the Red wire is correctly and properly connected to the battery (+) post.

Circuit Breaker does NOT remain set.

FEED ROLLS & ATTACHMENT CONTROLS - TORQUE SENSOR-PROTECTED MODELS Only The Torque Sensor does NOT open the Electric Clutch but instead ratchets when overloaded.

90

The Mode Switch is in the “MANual” position.

Change the Switch setting to “AUTOmatic”.

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″ from face of Sprocket.

Readjust the contact gap per details in the Adjustments chapter.

Torque Sensor Sprocket or Contact Points are coated with a material which does NOT conduct electricity.

Clean the Sprocket and Contact Points with a safety solvent.

Excessive ratcheting has caused a breakdown of the internal components in the Torque Sensor.

Contact dealer for possible Torque Sensor replacement.

FEED ROLLS & ATTACHMENT CONTROLS -TORQUE SENSOR PROTECTED MODELS Only(con.t) PROBLEM The Feed Rolls and Attachment are stopping without apparent cause.

CAUSE

REMEDY

For units with Metal Stop System ONLY, the System is receiving false signals.

To determine if the Metal Stop is receiving false signals, proceed as follows:

Speed Monitor is generating a slow speed signal to the Control Box.

1.

Disconnect the 5-way Metal Detector Plug, inside the Feed Roll Drive Frame. Tape over the ends of both Plugs.

2.

Disable the Stop Pawl by connecting the Pawl Spring to the rear.

If the problem NO longer exists, then the problem is in the Metal Stop System, which MUST be handled by your Gehl dealer.

To determine if the Speed Monitor is generating a signal to the Control Box, proceed as follows: 1.

Check for a disconnected Plug at the Tunnel Switch. Reconnect it, as required.

2.

Check the Tunnel Switch Vane to see if crop material is jamming the Vane in the deflected position. Clean Vane, as required.

3.

After doing related steps 1 & 2, disconnect the Plug, at the Speed Monitor. If the problem NO longer exists, the Speed Monitor itself may have failed.

If NONE of the preceding steps correct the problem, contact your Gehl dealer.

The Feed Rolls and Attachment are stopping under a very light load right after they start to operate.

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 0.036″ from face of Sprocket.

Readjust the Contact gaps per details in the Adjustments chapter.

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 Contact does NOT make contact with anything which is grounded to the machine.

91

FEED ROLLS & ATTACHMENT CONTROLS -TORQUE SENSOR PROTECTED MODELS Only(con.t) PROBLEM

CAUSE

REMEDY

The “AUTOmatic” portion of the Control Box circuit is NOT functioning.

Faulty components exist inside the Control Box.

Contact dealer for a complete circuit troubleshooting test. In the mean time, Mode Switch can be set to “MANual” and careful harvesting can be carried out. BE SURE to avoid overfeeding the Harvester, since the reverse capability of the unit is temporarily deactivated in manual mode. The Torque Sensors, Speed Monitor, and Metal Detector are also deactivated in the “MANual” mode.

FEED ROLL DRIVE Feed Roll Drive overloads frequently.

92

Smooth Feed Roll Scraper packed with forage or raised above the Feed Roll.

Remove the Scraper, clean it and the Feed Roll and reposition the Scraper against the Feed Roll.

A Bearing has failed.

Replace the Bearing.

Material is being pulled between the Front and Rear Feed Rolls.

Remove the burrs and straighten the teeth of the Roll. If cutting straw, reduce the ground travel speed.

Feed Roll interference with the Attachment.

Check the Throatsheets 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 to the lowest position.

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.

FIELD OPERATION PROBLEM

CAUSE

High horsepower required.

Knives are NOT sharp.

Sharpen the Knives per details in Service chapter.

NO Knife heel relief.

Use the Template provided to determine how much to adjust the Knife to Grindstone relationship.

Cutterbar is NOT set up to Knives.

Correctly adjust Cutterbar to Knives.

Cutterbar is worn excessively

Remove and rotate Cutterbar to the second sharp edge, sharpen or replace the Cutterbar. Then, resharpen 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 Tank system.

Length-of–Cut is too short for the power available.

Increase the Length-of–Cut; using a longer Length-of-Cut may increase shelled corn loss.

Screen is NOT properly set up to Knives.

Readjust the Screen per details in the Adjustments chapter.

Screen is worn excessively.

Remove and rotate or replace the Screen.

Using too small a Screen for the Length-of-Cut desired.

Use a larger Screen and/or a longer Length-of-Cut.

Wagon Hitchplate is positioned too far to the right.

Move the Hitchplate to the left. If necessary, obtain and install Offset Trailer Hitch option to move Wagon farther 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 Drawbar too far to the left.

Move the Drawbar closer to the row.

Harvester and/or wagon tires are running on top of the row.

Reposition the Tires and Wagon Hitchplate to move between rows; see details in Adjustments chapter.

Tires are running on the rows.

Reposition the Tires per details in the Adjustments chapter.

Harvester Downstop position is set too high.

Adjust the Downstop position per details in the Adjustments chapter.

Harvester Frame is set too high.

Lower the Frame by moving the Wheel Spindles up.

Harvester is sidetracking.

Row Crop stubble is too long.

REMEDY

93

KNIFE SHARPENER PROBLEM

CAUSE

REMEDY

Sharpener Stone is gouging or skipping at the right end.

The lower left Knife Roller is NOT correctly positioned.

Adjust the Roller position per details in the Service chapter.

Sharpener Stone is turning clockwise when viewed from above.

Motor Check Valve is NOT functioning properly.

Inspect the Valve for dirt and contamination; repair or replace Valve, as required.

Sharpener does NOT work.

Hydraulic Fuse is tripped.

Reset the Fuse per details in the Service chapter.

Sharpener is kicking-out Fuse before the appropriately adjusted tractor speed can be reached.

Cold hydraulic oil in the tractor is tripping the Fuse too soon.

Run the Sharpener, without grinding the Knives or Cutterbar, until the oil is warm.

This should enable the normal tractor speed setting to be used for sharpening.

LIFT SYSTEM Attachment lift height is NOT correct.

94

Attachment is raising too high or dropping too low.

Adjust the the Lift Height Cam per details in the Adjustments chapter.

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 MACHINES PROBLEM Nothing happens when Harvester Control Box Switches, for the Feed Rolls, are moved.

Buzzer comes on when Mode Switch is in “AUTO” and Feed Roll Selector is moved to “Forward”.

Buzzer comes on when PTO is engaged. (Mode Switch is in “AUTO” position and Feed Roll Selector Switch is in “Forward” position.)

Stop Pawl Solenoid is NOT retracted.

CAUSE

REMEDY

Keyswitch is OFF.

Turn Keyswitch ON.

Mode Switch is OFF or in “MANual” position.

Turn Mode Switch to “AUTO” and leave it in the “AUTO” position.

Circuit Breakers are open.

The power wire MUST be connected to the “POS” and the White wire MUST be connected to the “NEG” battery connections. The tractor MUST have a negative ground system. Check all Plugs for corrosion problem or contact your Gehl dealer for additional help.

Metal Stop system is NOT on.

Reset system by shifting Feed Rolls into reverse. Harvester Light will go 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. Harvester Light will go off when system is reset.

Fuse is blown.

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 sold 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.

Open wire to Pawl Solenoid.

Check for corroded or loose connections at Pawl Solenoid.

95

METAL STOP MACHINES (continued) PROBLEM

CAUSE

REMEDY

Buzzer comes on when Mode Switch is in “AUTO” position and Feed Roll Selector Switch is moved to the “Forward” position.

Low voltage at the Pawl Solenoid.

Manually hold the Stop Pawl away from the Ratchet Wheel. Set the Control Box Mode Switch to “AUTO”. Shift into reverse to reset. If Harvester flashing Light goes off, but 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:

Harvester Light does NOT come on when Mode Switch is moved from OFF to AUTO.

96

1.

Low battery voltage.

2.

The Power Cable is connected through the tractor wiring harness rather than directly to the battery or starter.

3.

Corrosion in any of the Plugs between the battery and the Pawl Solenoid.

Contact your Gehl dealer for a complete system checkout.

Shorted Pull Coil in Pawl Solenoid.

Disconnect wire #19 from Solenoid. Shift into reverse. If Harvester Light goes 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 outside Amplifier Box.

Unplug Amplifier Box Harness. Move Mode Switch to “AUTO” and Feed Roll Selector Switch to “Forward”. If this makes the Control Box Buzzer come on, the problem is NOT in the Metal Stop system.

Declutch Circuit is grounded inside Amplifier Box.

Unplug Amplifier Box Harness. Move Mode Switch to “AUTO” and Feed Roll Selector Switch to “Forward”. If Control Box Buzzer stays off, the problem is in the Amplifier Box. Contact dealer for complete system checkout.

Faulty Bulb.

Checkout Bulb for open filament. When replacing Bulb, obtain locally and use a #1156 turn signal bulb.

Corrosion in Bulb Socket.

Remove corrosion.

Flasher stuck open inside Light Box.

Check for open Flasher. Replace Flasher, if defective.

Open wire or corrosion at Terminals.

Repair wire or clean Terminals.

METAL STOP MACHINES (continued) PROBLEM

CAUSE

REMEDY

Harvester Light does NOT come on when Mode Switch is moved from OFF to AUTO.

Poor ground connection.

Thoroughly clean off paint or corrosion at Lamp mounting screws. Clean off any paint or corrosion at the threads of the Light Box mounting studs. Contact your Gehl dealer for checkout of Light Box components.

Harvester Light comes on but does NOT flash when Mode Switch is moved to AUTO.

Flasher is stuck closed.

Replace Flasher in Light Box.

Harvester Light does NOT go off when shifting into Reverse when Stop Pawl Solenoid is in “Retracted” position.

Open Ground wire from Light Box Relay.

Thoroughly clean off any paint or corrosion at the threads of the Light Box mounting studs.

Metal Detector does NOT reset. Amber Light comes back on after releasing “Hold for Reverse” Switch.

Foreign material and/or water on Terminals on right side of Amplifier Box.

Thoroughly clean and dry Terminals.

Make sure Terminal Cover is installed.

Harvester Frame is NOT grounded to negative post of the battery used with the Control Box.

If Control Box is connected to a tractor battery, that tractor’s drawbar MUST be attached to, and supporting the weight of, the Harvester’s Drawbar.

If the Control Box is connected to a separate (or independent) battery, a battery jumper cable MUST be connected between the Harvester’s Frame and the negative post of of that battery. Do NOT connect anything to the positive battery post except the Red Wire from Control Box.

Metal is NOT being detected during testing (after Metal Stop system has been turned on).

Buzzer does NOT come on during testing. Stop Pawl moves and Harvester Light flashes.

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 following instructions in Service chapter.

If system still does NOT operate, contact your Gehl for complete system checkout procedures.

Feed Roll Selector Switch is NOT in “Forward” position.

Move Feed Roll Selector to “Forward” position to do this test. Buzzer does NOT operate in “Neutral” or “Reverse”.

97

METAL STOP MACHINES (continued) PROBLEM Metal Stop System false alarms when Harvester is NOT running.

CAUSE

REMEDY

Power wire momentarily opens.

