Gehl MC2240 MC2270 Mower Conditioners Operator's Manual 904987 - PDF DOWNLOAD

Form No.

904987 Replaces 904346

- M 2240/2270 ~ Mower Conditioners

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OPERATOR'S MANUAL

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GEHL NEW AGRI CULT URAL EQUIPMENT DISC MOWER CONDITIONER WAR RANT Y GEHL AGRICULTURE DIVISION of the GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl Disc Mower Conditioners and attachments, to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months {ninety (90) days for commercial/custom use} from the Warranty Start Date, except as set forth below: The Cutterbar is warranted for a period of two (2) years from the Warranty Start Date for replacement only, labor and freight excluded, unless defect occurs during initial twelve (12) month warranty period.

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

GEHL MAKE S NO REPRESENTATIONS OR WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIE S OF MERC HANT ABILIT Y AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

GEHL WARRANTY DOES NOT INCLUDE: 1.

Transportation to selling dealer's business location or, at the option of the Original Retail Purchaser, the cost of a service call.

2.

Used equipment.

3.

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

4.

Normal maintenance service and expendable, high wear items.

5.

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

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

6.

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.

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TABLE OF CONTENTS Description

Chapter

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Page

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Safety . . . . . . . . .. . . . . . . . . . . . . . . .. .. . . . . . . . . . .. . . . . 8-13 Controls & Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17 Operation . . . .. . . .. . . . . . . .. . . . . . . . . . . . . .. .. . . . . . . .. 18-22 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-27 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-29 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-39 Preparing for Field Operation . . . . . . .. .. . . . . . . . . . . . . . . . . . . . .40-42 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45-48 Set-up & Assembly . . . . . .. . . . . . . . . . . . . . . . . . . . .. .. . . . ..49-53 Optional Features & Accessories . . . . . . . . . . . . . . ~ : . . . . . . . . . . . .54-59 Decal Locations . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . .. .60-62

lrldex . . . . . . . .. . . . . . . . . . . . . . . . . . . . . ... .. . . . . . . .. .63-64 Standard Hardware Torque

. . . . . . . .. . . . . . . . . . . . . . . . Inside Back Cover

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CHAP TER 1 INTRODUCTION Your decision to purchase this piece of GEHL• equipment was a good one. We are sure that your decision was strongly considered and that you are looking