Reset system. Wiggle Wire Harness and Plugs to find a loose connection in wire #9, between Control Box in tractor and Amplifier Box on Harvester. Repair the wire or Plug connections.

Ground wire momentarily opens.

Unhook tractor from Harvester and drive away a short distance (6 to 12″).

Disconnect everything between Harvester and tractor except the electrical Harness. Reset the system. If it does NOT reset, there is an open in the “GND” wire between the Amplifier Box and the negative (–) post of the battery.

Search for the break in the wire and repair it. If the system resets, wiggle the Harness and Plugs containing wire “GND”. Do this from the Amplifier Box to the negative (–) post on the battery.

When the system trips, you have wiggled the portion of the Harness that has a break in it. Repair the break.

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.

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 following instructions in Service chapter.

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 electrical Plugs going into or coming out of Control Box.

Secure Wire Harnesses so that they do NOT pull away from Control Box.

Loose wire on Stop Pawl Solenoid.

Check wires and tighten Screws at Stop Pawl Solenoid.

Loose Brushholder 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 Brushholder Housing to see if it is loose on its Bearing. If loose, replace Brushholder.

98

METAL STOP MACHINES (continued) 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 Sidesheets 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.

PTO DRIVE Universal Joints are noisy.

Telescoping and Main Drives are NOT in-line.

Correctly adjust the Bearing Support height; see Preparing for Field Operation chapter.

Tractor drawbar hitchpin hole NOT correct distance from end of PTO.

Correctly adjust tractor drawbar; see Preparing for Field Operation chapter.

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 hitchpin.

Use 1″ diameter Hitchpin (provided with Harvester), or equivalent.

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.

99

PTO DRIVE (continued) PROBLEM Main Drive Shaft vibrating excessively.

Main Drive Impact Pins are failing.

CAUSE

REMEDY

Transmission Shaft is bent.

Straighten the Shaft to within 0.015″ or replace Shaft.

Rear U-Joint Bushing is worn excessively.

Replace the rear Yoke Bushing.

Telescoping Drive Spline, attaching to tractor PTO shaft, is worn.

Replace the splined Yoke.

Entire Drive Line timing is out of phase.

Correct timing so that 1st, 4th & 6th Yokes are in phase; see Drive Line Alignment detail drawing in Preparing for Field Operation chapter.

Tractor PTO is being engaged at too fast an engine speed.

Engage the PTO at a slower engine speed.

Impact Pins are too loose.

Tightly secure and double-nut.

Excessive amount of material is building-up on Cylinder Knives, Cylinder Cover, and Spinner Cover and thus NOT allowing the cut material to pass from the Cylinder to the Spinner.

Order and install an accessory Wet Crop Deflector Kit; refer to information provided in Optional Features & Accessories chapter.

SPINNER Spinner Chute or Spout is plugged with forage.

100

Rated PTO speed is NOT being maintained.

Operate tractor at the proper PTO speed and/or reduce ground speed.

Harvester was NOT cleaned-out before PTO was disengaged.

Keep the PTO speed up until the forage stops coming out of the Spout.

Spinner and Chute are gummed-up.

Remove the gum and dirt by either scraping it out or by running very wet forage or freshly cut crop through it.

A large amount of material is suddenly fed into the unit while the tractor is idling.

Do NOT run a slug into the Harvester while the tractor is idling.

A large amount of material is adhering to the Spinner Cover, then, dropping onto the Spinner when harvesting extremely low fibrous crops.

Obtain and install an accessory Wet Crop Spout Kit. Keep in mind that the Wet Crop Spout drastically reduces capacity and increases horsepower requirements.

Spinner Air Inlet hole, under Spinner Disc, is plugged.

Clean-out material from hole.

Notes

101

CHAPTER 14 SET-UP & ASSEMBLY The Forage Harvester is shipped in the configuration shown in Fig. 92. The following common component completing parts are NOT attached to the Main unit:

Extension is being installed in the future (anytime after initial set-up), some assembled components will have to be removed and replaced.

NOTE: The following abbreviations are used in these procedures:

Fig. 92: Typical Shipping Configuration

—

Axles, Wheels & Tires

—

Tongue

—

Hitchjack

—

Front Bearing Stand, Main Drive and Guard

—

Telescoping PTO Drive

—

1-3/4 Drive Tongue Extension

Procedures established in this set-up instruction are given in a step-by-step manner, with various parts of the assembly process listed in such a way as to make it possible for one set-up person (with appropriate tools and equipment) to do the sequence without having to remove parts in order to make other component attachments. This chapter is divided into two topics: Common Components and Accessory Components.

Accessory Components, such as a Tripod or Horizontal Extensions, are also referenced in the Spout and Controls mounting procedures so as to likewise help to avoid unnecessary removal and replacement steps during initial set-up. It should be understood that, if an additional Vertical Spout Extension or Horizontal Spout

102

CB

-

Carriage Bolt

CS

-

Cap Screw (Hexagon Head)

RHMS

-

Round Head Machine Screw

SHSS

-

Socket Head Set Screw

THMS

-

Truss Head Machine Screw

N

-

Nut (Hexagon)

LN

-

Lock Nut (Hexagon)

HMN

-

Hexagon Machine Nut

WN

-

Wing Nut

L

-

Lock (Washer)

P

-

Plain (Washer)

NF

-

National Fine (Thread)

Unless otherwise noted, the standard fastening procedure is to secure two parts with a CS, L and N. A part with a mounting slot should be secured with a P against the slotted surface. Attaching hardware, which will require installation in the path of the cut crop, should always be installed with the head of the screw on the same side of the part which will be in contact with the material.

NOTE: Before proceeding, remove all components which are attached or banded to the Harvester Frame or otherwise included in the Toolbox.

Shear Bolts should also be taken out of the Toolbox and placed in appropriate Shear Bolt Holders, where provided. As shown in Fig. 92, The Spout and Cap assembly is shipped attached to the Harvester Frame and MUST be removed before proceeding to setup the unit..

COMMON COMPONENTS Step 1: Tongue (Fig. 93)

1

Before the Tongue is attached to the Main Frame, grease the pivot surfaces. Then, slide the Tongue into the Main Frame and fasten it with the Pivot Pin and a 1/4 x 2 Cotter Pin (from Toolbox).

2 3

4

1 – End Spacer 2 – Notch Grinding Decal 3 – Axle Extension

Fig. 94

1 3

2

3

2 1 6

5

1 – Control Cord 2 – Latch Lock Clip 3 – Tongue Latching Mechanism 4 – Pivot Pin Secured with 1/4 x 2 Cotter Pin 5 – Tongue Pivot Surfaces 6 – Tongue

1 – Axle Extension 2 – Angled Axle Spacer Secured with (2 each) 1/2 x 3/4 CS & L 3 – Harvester Frame Axle

Fig. 95

Fig. 93: Manual (Control Cord) Tongue Control

Step 2: Axles, Wheels and Tires (Figs. 94, 95 & 96) Mounting procedures for the Single Axles, the Flotation Axles, or the Tandem Axle assemblies are essentially the same. If Single Wheel Axles are being installed and the Tires were purchased locally, BE SURE to have the appropriate Tires properly mounted on the Wheels before attempting to install the Axle Extensions into the Harvester Frame.

NOTE:

Before the Axle Extensions can be installed, a notch to match the inside weld flash location may have to be ground into the End Spacer of both Axle Extensions. A Decal, displaying this information is provided on the Extension.

2 1 2 3

1 – Axle Extension 2 – Gusset (At Top of Spindle) 3 – Spindle Height Adjustment Bolts (3 of 6 each Spindle)

Fig. 96

To install the Axle Extensions, carefully raise and properly block the Main Frame off the floor a sufficient amount to provide clearance to insert the Axles with mounted Wheels and Tires. BE SURE when the Tires

103

are mounted that the Valve Stems face out. The Wheels should be installed and secured with 90 ft-lb (124.5 Nm) torque. The standard Single Wheel Axle Extensions have Gussets on the ends which MUST be installed facing down. The Flotation Axle Extensions have Gussets on the ends that MUST be installed facing up.

The Tandem Axle Spindle assemblies have Gussets on their top sides which MUST be installed facing up. For Flotation and Tandem Axle assemblies, BE SURE to install assembly labeled ’’Left’’ on the left side of the Harvester. Before an Axle Extension can be inserted into the Harvester Frame Tube on either side, the Angled Axle Spacers MUST be temporarily removed and then replaced after the Extensions are inserted. After the Spacers are secured, the Extensions should be secured with (1 each) 1/2 x 6 CS, L and N.

NOTE: Refer to the Adjustments chapter for Spindle height and Wheel positioning details, if an Attachment is being mounted as part of this set-up and assembly procedure.

Step 3: Hitchjack (Fig. 97)

1

NOTE: The following mounting procedure is best accomplished by two setup people.

First, layout the components along side the Tongue and align them with regard to their appropriate direction and position of attachment. Next, remove and retain the Top and Bottom Drive Joint Guards and their attaching hardware, and the two PTO Support Side Shields and their attaching hardware. Then, remove and retain the (2 each) 3/8 x 5-1/2 CS, P, L and N from the Front Bearing Bracket.

Next, raise the entire Main Drive assembly up and rest it on top of the Tongue, Then, raise the back end of the Drive and attach the Flange on the end to the Overrunning Clutch with the two Impact Pins (5/16 x 3-1/4 Grade 5 Bolts) and double Nuts. Then, raise the front end of the Drive and place the Front Bearing Stand over the Drive Line while aligning the (4) Stand mounting holes with the holes in the Tongue. Secure the Stand to the Tongue with (4 each) 1/2 x 5-1/2 CS, L and N. After the Stand is attached, raise the front end of the Drive and secure the Front Bearing Housing into the appropriate holes of the Stand with (2 each) 3/8 x 5-1/2 CS, P, L and N.

6

2

3

1

3

4

2 4

5

1 – Front Bearing Stand 2 – Top Drive Joint Guard 3 – Bottom Drive Joint Guard 4 – Stand Secured to Tongue with (4 Each) 1/2 x 5-1/2 CS, L & N 5 – Hitchjack Secured to Tongue with Lockpin 6 – Side Shield on both Sides of Bearing Stand (Secured with Two Each Side 3/8 x 2 CB, P & LN

Fig. 97: 1-3/8 Telescoping PTO

Attach the Hitchjack to the mating Hub on the Tongue.

Swing the Jack down and lock it in the ”Supporting” position with the Lockpin provided. Block the Wheels, in the front and back on both sides of the Harvester, and adjust the Jack to level the Tongue.

104

Step 4: Front Bearing Stand, Main Drive and Guards (Figs. 97 & 98)

1 – Back End of Main Drive Line 2 – Bracket Slides Adjusted to Centers of Slots 3 – Flanges 4 – Double Nuts on 5/16 x 3–1/4 Grade 5 Cap Screws (Two Impact Pins)

Fig. 98

NOTE: Select the appropriate pair of holes for aligning the Bearing Housing according to details in the Preparing for Field Operation chapter.

Properly position and fasten one Side Shield to each side of the Front Bearing Stand, using (2 each) 3/8 x 2 CB, P and LN, for each Shield. Place the CB through the top and bottom holes in the Shield and through the

corresponding holes in the Front Bearing Stand. If the Front Bearing hardware occupies one of the sets of holes in the Bearing Stand, then fasten the Shield using the remaining two holes.

At the front end of the Main Drive, loosen (but do NOT remove) the (2 each side) 3/8 Bolts which are securing the front end of the main Drive Guard to the Bearing Support. Raise the rear of the Main Drive Guard and place it between the two PTO Shield Support Channels and secure the parts with (2 each side) 3/8 x 3/4 CS, L & N. Before retightening the (4) 3/8 Bolts which secure the front end of the Tubular Drive Guard to the Bearing Support, position the Tongue and latch it in the center Notch in the Pivot Frame. Then, slide the Tubular Drive Guard ahead and back in order to find the center point of its travel. Once the center point is obtained, the (2 each side) 3/8 Bolts can be tightly secured to fix the position of the Guard.

Step 5a: Telescoping PTO Drive (Figs. 99 & 100 & see Fig. 97)

NOTE:

The Telescoping Drive Yoke and Main Drive Shaft Splines are manufactured to mate together in only one position.

Remove and retain the Safety Wire, Special Cap Screw and large Washer from the end of the Main Drive Shaft, which protrudes through the Front Bearing. Clean and lightly grease the Telescoping Drive Yoke and Drive Shaft Splines before proceeding to slide the Yoke onto the Shaft. Secure the Yoke to the Shaft by installing and securing the Special Cap Screw and large Washer. After tightening the Special Screw, thread the Safety Wire through the hole in the head of the Special Cap Screw and fasten the Wire around the Drive Yoke. After the Safety Wire is secured, install and secure the Top and Bottom Joint Guards which were removed in step 4.

Step 5b: 1-3/4 Drive Tongue Extension (Fig. 100) NOTE: The following information applies only to a Harvester which is going to be equipped with a 1-3/4 Telescoping PTO Drive.

Install the Tongue Extension in the following manner: 1.

Remove and retain the Upper and Lower Hitch Clips and Spacer.

WARNING The Safety Lock Wire MUST be installed as a precaution to prevent the Special Screw from loosening and falling-out and thus enabling the Telescoping Drive to separate from the Drive Shaft while operating Harvester. NEVER attempt to mix the Front and Rear Halves of the 1-3/8 and 1-3/4 Telescoping PTO Drives.

1

3

2

5

4

7 6

1

2

3 1 – Implement End of Telescoping PTO Drive 2 – Special Cap Screw & large Washer 3 – Safety Wire Threaded Through Hole in Bolt Head and Wrapped Around Joint Yoke

Fig. 99

7 1 – Wiring Harness Secured to Top Inside Portion of Front Bearing Stand (2 Places) 2 – Sharpener/Lift Cylinder Hoses Secured to Right Side of Front Bearing Stand 3 – Tongue Control Cylinder Hoses Secured to Left Side of Front Bearing Stand 4 – Coupler Lock Bolt (1 of 2) 5 – 5/8 x 6-1/2 CS L & N ( 1 each of 2) 6 – 5/8 x 5 CS, L, N & (2) Special Washers & Original Spacer Mounted Between Upper & Lower Hitch Clips 7 – 5/8 x 6 CS, L & N (2 each) Attaching Extension to Tongue

Fig. 100: 1-3/4 Telescoping PTO Drive

105

2.

Refer to the illustration provided and properly position and secure the Tongue Extension as shown using the existing 5/8 x 6 CS, L and N.

3.

Preassemble Upper Clip, Special Washer, existing Spacer, Special Washer and Lower Clip with a 5/8 x 5 CS, L and N. Next, secure this assembly to the Tongue Extension, with (2 each) 5/8 x 6-1/2 CS, L and N.

4.

Tightly secure all mounting hardware.

Step 6a: Tongue Control Latch Rope (Fig. 101) NOTE: The following information applies ONLY to a Harvester which is NOT going to be equipped with the optional Hydraulic Tongue Control Cylinder.

1

2

the Rope MUST be kept away from the Telescoping PTO Drive.

Step 6b: Tongue Control Cylinder & Hoses (Figs. 102, 103, 104 & 105) NOTE: The following information applies ONLY to a Harvester which is going to be equipped with the optional Hydraulic Tongue Control Cylinder. In addition, when routing the hydraulic Hoses inside the Hose Side Cover, the Tongue should be swung-out to the maximum left (opposite of Transport) position to assure an ample amount of Hose will be available at the rear of the Drive Line.

To install the Tongue Controls, proceed as follows: 1.

Properly position and secure the Notch Cover to the Harvester Frame with (1 each) 5/16 x 1 CS, L and N and, a 5/16 TFS as shown.

2.

Properly position and secure the Cylinder to the Tongue and Harvester Frame with a Cylinder Pin and two 3/16 x 1-1/2 Cotter Pins on each end as shown.

1

2

3

3 1 – Control Rope Fastened into top hole in Tongue Latch 2 – Tongue Latch 3 – Tongue

4

Fig. 101: Tongue Swung-out to Next to Widest Field-operating Position

The standard mechanical Tongue Latch is operated with a Control Rope. Attach and secure the Rope (taken from the Toolbox) to the top (chamfered) hole in the Tongue Latch. Route the Rope towards the tractor. The Rope needs enough slack for making turns with the tractor, but

106

1 – 90° Swivel Adapter Unions (2) 2 – 5/16 x 1 CS, L & N 3 – 5/16 TFS 4 – Notch Cover

Fig. 102: Hydraulic Tongue Control Kit (Installed)

1

4.

Remove the Top Cover from the Hose Side Cover.

Then, properly position and secure the two Hose Guards into the hole in the bottom of the Hose Side Cover with (2 each) 1/4 x 1/2 CB, L and N.

5.

Attach the Hoses to the Fittings on the Cylinder and route the Hoses from the Cylinder up through the Access Hole in the bottom of the Hose Cover, along the Main Drive Line Shield and up under the Hose Holder on top of the Front Bearing Stand.

Anchor the Hoses to the Hose Holder with the Double Hose Clamp on the left side.

2

3

1 – Lift Cylinder/Knife Sharpener Hoses and Wire Harness Entering Back End of Hose Side Cover 2 – Tongue Control Cylinder Hose Access Hole in Bottom of Hose Side Cover 3 – Tongue Control Cylinder Rod End Attached to Harvester Frame with Cylinder Pin Secured with (2) 3/16 x 1-1/2 Cotter Pins

1

2

Fig. 103

3

NOTE:

The Rod end of the Cylinder MUST be attached to the Harvester Frame. The Cylinder Ports MUST face the left side of the Harvester.

3.

Using a drop of Loctite (or equivalent hydraulic sealing compound), install a 90° Swivel Adapter Union into each of the Cylinder ports; one of the Adapter Unions has a built-in Restrictor. When correctly installed, the 90° Fittings are to face upward and toward the opening in the bottom of the Hose Cover.

1 – Anchor End of Cylinder Attached to Tongue with Cylinder Pin Secured with (2) 3/16 x 1-1/2 Cotter Pins 2 – Transport Pin and Lock Pin 3 – Cylinder Ports MUST Face Left Side of Harvester

Fig. 105

NOTE: Other Hoses and wiring will be added in later steps before reinstalling the Top Hose Cover.

6.

2 1

Obtain and install appropriate disconnects to match your tractor’s hydraulic output terminations.

Step 7: Spout, Cap and Controls (Figs. 106, 107, 108 & 109) 3

1 – Removed Top Cover Resting on top of Drive Line Guard 2 – Hose Side Cover 3 – Two Hose Guards Secured with (1 each) 1/4 x 1/2 CB, L&N

Fig. 104: Tongue Control Cylinder Hose Access Hole in Bottom of Hose Side Cover

CAUTION Because of the weight and awkwardness of the Spout (and Extensions), it is best that at least two people carry-out these Spout mounting procedures.

107

NOTE:

If the Harvester is going to be set-up with mounted Vertical and/or Horizontal Extensions, refer to the Accessory Components topic, in this chapter, for mounting details. In addition, if the Spout MUST be installed without the standard 1-foot Vertical Extension provided, a special Spout Capmotor Relocation Kit MUST be obtained and installed per the information provided with the Kit.

Vertical Spout Extension. The bottom (rear side) of the Spout should be on the same side of the Extension as the Cap Control Motor. Install eight (8) 1/2 x 1-1/4 CS through the Spout and Extension. Secure each CS with a LN. 1

Begin this assembly by first installing the Cap Spring (from the Toolbox) between the hole in the Cap and the Bracket on the Spout (or Horizontal Extension).

2 4 5

3

1 2

6 1 – Cap Spring Attached into Hole in Cap 2 – Cap Spring Anchored onto Bracket on Spout or Horizontal Spout Extension

Fig. 106

Remove the Spout and its shipping parts from the Harvester Frame; discard the shipping parts.

1 2

3 4

1 – Spout Flange Secured to 1-Foot Vertical Extension with (8 each) 1/2 x 1-1/4 CS & LN 2 – Cap Control Motor (Factory-installed) on Back of 1-Foot Vertical Extension 3 – Cap Control Motor Spool Secured to Motor Shaft with 5/32 x 11/16 Spiral Pin Provided 4 – Spout Control Gearmotor

Fig. 107

Carefully raise and properly support the Spout in the ’’rear delivery’’ position on top of the standard 1-foot

108

1 – Cap Spring (Shipped in Toolbox) 2 – S-Hook & Pulley Assembly on Cap Bracket 3 – Wire Rope Clamp 4 – Angle Bracket & S-Hook 5 – S-Hook & Pulley Assembly on Left Rear 1/2 CB (S-Hook Secured Between the 1/2 P and 5/8 P with a 1/2 L & N) 6 – Wire Rope Started Through Hole in Cap Control Motor Spool and Routed Through the Pulleys To the S-Hook Attached to Angle Bracket on Side of Spout

Fig. 108

NOTE: Check that the Spout is NOT binding before proceeding. If necessary, readjust the Clamps and Spacers. At this time also, adjust the Tripod Brace and Arm (where applicable), to find the proper alignment for the Spout (and Tripod) which best enables turning the Spout with the least amount of resistance.

Mount the Angle Bracket to the side of the Spout (or Horizontal Extension) using the hole provided. Secure the Angle with a 5/16 x 3/4 CS, L and N. Place the head of the CS inside the Spout.

Temporarily remove the rear 1/2 N, L and (1 of 2) P from the middle of the left side of the Spout. Then, install a Pulley onto the smaller end of an S-Hook and squeeze the S-Hook shut. Install the larger end of the S-Hook over the 1/2 CB and replace the P, L and N. The S-Hook should be between the two (2) P.

Form another S-Hook and Pulley assembly and install this onto the Cap. BE SURE to secure the S-Hook to the Cap and Pulley by squeezing the ends shut.

For a horizontally extended Spout application, temporarily remove the LN from the 5/16 x 1-1/2 THMS above the Spout Brace on the left side. Then, place an S-Hook and Pulley assembly over the THMS and reinstall the LN; make sure the S-Hook pivots freely when the LN is tightened. Secure the S-Hook to the Bolt and Pulley by squeezing the ends shut.

Attach another S-Hook to the Angle Bracket attached on the left side of the Spout (or Horizontal Extension).

Squeeze both ends shut.

Step 8: Lift Cylinder Hoses (See Figs. 103 & 104) NOTE: When routing the Hydraulic Hoses inside the Hose Side Cover, the Tongue should be swung-out to the maximum left (opposite Transport) position to assure an ample amount of Hose will be available at the rear of the Drive Line.

Remove the top Cover from the Hose Side Cover, route the Hoses from the Lift Cylinder in the bottom of the Hose Cover, along the Main Drive Line Shield and up under the Hose Holder on top of the Front Bearing Stand. Anchor the Hoses to the Hose Holder with the Double Hose Clamp on the right side. Other Hoses and/or wiring will be added in later steps before reinstalling the Top Hose Cover.

Step 9: Implement Wiring Harness (See Figs. 100 & 101) 1

3 2 1 – Spout Pivot Mast 2 – S-Hook & Pulley Assembly Mounted on Left Rear 1/2 CB (S-Hook Secured Between Spout Pivot Mast and 1/2 P with a 1/2 L & N)

3 – S-Hook & Pulley Assembly Mounted on 5/16 x 1-1/2 THMS Secured with LN

Fig. 109: Horizontally Extended Spout

Insert the Cap Control Cable (Wire Rope) into the hole in the Cap Gearmotor Spool, from outside of Flange, into the middle of the Spool (Fig. 107). Then, route the end of the Wire Rope up through the Pulleys and back to the S-Hook on the Angle Bracket as shown (Fig. 108).

Form a loop over the end of the S-Hook and install a Wire Rope Clamp to secure the loop to the S-Hook.

Cut-off any excess Cable, extending beyond the Cable Clamp.

NOTE:

The Wire Rope should be cut to length so there are NO wraps around the Spool when the Cap is in the raised position. Any wrapping on the Spool, when the Cap is ’’up’’, will uncoil and the Cable will jump-off of the Spool.

The Main Implement Wiring Harness is the electrical connection between the tractor-mounted Control Box and the Harvester-mounted electrical components. The following information describes routing the Harness, making the appropriate Plug connections and Clamp locations for the Wiring Harness and Power Leads.

Refer to the Wiring Diagrams provided in the Service chapter for additional identifications and proceed as follows:

NOTE: When routing the Main Wiring Harness or the Hydraulic Hoses inside the Hose Side Cover, the Tongue should be swung-out to the maximum left position to assure that an ample amount of Harness and Hoses is available at the back end of the Drive Line. In addition, all Hydraulic Hoses should be installed in the bottom of the Hose Side Cover and the Wiring Harness(es) should be installed above the Hoses.

Begin by routing the Main Wiring Harness inside the Hose Side Cover on the side of the Main Drive Line.

Pass the Connector directly underneath the sloped portion of the Front Bearing Stand. Allow enough Harness to extend to the tractor-mounted Connector, while keeping the Harness above the Telescoping PTO Drive.

The Wiring Harness should be routed on the right side of the Stand. For Shear Bolt models, install two (2) oblong 1/2 x 1 Vinyl-coated Wire Clamps around the

109

Harness and fasten them to the top inside surface (at each end) of the Front Bearing Stand with (1 each) 5/16 x 1 CB-SN, L and N. For Metal Detector and Torque Sensor models, install two (2) round 1-1/4 Vinylcoated Wire Clamps around the Harness and fasten them to the top inside surface (at each end) of the Front Bearing Stand with (1 each) 5/16 x 1 CB-SN, L and N.

NOTE:

Do NOT install any Hoses between the top of the Harness and the underneath slope of the Front Bearing Stand. The weight of the Hoses could damage the Wire Harness. In addition, do NOT clamp the Implement Wiring Harness to any portion of the tractor. This will surely damage the Harness if the tractor moves away from a parked Harvester with the Wiring Harness still attached.

ONLY use the electrical Connector to attach the Implement Harness to the Tractor Connector. The Connector has a “Breakaway” feature to prevent damage. For additional details, refer to the Control Box & Wiring Harness Mounting step at the end of this chapter.

Store the excess Implement Harness inside the Hose Side Cover. Reinstall the Top Cover onto the Hose Side Cover after all of the Hoses and the Wiring Harness are installed.

Step 10a: Control Box for Shear Bolt Models Mounting & Wiring (Figs. 110 & 111) Refer to Fig. 110 for a typical installation of a Control Box. Use your own judgement to select a conveniently reached mounting location on your particular tractor.

Proceed as follows: 1.

Select the desired Control Box mounting location in the tractor cab or on the fender. Using the Spade Mounting Bracket as a template, locate and drill the two 9/32″ diameter holes. Then, secure the Bracket with (2 each) 1/4 x 1 CS, P, L and N.

NOTE: The Spade Mounting Bracket can be bent, drilled, or otherwise modified to fit the tractor, as required.

110

CAUTION Make sure to avoid sharp metal corners or objects and pinch points along the path of the Harness which could cause insulation break down and a short-circuit.

2.

Attach the Control Box onto the Spade Mounting Bracket.

3.

Make the proper Red (+) and White (-) Ring Terminal Power Supply Harness connections to the tractor battery or starter. The Harvester controls will NOT always operate as desired, if the Control Box wires are attached anywhere else except at the battery or tractor starter connections. The battery MUST provide 12 volts D.C. The tractor MUST have a negative (-) ground. Route the Harness Plug to the Control Box.

NOTE: Before plugging the Power Supply Harness Plug into the Control Box Power Receptacle for the first time, BE SURE to have the Power Keyswitch Key in the ’’ON’’ position but, do NOT have the Implement Wiring Harness connected to the Control Box. If the Implement Wiring Harness is connected and the White (-) or Red (+) Power Supply Harness wires are incorrectly connected, a dead short circuit will be developed which would cause the wires inside the Control Box to overheat.

If the Implement Wiring Harness is NOT connected, the Control Box Circuit Breaker will trip to indicate a Power Wiring problem.

4.

After the Power Wiring connection is properly made and tested, turn the Control Box Power Keyswitch OFF and remove the Key. Then, select a convenient path to route the Extension Wiring Harness from the Control Box to the back of the tractor. If the standard Extension Harness can NOT reach from the Control Box to the back of the tractor, order and use another Extension Harness.

Connect the two Extension Harnesses end to end to reach the Control Box.

5.

Attach the Receptacle Bracket using field-supplied holes in the back of the tractor. Secure the Bracket with ( 2 each) 5/16 x 1 CS, P, L and N. The Bracket MUST be securely mounted so that the electrical connection is near the center of the tractor, parallel to the ground, and facing straight back toward the Harvester.

NOTE:

The preceding information is identical for installing a second tractor Control Box Wiring package.

6 2

4

NOTE: If the Connector is NOT properly and securely mounted, its “Breakaway” feature may NOT work. This could cause damage to the Connector and the Wiring Harnesses.

7 5

1

8

3

1 1 – Power Supply Harness 2 – Electrical Control Box 3 – Spade Mounting Bracket 4 – Wiring Harness Extension 5 – Receptacle Clamp 6 – Receptacle Bracket 7 – Tractor Plug Cap 8 – Implement Wiring Harness

2

Fig. 111: Shear Bolt Model Control Box & Wiring Connections

Step 10b: Control Box for Torque Sensor and Metal Detector Models Mounting & Wiring (Figs. 112 & 113) 1 – Wiring Harness Extension Going to Control Box in Tractor 2 – Receptacle Bracket Secured to Back of Tractor

Fig. 110

6.

Insert two 5/16 x 1 CS through the rear of the Receptacle Bracket and secure them with 5/16 N. Loop the tractor Plug Cap wires and install them onto one of the 5/16 x 1 CS.

7.

Install the Receptacle Clamp over the Plug on the end of the Wiring Harness Extension and align the Plug while pushing it into the mating rectangular hole in the Receptacle Bracket. Anchor the Plug with the Receptacle Clamp installed over the (2) 5/16 x 1 CS and secure the Clamp with (2) 5/16 N.

Refer to Fig. 112 for a typical installation of a Control Box. Use your own judgement to select a conveniently reached mounting location on your particular tractor.

Proceed as follows: 1.

Select the desired Control Box mounting location in the tractor cab or on the fender. Using the Spade Mounting Bracket as a template, locate and drill the two 9/32″ diameter holes. Then, secure the Bracket with (2 each) 1/4 x 1 CS, P, L and N. Place the second Spade Mounting Bracket into the Receptacle on the back of the Box and temporarily install the Box onto the other attached Bracket in order to locate the two additional 9/32″ diameter holes. Then, remove the Box, drill the holes and attach the second Spade Mounting Bracket.

111

NOTE:

The two Spade Mounting Brackets can be bent, drilled, or otherwise modified to fit the tractor, as required.

CAUTION

NOTE:

The flat part of the “D-shaped” hole should be on top when the Bracket is installed. If the Connector is NOT properly and securely mounted, its ”Breakaway” feature may NOT work.

This could cause damage to the Connector and the Wiring Harnesses.

5.

Remove the Special Nut and Lock Washer from the Control Harness Connector and retain these parts. Then, insert the Control Harness Connector into the ”D-shaped” hole in the Mounting Bracket.

Carefully, tighten the Special Nut and Lock Washer to secure the Control Harness Connector.

6.

Route the Control Harness to the Control Box and connect the two (2) Plugs. Connect the 8-way Plugs to each other and the 3-way Plugs to each other. Do NOT cross-connect the Plugs.

Make sure to avoid sharp metal corners or objects and pinch points along the path of the Harness which could cause insulation break down and a short-circuit.

2.

Make the proper Red (+) and White (-) Ring Terminal Power Supply Harness connections to the tractor battery or starter. The Harvester controls will NOT always operate as desired, if the Control Box wires are attached anywhere else except at the battery or tractor starter connections. The battery MUST provide 12 volts D.C. The tractor MUST have a negative (-) ground. Route the Harness Plug to the Control Box.

NOTE: The preceding information is identical for installing a second tractor Control Box Wiring package.

1

NOTE:

Before plugging the Power Supply Harness Plug into the Control Box Power Receptacle for the first time, BE SURE to have the Power Keyswitch Key in the ’’ON’’ position but, do NOT have the Implement Wiring Harness connected to the Control Box. If the Implement Wiring Harness is connected and the White (-) or Red (+) Power Supply Harness wires are incorrectly connected, a dead short circuit will be developed which would cause the wires inside the Control Box to overheat.

If the Implement Wiring Harness is NOT connected, the Control Box Circuit Breaker will trip to indicate a Power Wiring problem.

3.

4.

112

After the Power Wiring connection is properly made and tested, turn the Control Box Power Keyswitch OFF and remove the Key. Then, select a convenient path to route the Control Wiring Harness from the Control Box to the back of the tractor.

Attach the Control Mounting Bracket using fieldsupplied holes in the back of the tractor. Secure the Bracket with ( 2 each) 3/8 x 1 CS, P, L and N. The Bracket MUST be securely mounted so that the electrical connection is near the center of the tractor, parallel to the ground, and facing straight back toward the Harvester.

2

3

4

1 – Control Wiring Harness on Tractor 2 – Control Box Mounted on Spade Mounting Bracket Secured to Fender Inside Tractor Cab (At Conveniently-reached Location) 3 – Control Wiring Harness Connector with “Breakaway” Feature Secured in Harness Mounting Bracket Secured with (2 each) 3/8 x 1 CS, P, L & N (As Required) (Bracket can be Secured with a single CS, provided Anchoring Surface is Rigid) 4 – Harvester Wiring Harness

Fig. 112

NOTE:

If Extensions are going to be used, they MUST be attached to the Spout before the Tripod Kit is mounted.

1 2

CAUTION

3

Because of the weight and awkwardness of the extended Spout, at least two people should carry-out the Spout mounting procedures.

5 4

With the desired Spout Extension(s) mounted onto the Spout, proceed to mount the Tripod Kit as follows: 1.

6

Properly position and secure the Tripod to the top of the Lift Cylinder Post with (4 each) 3/8 x 1-1/4 CS, L and N. When correctly positioned, the Vertical Tube of the Tripod should be facing towards the rear of the Post.

5 1

1 – Optional Control Harness Extension 2 – Electrical Control Box 3 – Power Supply Harness 4 – Spade Mounting Brackets (2) 5 – Control Harness 6 – Control Harness Mounting Bracket

Fig. 113: Control Box & Wiring Connections

ACCESSORY COMPONENTS

2

NOTE: The following components are customer selected accessories which may be dealer installed during the regular set-up and assembly procedures or, customer performed procedures.

Step A: Tripod Kit (Figs. 114, 115, 116, 117 & 119) The Tripod Kit is furnished as part of the 3-1/2 or 5-1/2-ft Horizontal Spout Extension packages. It is also available for separate order whenever additional Spout support is desired as for when 3 or 4 feet of Vertical Extensions are going to be installed.

1 – Tripod Secured to top of Lift Cylinder Post with (4 each) 3/8 x 1-1/4 CS, L & N 2 – Right Tripod Brace Secured to Axle Bracket with a 5/8 x 1-3/4 CS, L & N

Fig. 114

2.

Preassemble (6 each) 5/8 x 1-1/2 CS and N into the welded-on Nuts on the Tripod Arm and Tripod Bracket.

113

1 3

1

3

2 2

1 – Tripod Bracket 2 – Tripod Arm with extended Hub facing down 3 – Spout Bracket

Fig. 115: Arm & Bracket Positions for 2 or Less Feet of Vertical Extensions

3.

4.

1 – Tripod Arm with extended Hub facing up 2 – Tripod Bracket 3 – Spout Bracket

Fig. 116: Arm & Bracket Positions for 3 Feet of Vertical Extensions

Based on the number of feet of Vertical Extensions to be used, determine the position and direction of the Tripod Arm with respect to the Tripod Bracket. Referring to the illustrations provided, position the Arm below the Bracket for 1 or 2 feet of Vertical Extensions as shown in Fig. 115. For 3 or 4 feet of Vertical Extensions, the Arm MUST be positioned above the Bracket. In addition, for 3 feet of Vertical Extensions, the Arm MUST positioned as shown in Fig. 116. For 4 feet of Vertical Extensions, the Arm MUST be turned around as shown in Fig. 117.

On the basis of the above determination, install the Tripod Arm and Tripod Bracket over the Tripod Tube in the required position.

Align the Tripod Bracket so that its mounting holes line up with appropriate holes in the Tripod Tube in the required position. The slotted ear MUST face the front of the Harvester. Secure the Tripod Bracket with (2 each) 1/2 x 3-1/2 CS and LN. Also, secure the Tripod Bracket by tightening the (2) 5/8 x 1-1/2 CS and the (2) 5/8 N to lock the positions of the CS.

3

2 1

1 – Tripod Bracket 2 – Tripod Arm with extended Hub facing down 3 – Spout Bracket

Fig. 117: Arm & Bracket Positions for 4 Feet of Vertical Extensions

7.

Attach and tightly secure the Right Tripod Brace to the right ear of the Tripod Bracket with (2 each) 5/8 x 1-3/4 CS, L and N.

5.

Loosely attach the bottom end of the Front Tripod Brace to the Tongue Cylinder Bracket. Install a 5/8 x 3 CS through the Frame, the thick end of the Tripod Anchor and the Tripod Brace as shown in Fig. 118. Secure the assembly with a 5/8 L and N.

8.

Loosely attach the Front Tripod Brace to the front ear of the Tripod Bracket using the Tripod Brace Clamp and (2 each) 5/8 x 1-3/4 CS, L and N. BE SURE to position the Clamp and Brace on the opposite sides of the Tripod Bracket ear.

6.

Loosely attach the Right Tripod Brace to the Axle Bracket with a 5/8 x 1-3/4 CS, L and N.

9.

Tightly secure the hardware at the lower end of both Tripod Braces.

114

10.

Properly position and attach the Spout Pivot Bracket onto the Spout using the upper Spout Bracket mounting holes and existing holes and hardware in the Spout. BE SURE to delete the (4) 5/8 P from the Spout Carriage Bolts when installing the Bracket.

NOTE: The following procedure can only be carried-out after the Spout is in position to be installed and secured onto the Blower Outlet.

11. Install the Spacer into the hole in the Spout Bracket and position the Bracket between the plates of the Tripod Arm. Install a 1/2 x 3-3/4 through the Arm. Secure the 1/2 CS with a LN. NOTE: To facilitate Tripod adjustment, rotate the Spout so that it is in-line with the Tripod Arm. 12. After the Spout (with mounted Extensions) is properly secured onto the Blower Outlet, the Tripod Arm can be adjusted (up or down) to position the Spout Bracket midway between the plates of the Tripod Arm. Once the Arm is centered, it can be secured to the Tripod by tightening the (4) CS and the (4) 5/8 N can be tightened to lock the positions of the CS. Proper attachment of the Tripod Arm accomplishes the side-to-side alignment of the Tripod. Forward and backward alignment of the Tripod is accomplished by forcing up on the Cap end of the Spout and tightening the Clamp and front Tripod Brace connection to the Tripod Bracket. If the limit of the slot in the Bracket is reached before correct Tripod and Spout alignment can be obtained, (1 of the 2) 5/8 x 1-3/4 CS should be temporarily removed and repositioned through the other hole in the Brace, after the Clamp is rotated.

2 1

1 – Front Tripod Brace Secured to Thick End of Tripod Anchor and Right Side of Tongue Cylinder Bracket with a 5/8 x 3 CS, L & N 2 – Tripod Anchor

Fig. 118

115

1 2 21 3

20 19 5 4 16

18

8

7

9

17 4 13

6 10

9

12

15 11 14 1 – Existing Cap & Attaching Hardware 2 – Accessory 3-1/2-ft or 5-1/2-ft Horizontal Spout Extension 3 – Cleanout Cover 4 – Wire Rope Clamp 5 – Extension Tie Plate 6 – Cable 7 – Spout Extension Brace 8 – Horizontal Extension Bracket (1 of 2) 9 – S-Hook 10 – Pulley

11 – Factory Installed 1-foot Vertical Spout Extension & Cap Control Motor 12 – Accessory 1 or 2-ft Vertical Spout Extension 13 – Existing Spout 14 – Tripod Anchor 15 – Tripod Braces (2) 16 – Tripod Brace Clamp 17 – Tripod 18 – Tripod Bracket 19 – Tripod Arm 20 – Spacer for Spout Bracket 21 – Spout Pivot Bracket

Fig. 119: Spout Extensions & Tripod

Step B: Vertical Extensions (Fig. 119)

to the Blower. A set of (8 each) 1/2 x 1-1/4 CS and LN is provided with each Extension for attaching that Extension.

The Harvester is provided with a factory-installed, 1-ft Vertical Extension. This allows the Capmotor and Spout Control Motors to be factory installed and pre-wired.

When a 1-ft and/or 2-ft Vertical Extension is being installed, the additional Vertical Extension(s) should be mounted above the factory-installed 1-ft Vertical Extension. This will keep the Cap Motor and its wiring close

NOTE: If the factory-installed, 1-ft Vertical Extension is removed and the Spout is attached directly to the Blower Outlet Flange, a special Spout Capmotor Relocation Kit MUST be obtained and installed per the information provided with the Kit.

116

Step C: Horizontal Extensions (Figs. 119 & 120) Mounting procedures for either the 3-1/2-ft or 5-1/2-ft Horizontal Spout Extension packages are the same.

Refer to the Tripod Kit mounting procedures, after the Extension is attached to the Spout. To mount either Extension, proceed as follows: 1.

Remove and retain the Clean-out Cover(s).

2.

Remove the Cap and attaching hardware from the Spout and reinstall these same parts onto the end of the Extension.

tops of the Spout and Extension, as the material is being discharged. Once the correct alignment is obtained, all loosely attached mounting hardware can be tightly secured.

NOTE: If the Cap Control Cable is too short for the Horizontal Extension, splice a second Cable (provided) as shown in Fig. 120. Cut off and discard any excess Cable.

3 2

NOTE:

Throughout this assembly procedure, BE SURE to install all attaching hardware from inside the Spout or Extension so that all bolt heads are located on the inside.

3.

Attach and loosely fasten the Horizontal Extension Brackets to each side of the Extension with (3 each side) 5/16 x 3/4 THMS, L and N.

4.

Slide the Extension with Brackets over the end of the Spout and loosely secure the Brackets to the Spout with (1 each side) 5/16 x 3/4 THMS, P, L and N.

5.

Install and loosely attach the (1) 5/16 x 1-1/2 THMS into the left lower rear hole in the Spout and Extension Bracket. Install the THMS through Spout, through Extension Bracket, through Extension and secure it with (2) P, a L, N and a LN.

6.

Install and loosely fasten a 5/16 x 1 THMS in the remaining (3) holes with L and N.

7.

Attach and loosely fasten the Extension Spout Tie to the Spout and Extension using (4 each) 1/4 x 1/2 THMS, L and N.

8.

9.

Properly position and install the Spout Extension Brace between the Spout Flange and the Extension Brackets. Loosely attach the top end of the Brace to the Extension Brackets with (2 each side) 1/2 x 1-1/4 CS, P, L and N as shown. Mount the bottom end of the Brace to the Spout Flange and Vertical Extension Flange or Spout Clamps with (2 each) 1/2 x 5 CS and attaching hardware.

Make sure that the inside top end of the Horizontal Extension is slightly above the inside top end of the Spout, in the area where the two parts meet.

Likewise, make sure that the Cap end of the Extension is down and properly in line (to provide a good radius) for smooth material flow against the

1

4 5 3 1 – Pulley & S-Hook 2 – Cable Clamps 3 – Wire Rope 4 – S-Hook 5 – Spout Brace

Fig. 120

Step D: Tunnel Switch (Figs. 121, 122 & 123) NOTE: The following instructions ONLY apply when adding a Water Tank Accessory to a Shear Bolt Model Harvester.

1.

Preassemble the Vane to the Tunnel Switch. Secure the Vane with the (2) Self-drilling Screws provided.

2.

Remove the Coverplate from the Spinner Chute and properly orient and attach the Tunnel Switch with (3 each) 5/16 x 3/4 CB, L and N.

3.

Anchor the Plug from the Tunnel Switch to the Spinner Chute in the area shown using a Vinylcoated Clamp.

4.

Route the Tunnel Adapter Harness from the Tunnel Switch along the face of the Rear Blower Sidesheet and over the corner of the Blower Frame.

Anchor the Tunnel Adapter Harness in the three places shown with Vinyl-coated Clamps.

117

5.

Using existing hardware, make the Ground Ring Terminal anchor to the Blower Frame as shown in Fig. 123. Remove the paint in this area to provide a good electrical ground.

6.

Connect the Adapter Harness Single Male Plug to the Water System Control Wire coming from the Water System Control Box inside the tractor.

5

2

2

4

1

NOTE: The Single Female Plug in the Adapter Harness will NOT be used on Shear Bolt Model Harvesters.

3

1 – Tunnel Switch Installed 2 – Vinyl-coated Clamps 3 – Plugs Coupled Together 4 – Tunnel Switch Harness 5 – Wire to Water System Control Box Connected to Tunnel Switch Harness

Step E: Square-holed Screens & Wet Crop Deflector (Figs. 124 & 125) NOTE:

To install a Screen or a Wet Crop Deflector, a Cam Kit MUST be ordered separately.

5

Fig. 121

1 2 1

4

3 2

1 – Plug Uncoupled When Chute is Removed 2 – Plug From Tunnel Switch with Chute Removed

Fig. 122

1 – Cylinder Cover 2 – Rear Cylinder Tie 3 – Square-holed Screen 4 – Screen Adjustment Cams (2 of 3 each side) 5 – Cylinder Cover Mounting Bracket (1 of 2)

Fig. 124

To install a Screen or a Wet Crop Deflector, proceed as follows: 2

1.

Remove the Spinner Cover and the Cylinder Cover.

2.

Remove the (6) Cam Hole Plugs from the Cylinder Sidesheet. Clean the debris and build-up (if present) from the inside walls of the Cylinder Sidesheets with a scraper.

1

1 – Ground Connection to Blower Frame 2 – Tunnel Switch Harness

Fig. 123

118

NOTE: If desired and to obtain additional clearance, temporarily remove the Rear Cylinder Tie. BE SURE the Tie is replaced and properly adjust the Cylinder Cover Mounting Brackets before attempting to adjust the Cams.

NOTE:

Refer to the Adjustments chapter for Screen adjustment procedures. BE SURE to replace the Rear Cylinder Sidesheet Tie, the Cylinder Cover and the Spinner Cover BEFORE restarting the Harvester.

2

An optional Control Harness Extension is available, if the Control Harness can NOT reach the Control Box. This Extension Harness may be needed for most 4-wheel drive tractors. It is installed between the Control Box and the Control Harness.

1

1 – Wet Crop Deflector 2 – Screen Adjustment Cams (2 of 3 each side)

Fig. 125

3.

4.

5.

Step F: Control Box Extension Harness (See Fig. 111)

Position the Screen or Wet Crop Deflector under the Cutting Cylinder and: a.

For a Screen, insert the (6) Cam Bolts through the slots in the Screen flanges and through the left and right Sidesheets. Install the (6) Cams over the (6) Cam Bolts from the outside of the Harvester Sides. Secure the Cam Bolts with the 1/2 Nuts and L. Before the Nuts are tightened, make sure that the Cam Bolts are on the forward edges of the Screen flange slots to prevent the Screen from moving rearward during Cylinder operation. Tightly secure the Cam hardware.

b.

For the Wet Crop Deflector, insert the (2 each side) Cam Bolts through the holes in the Deflector flanges and through the left and right Sidesheets. Install the remaining (2) Cam Bolts through the left and right Side Sheets with the Bolt heads inside the Side Sheets. Install the (6) Cams over the (6) Cam Bolts from the outside of the Harvester Sides. Secure the Cam Bolts with the 1/2 Nuts and L. Tightly secure the Cam hardware.

Install the Rear Cylinder Tie and Cylinder Cover Mounting Brackets, if they were removed. Refer to the Adjustments chapter for Cylinder Cover Bracket position adjustments.

Replace the Cylinder and Spinner Covers and secure them.

The Torque Sensor and Metal Detector models use the same eleven-wire Extension Harness. The Shear Bolt model uses an eight-wire Extension Harness. All models use a 2–wire Extension Harness with the Water Tank accessory.

Step G: Long Cut Kit (Figs. 126 & 127) The optional Long Cut Kit provides a means of increasing the achievable Length-of-Cut by replacing the factory-provided Sprockets on the Feed Roll Drive Transmission Input Shaft and and the Attachment Drive Shaft. With all eight Knives installed, the Length-of-Cut can typically be increased to 9/16 ″. As shown in Fig. 126, the original 28T Sprocket is replaced by a 20T Sprocket. Similarly and as shown in Fig. 127, the original 40T Sprocket is replaced by a 28T Sprocket.

Both Sprockets are secured to their respective Shafts with two SHSS each. The Input Chain to the Shifter Transmission and the Chain driving the Attachment Drive Torque Sensor will have to be shortened to fit the new Sprockets.

1

2 1 – Original 28T Sprocket (Item 23) to be Replaced by 20 T Sprocket in Kit - Secured with Two SHSS Supplied with Kit 2 – Attachment Driver Shaft (Item 29)

Fig. 126: Portion of Drawing From Service Parts Manual

119

1

1

3 2 4 2

1 – Original 40 T Sprocket (Item 24) to be Replaced by 28 T Sprocket in Kit - Secured with Two SHSS Supplied with Kit 2 – Shifter Transmission (Item 28)

Fig. 127: Portion of Drawing From Service Parts Manual

NOTE:

After the correct Chain lengths have been obtained, BE SURE to adjust the Chains for proper operating tension.

Step H: Safety Chain NOTE: Routing and anchoring an accessory 30,000 Pound Safety Chain Kit should be done in the manner shown in Transporting chapter.

Step I: Offset Wagon Hitch (Fig. 128) The accessory Offset Wagon Hitch is available for adapting your Harvester to reposition the Hitchplate so that the forage box pulls more directly behind the tractor when harvesting row crops. Installation of the Offset Hitch reduces side draft and helps keep the row crop attachment centered on the rows. Installation instructions are provided with the package of parts.

120

1 – 36″ (914 mm) Between Outside Bolts 2 – Offset Wagon Hitch Tube 3 – Hitch Tube Plates (2) 4 – Wagon Hitch Tube Clamp Plates (2) – Can also be used for towing Wagons

Fig. 128: Offset Wagon Hitch

Step J: Second Tractor Control Box Wiring Kits Accessory Second Tractor Control Box Wiring Kits are available for adapting the same Control Box to a second tractor. The Kit for the Torque Sensor and Metal Detector models contains a Power Supply Harness, a Control Harness, a Control Harness Mounting Bracket and two Control Box Mounting Plates. The Kit for the Shear Bolt model contains a Power Supply Harness, an Extension Harness, an Extension Harness Mounting Bracket, a Mounting Clamp, a Dust Plug, and one Control Box Mounting Plate. Refer to Control Box Mounting and Wiring procedures, steps 10a or 10b, for comparable installation details.

Step K: Highway Transport Lighting Kit NOTE:

If the Harvester is going to be transported on a public highway, a Transport Lighting Kit should be obtained and installed per details provided in the Kit. An accessory Highway Transport Lighting Kit is available for all Harvester models. It includes Lights, Wiring Harnesses, an Outlet, and installation instructions. The Outlet allows connecting the Transport Lights of a wagon towed behind the Harvester.

CHAPTER 15 OPTIONAL FEATURES & ACCESSORIES Most of the optional features & accessories, listed in this chapter, are covered by information listed in the Set-up & Assembly chapter. Some accessories are shipped with separate instructions to install. Refer to your Gehl “Farm Equipment Suggested List Prices” for stock numbers and ordering information.

AXLES, WHEELS & TIRES The Harvester can be obtained with several choices of Axles, Wheels and Tires. The various choices are: 1.

Standard Axle Set with Hubs and 14 x 8.00 D.C. Wheels (less Tires) - set of two

2.

Standard Axle Set with Hubs and 14 x 8.00 D.C. Wheels and 11L x 14 6–ply rating Implement Tires - set of two

3.

Standard Axle Set with Hubs and 15 x 10.00 D.C. Wheels (less Tires) - set of two

4.

Standard Axle Set with Hubs, 15 x 10.00 D.C. Wheels and 12.5L x 15 8-ply rating Implement Tires - set of two

5.

Flotation Axle Set with Hubs, W11C x 16.1 Wheels and 16.5L x 16.1 8-ply rating Implement Tires - set of two

6.

Tandem Axle Set with Hubs, 15 x 8.00 D.C. Wheels and 27 x 9.50 x 15, 6-Ply Rating Implement Tires - set of four

BLOWER RIM SHEET LINER The Harvester is designed with a replaceable Wear Liner for the Blower Rim Sheet. A replacement Liner is available by part number 094948. Instructions for installation are included with the Kit of parts.

CONTROL BOX EXTENSION HARNESS A Control Harness Extension is available, if the Control Harness can NOT reach the Control Box. It is installed between the Control Box and the Control Harness.

Installation information is provided in the Set-up & Assembly chapter.

HYDRAULIC TONGUE KIT A Hydraulic Tongue Kit is available to remotely adjust the Tongue position from the tractor seat. The Kit contains a standard double-acting 8″ stroke, 3″ bore Cylinder, two (2) Hose assemblies, two (2) Cylinder Anchor Pins, four (4) Cotter Pins, two (2) Hose Guards, two (2) Swivel Adapter Unions, a Notch Cover and appropriate attaching hardware. Mounting details are provided in the Set-up & Assembly chapter. This Kit requires a second pair of tractor hydraulic outlets.

LENGTH-OF-CUT KITS The Harvester is designed and provided with changeable Length-of-Cut (LOC) Sprockets. A 25 Tooth (1/4 LOC) is provided on the Feed Roll Transmission. Other Lengths-of-Cut can be obtained by ordering a 20 Tooth (3/16″ LOC), a 30 Tooth (5/16″ LOC), or a 37 Tooth (3/8″ LOC) Sprocket.

LONG CUT KIT A Long Cut Kit is available to provide a 9/16″ Length-of-Cut by replacing the factory-provided Sprockets on the Feed Roll Drive Transmission Input Shaft and the Attachment Drive Shaft. Both Sprockets are secured to their respective Shafts with two SHSS each.

MAIN DRIVE IMPACT PINS Replacement 5/16 x 3–1/4, Grade 5 Impact Pins and Hexagon Nuts are available by GEHL part number 080699. One package contains eight Bolts and sixteen Nuts.

OFFSET WAGON HITCH An Offset Wagon Hitch is available to reposition the Hitchplate so that the forage box pulls more directly behind the tractor when harvesting row crops. This reduces side draft in muddy fields, so that the Harvester can stay on the rows. Installation instructions are provided with the package of parts.

SAFETY CHAIN 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.

121

A 30,000 pound Safety Chain Kit is available to accommodate the potential weight of the Harvester and a forage box.

SCREENS & COMPONENTS Screen Cam Kit A Screen Cam Kit MUST be ordered separately for mounting a Screen or the Wet Crop Spout. The Kit contains six (6) Cams and Cam mounting hardware.

Square-hole Screens Numerous Square-holed Screens are available to match a variety of length-of-cut requirements in different crops. Reversible Screens are available in 4″, 3″, 2″, 1-1/2″, 1-1/4″, 1″ and 3/4″ sizes. Refer to the Set-up & Assembly chapter for positioning details. For mounting, order and use a Screen Cam Kit.

SECOND TRACTOR CONTROL BOX WIRING KIT

Vertical Spout Extension factory-installed onto the Blower Outlet. This enables factory-installation of both the Spout and Cap Control Motors. Several Kits are available singly or in combination for relocating the effective position of the Cap, higher, lower or farther away from the Blower Outlet. The following information defines the various Kits which are available:

Cap Motor Relocation Kit (Fig. 129) If the Cap is too high for the forage box being used and it becomes desirable to lower the Cap by removing the factory-installed 1-foot Vertical Extension, a Cap Motor Relocation Kit MUST be obtained separately. The Relocation Kit contains an Actuator Support Bracket and a Wire Harness Loom. Installation instructions are provided with the Kit of parts.

2 1

A Second Tractor Control Box Wiring Kit is available for adapting the same Control Box to a second tractor.

Installation information is provided in the Set-up & Assembly chapter.

SHEAR BOLTS

1 – Flexguard Loom 2 – Actuator Support

Additional Shear Bolts are available in packaged quantities of eight (8) per package, as required. Order Shear Bolts by the following numbers: Order Number

Description

095139

(8) 5/16 x 1 Gr. 2 (Carriage Bolts) Spinner Shear Bolts & (8) 5/16 Hexagon Lock Nuts

080079

(8) 1/4 x 1-1/2 Gr. 8 Feed Roll Shear Bolts & (8) 1/4 Hexagon Lock Nuts

SPOUT EXTENSIONS & COMPONENTS The Harvester is shipped from the factory with a 1-ft

122

Fig. 129: Typical Relocated Cap Motor Mounting & Wiring

Horizontal Extensions Horizontal Spout Extensions are available in 3-1/2-foot and 5–1/2-foot lengths. Both Kits contain all of the same components and the appropriate 3-1/2-foot and 5-1/2 foot long Extension. These same components are: a Tie Plate and attaching hardware and a Tripod Kit. The Tripod Kit is also available separately.

Tripod Kit The Spout Tripod Kit is supplied with either Horizontal Spout Extension package or available separately when additional Spout Support is desired or needed.

Vertical Extensions

tions. The Outlet allows connecting the Transport Lights of a wagon towed behind the Harvester.

Vertical Spout Extensions are available in 1-foot and 2-foot sizes. A maximum of 4 feet of vertical Extensions can be installed. A Tripod Kit is required when a total of more than 2 feet of Vertical Extensions is installed.

TUNNEL SWITCH KIT

NOTE: A Kit is also available to relocate the Cap Control Motor when the original factory-installed 1-foot Vertical Extension is removed. Refer to the Cap Motor Relocation Kit topic for additional information.

SPOUT LINER The Harvester is designed with a replaceable Wear Liner for the Spout. A replacement Liner is available by part number 112182. Installation details are provided in the Service chapter.

TELESCOPING PTO DRIVES The Harvester can be ordered and obtained with either a 1-3/8 or a 1-3/4 Telescoping PTO Drive. The 1-3/4 Drive also includes a Drawbar Extension for relocating the Hitch Clips. Mounting details are provided in the Set-up & Assembly chapter.

TRANSPORT LIGHTING KIT NOTE: If the Harvester is going to be transported on a public highway, a Transport Lighting Kit should be obtained and installed per details provided in the Kit. An accessory Highway Transport Lighting Kit is available for all Harvester models. It includes Lights, Wiring Harnesses, an Outlet, and installation instruc-

A Shear Bolt model Harvester can be equipped with a Tunnel Switch Kit for activating a Water System.

NOTE:

The Tunnel Switch Kit functions as a sensing element for the Water System. In addition, a Water Tank Kit, for the Hay Attachment, MUST also be ordered separately and installed on the Attachment.

The Tunnel Switch assembly is designed for installation in the Spinner Chute to detect the presence of material flow through the Tunnel and then provide a Switch Contact change signal to the Water Tank System. The Tunnel Switch Kit includes the Tunnel Switch, a Tunnel Adapter Harness, a Tunnel Vane, and mounting hardware. Installation details are provided in the Set-up & Assembly chapter.

WET CROP DEFLECTOR A Wet Crop Deflector is available for installation on the Harvester in the area of the Spinner Disc. It is designed for use when harvesting extremely wet, low fibrous materials which tend to stick to the walls and the Spinner Cover and then, fall-off as a mass which causes plugging in the Spinner Chute. For mounting the Deflector, a Screen Cam Kit, which is the same as for mounting Screens, MUST be ordered separately.

Mounting details are given in the Set–up & Assembly chapter along with the Screen installation information.

NOTE: When a Wet Crop Deflector is installed, a Screen can NOT be used.

123

CHAPTER 16 DECAL LOCATIONS GENERAL INFORMATION

CAUTION ALWAYS read and abide by the Safety Rules and information shown on Decals. If Decal(s) become(s) damaged, unreadable or if the unit is repainted, the Decal(s) MUST be replaced.

If repainting, MAKE SURE ALL Decals which apply to your machine are properly affixed to your unit in their proper locations.

Decal Locations information is provided to assist in the proper selection and application of new decals, in the event the original decal(s) become(s) damaged or the machine is repainted.

For correct replacement of decal(s), compare the close-up location photographs to your machine BEFORE starting to refinish the unit. Check-off each required decal using the illustration reference number to find the part number, description and quantity in the list. Refer to the appropriate illustration(s) for replacement location(s).

a die-cut Decal, first remove the backing paper. Then, properly position the Decal onto the clean mounting surface. After the Decal is firmly applied and smoothly pressed-down, remove the front covering paper.

The Decal Set for the 1060 Forage Harvester is 093440 The Set includes the following: Ref. No. 1 2 3 4

Part No. 065269 067493 093211 073085

5 6 7 8 9

077223 074707 075808 076166 075835

10 11

075837 077215

12 13

093212 077745

14 15 16 17 18 19

078107 078251 076165 078676 078742 112204 078810

NOTE:

Refer to the SAFETY Chapter of the Operator’s Manual for the specific information provided on all of the various Safety Decals.

PAINT NOTICE Use this list to order paint for refinishing: 901225 One Gallon Blaze Paint 901226 One Gallon Maize Paint 610239 6 (12 oz. Spray Cans) BIaze Paint 610240 6 (12 oz. Spray Cans) Maize Paint

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 off the other portion of the backing paper while applying hand pressure to smooth-out the decal surface. To apply 124

20 21 22

078837 080247 093730 088328 083003 080694

23 24 25 26

091444 093020 093202 093204

27 28

093210 093213

29

093365

30 31

093366 093367

32 33

093373 093374

Description & Quantity Knife Sharpener Operating Instructions Reflector/Red (2 Places) Cutterbar Removal & Replacement 1000 RPM ONLY (Early Style) - NOT Shown 1060 (Vertical) Length Of Cut Chart Decorative Stripe Decorative Gehl Drawbar Clip Setup (Before SN6186) - NOT Shown Stripe Point Wiring Diagram (Before SN8501) - NOT Shown Cutterbar Adjustment Speed Monitor Plug (Before SN8501) - NOT Shown 1060 (Horizontal) Maximum Tractor Horsepower Decorative Gehl (Rear) Metal Stop AUTO–MAX Wiring Diagram (Inside Torque Sensor Control Box) (After SN8500) Wiring Diagram (Inside Torque Sensor Control Box) (Before SN8501) - NOT Shown Wiring Diagram (Inside Light Box) NO Step Shear Bolt (After SN6700) Shear Bolt (After SN5725 & Before SN6701) - NOT Shown Shear Bolt (After SN5405 & Before SN5726) - NOT Shown Shear Bolt (Before SN5406) - NOT Shown DANGER - Rotating Drive Line Lubrication Symbol (12 Places) DANGER - Avoid Electrocution WARNING - Remove PTO BEFORE Sharpening Knives Patent (Forage Harvesters) Speed Monitor Terminations (Before SN8501) - NOT Shown WARNING - Close or Replace Guard (4 Places) IMPORTANT - Store Manual Here WARNING - Owner’s Responsibility & Read Manual WARNING - General Safety WARNING - Towing Implement Without Brakes

34 35

093376 093378

36

093379

37 38 39

093380 093381 093436

WARNING - Keep Hands Out DANGER - Rotating Components (4* Places) WARNING - Wear Goggles When Using Knife Sharpener WARNING - 1–3/4″ PTO Shaft Restriction WARNING - Use Drawbar Transport Lock WARNING - Use Locking Hitchpin (Before SN8501) - NOT Shown

40

093442

41 42 43

093465 093653 093439

Feed Roll Height Indicator (Before SN8501) - NOT Shown WARNING - 1000 RPM Operation Only WARNING - Rotating PTO Shield WARNING - Shear Bolt Model Control Box Operation

* (1 -NOT Shown) Supplied for Early 2-ft Vertical Deflector Extension

6

25

35 2 35

29

18

41

23

33 30

22

42 24

35

8

17

26

31 32

36 1

29 7 14

24 38

Rear Master

15 16

24

10

27

2 24

29

125

NOTE:

This list is a repeat of the Decal List on a previous page and is provided for your convenience when selecting Decals from the second page of photographs.

The Decal Set for the 1060 Forage Harvester is 093440 The Set includes the following: Ref. No. 1 2 3 4

Part No. 065269 067493 093211 073085

5 6 7 8 9

077223 074707 075808 076166 075835

10 11

075837 077215

12 13

093212 077745

14 15 16 17 18 19

078107 078251 076165 078676 078742 112204 078810

20 21

126

078837 080247

Description & Quantity Knife Sharpener Operating Instructions Reflector/Red (2 Places) Cutterbar Removal & Replacement 1000 RPM ONLY (Early Style) - NOT Shown 1060 (Vertical) Length Of Cut Chart Decorative Stripe Decorative Gehl Drawbar Clip Setup (Before SN6186) - NOT Shown Stripe Point Wiring Diagram (Before SN8501) - NOT Shown Cutterbar Adjustment Speed Monitor Plug (Before SN8501) - NOT Shown 1060 (Horizontal) Maximum Tractor Horsepower Decorative Gehl (Rear) Metal Stop AUTO–MAX Wiring Diagram (Inside Torque Sensor Control Box) (After SN8500) Wiring Diagram (Inside Torque Sensor Control Box) (Before SN8501) - NOT Shown Wiring Diagram (Inside Light Box) NO Step

22

093730 088328 083003 080694

23 24 25 26

091444 093020 093202 093204

27 28

093210 093213

29

093365

30 31

093366 093367

32 33

093373 093374

34 35

093376 093378

36

093379

37 38 39

093380 093381 093436

40

093442

41 42 43

093465 093653 093439

Shear Bolt (After SN6700) Shear Bolt (After SN5725 & Before SN6701) - NOT Shown Shear Bolt (After SN5405 & Before SN5726) - NOT Shown Shear Bolt (Before SN5406) - NOT Shown DANGER - Rotating Drive Line Lubrication Symbol (12 Places) DANGER - Avoid Electrocution WARNING - Remove PTO BEFORE Sharpening Knives Patent (Forage Harvesters) Speed Monitor Terminations (Before SN8501) - NOT Shown WARNING - Close or Replace Guard (4 Places) IMPORTANT - Store Manual Here WARNING - Owner’s Responsibility & Read Manual WARNING - General Safety WARNING - Towing Implement Without Brakes WARNING - Keep Hands Out DANGER - Rotating Components (4* Places) WARNING - Wear Goggles When Using Knife Sharpener WARNING - 1–3/4″ PTO Shaft Restriction WARNING - Use Drawbar Transport Lock WARNING - Use Locking Hitchpin (Before SN8501) - NOT Shown Feed Roll Height Indicator (Before SN8501) - NOT Shown WARNING - 1000 RPM Operation Only WARNING - Rotating PTO Shield WARNING - Shear Bolt Model Control Box Operation

* (1 -NOT Shown) Supplied for Early 2-ft Vertical Deflector Extension

12

5

24

21 24

34

3

Front Master

24 37 29

1–3/4″ PTO Drive Hitch Extension

19

20 43

Control Box for Shear Bolt Model Harvester

Control Box for Torque Sensor & Metal Stop Model Harvesters (Inside View)

Metal Detector Light Box (Inside View)

127

CHAPTER 17 MAINTENANCE LOG SERVICE EVERY 10 HOURS COMPONENT and SERVICE REQUIRED

PROCEDURE and/or 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 per details under Scraper topic in Adjustments chapter.

Check all Drive Chain tensions. Oil Chains every 6 to 8 hours with foaming aerosol lubricant.

See Drive Chains topic in Adjustments chapter and refer to Lubrication chapter.

Lubricate appropriate grease fittings.

Refer to Lubrication chapter.

Date After Service is Completed

SERVICE EVERY 50 HOURS Adjust Knives and check Knife Bolt torques.

See Knives topic in Adjustments chapter.

Check Blower Belt tension.

See Drive Belt topic in Service chapter.

Check Tire Pressure and Wheel Nut Torque.

Inflate Tires and torque Wheel Lugs per details in Service chapter.

Lubricate appropriate grease fittings.

Refer to Lubrication chapter.

Date After Service is Completed

128

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 Deflector positions.

Refer to Stem Deflectors topic in Adjustments chapter.

Inspect Blower Rim Sheet Liner.

See Blower topic in Service chapter.

Check and readjust Blower Fan Paddles.

See Blower topic in Service chapter.

Lubricate appropriate grease fittings.

Refer to Lubrication chapter.

Date After Service is Completed

SERVICE EVERY 200 HOURS (OR END OF SEASON) Check quality and level of Transmission oil.

Refer to Lubrication 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 Lubrication chapter.

Date After Service is Completed

129

Index A Adjustments, 36–53 Ammonia silage additive use, 55 Attachment positioning, 17 Attachment positioning adjustments, 36 Axles & Wheels, 36 Downstop, 36 Lift height, 36 Lift Spring, 37 Axle, Wheels and Tires installation, 103 Axles, Wheels & Tires avaialble, 121

B Bevel Gearbox service, 58 Blower, troubleshooting, 86 Blower Adjustments, 37 Belt Idler, 37 Drive Belt, 37 Fan Paddles, 37 Blower Rim Sheet Liner available, 121 Blower service Drive Belt, 58 Drive Sheave, 58 Driven Sheave, 59 Rim Sheet Wear Liner, 59

C Cap control, 17 Cap Motor Relocation Kit available, 122 Chain & Sprocket service, 61 Chain length table, 82 Checklists, delivery, 5–7 Control Box Extension Harness available, 121 Control Box Extension Harness mounting, 119 Control Box for Shear Bolt Models mounting and wiring, 110 Control Box for Torque Sensor and Metal Detector Models mounting and wiring, 111 Controls & Safety Equipment, 17–21 Cutterbar position adjustment, 38 Cutting Cylinder, troubleshooting, 87 Cutting Mechanism service Cutterbar, 61 Knife replacement, 63

D Decal Locations, 124–127 Decal locations, 125–128 Decal Set & List, 124, 126 Decals, applying new, 124

130

Deflector, troubleshooting, 89 Deflector service, 64 Drawbar Control Cylinder & Hoses installation, 106 Drawbar Control Latch Rope installation, 106 Drawbar Extension for 1–3/4 Drive installation, 105 Drawbar Hitch Clips, 80 Drawbar installation, 103 Drive Chains adjustment Attachment Driver, 42 Length–of–Cut, 42 Lower Feed Rolls, 43 Shifter Transmission & Spinner, 43 Upper Feed Rolls, 43 Drive Chains lubrication, 55 Drive Line, troubleshooting, 88 Drive Line alignment, 81

E Electric Clutch Reburnishing, 73 Electric controls service, 73 Emergency Shutdown, 22 Entering the crop, 22

F Feed Roll Drive, troubleshooting, 92 Feed Roll Spring tension adjustment, 43 Feed Rolls & Attachment Controls (Torque Sensor Protected models ONLY), troubleshooting, 90 Feed Rolls & Attachment Controls (All Harvester models), troubleshooting, 89 Field Operation, troubleshooting, 93 Front Bearing Stand, Main Drive and Guards installation, 104 Front PTO Bearing height adjustment, 44

G General operating information, 22 Grease Fitting locations, 56 Greasing, 55 Guards & Shields, 18

H Harvester–Attachment alignment, 81 Harvesting capacities, 24 Highway Transport Lighting, 84 Highway Transport Lighting Kit, 120 Highway Transport Lighting Kit available, 123 Hitchjack, 20 Hitchjack installation, 104 Horizontal Extension installation, 117 Horizontal Extensions available, 122

Index (Cont.)

Hydraulic circuit requirements, 55 Hydraulic Knive Sharpener, 20 Hydraulic Tongue control kit available, 121

I Identification numbers, 2, 3 Implement Drive Line Guards, 19 Inflation pressures. See Tire pressures Introduction, 2

J Jack. See Hitchjack

K Knife Sharpener, troubleshooting, 94 Knife Sharpener adjustments Guide Arm & Roller, 70 Rail alignment, 70 Sharpener Carriage removal, 70 Spring Plate, Spring & Upper Roller, 70 Stone angle, 69 Knife Sharpening Cutterbar sharpening, 67 Cylinder Knife sharpening, 66 General information, 65 Preparing Sharpener, 66 Storing Sharpener, 69 Using Closed Center System Tractors, 65 Using Open Center System Tractors, 65 Knives adjustment, 44

L Leaving the crop, 22 Length–of–Cut adjustment, 44 Length–of–Cut Kits available, 121 Lift Cylinder Hose installation, 109 Lift System, troubleshooting, 94 Lift System Lock, 18 Lift System lock for transport, 83 Long Cut Kit avaiable, 121 Long Cut Kit installation, 119 Lubrication, 54–57

M Main Drive Impact Pins, 121 Maintenance, 128–129 Mandatory Safety Shutdown Procedure, 8 Metal Detector model Bypassing the Metal Detector system, 34 Control Box, 29

Daily system inspections, 35 General information, 31 Introductory information, 30 Metal detection, 32 Stopping Harvester, 32 System detection reaction procedure, 33 System Start–up, 31 System start–up & reset procedure, 32 System test, 35 Metal Stop Machines, troubleshooting, 95 Metal Stop Solenoid & Stop Pawl adjustment, 45 Miscellaneous Guards, 19

O Offset Wagon Hitch installation, 120 Offsett Wagon Hitch available, 121 Oiling, 55 Operating Feed Rolls and Attachment, 27 Operator’s Manual, storing, 2 Optional Features & Accessories, 121 Overload protection Control Box, 25 Hydraulic Knife Sharpener, 25 Lower Feed Rolls, 25 Main Drive Line, 24 Spinner Drive, 25 Overrunning Clutch, 20

P Paint Notice, 124 Preparing Harvester for operation, 81 Protection of unpainted surfaces, 85 PTO Drive, troubleshooting, 99

R Reburnishing Electric Clutch, 73 Remote Grease Lines, 71

S Safety, 8–16 Safety Chain & Transport Lighting, 21 Safety Chain & Transport Lighting for transport, 83 Safety Chain available, 121 Safety Chain installation, 120 Scaper adjustment, 46 Screen Cam kit available, 122 Screens & components available, 122 Second Tractor Control Box Wiring Kit, 120 Second Tractor Control Box Wiring Kit available, 122 Serial number record, 5, 7 Service, 58–79

131

Index (Cont.)

Set–up & Assembly, 102–120 Shear Bolts available, 122 Shifter Transmission control, 20 Shifter Transmission service, 71 SMV Emblem & Reflector for transport, 84 Specifications, 3–4 Speed Monitor service, 71 Spinner, troubleshooting, 100 Spinner Gearbox lubrication, 55 Spinner service Disc & Paddles, 71 Drive Chain, 71 Spout adjustments, 40 Spout control, 17 Spout Liner available, 123 Spout, Cap & Controls installation, 107 Square–holed Screen & Wet Crop Deflector installation, 118 Square–holed Screen adjustment, 47 Square–holed Screens available, 122 Start–up, 22 Stem Deflector adjustment, 47 Storage, 85

T Telescoping PTO Coupler Lock, 21 Telescoping PTO Drive installation, 105 Telescoping PTO Drive service, 72 Telescoping PTO Drives available, 123 Tire & Wheel service, 72 Tire pressures, 73 Tires, Wheels & Axles adjustment Flotation Tire Axles, 48 Standard Single Wheel Axles, 48

132

Tandem Wheel Axles, 49 Tongue position adjustment, 41 Tongue position for transport, 83 Tongue positioning, 18 Torque Sensor Contact Points adjustment, 45 Towing on highway, 84 Tractor Hitch alignment, 80 Transmission lubrication, 54 Transporting, 83–84 Tripod installation, 113 Tripod Kit available, 122 Troubleshooting, 86–101 Tunnel Switch (for Water Tank) installation, 117 Tunnel Switch Kit (for Shear Bolt Models Harvesters only) available, 123

U Unplugging Blower, 23 Cylinder, 23 Feed Rolls, 29 Spinner & Spinner Chute, 24 Spout, 23

V Vertical Extension installation, 116 Vertical Extensions available, 123 Voltage checks, 73

W Wagon Hitchplate adjustment, 49 Wet Crop Deflector available, 123 Wiring Harness installation, 109

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

Grade 8

Dry

Lubed

Dry

Lubed

Dry

Lubed

8-32 8-36

19* 20*

14* 15*

30* 31*

22* 23*

41* 43*

31* 32*

10-24 10-32

27* 31*

21* 23*

43* 49*

32* 36*

60* 68*

45* 51*

1/4-20 1/4-28

66* 76*

50* 56*

9 10

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



Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179

907051/AP793

GEHL Company 1993

Printed in U.S.A.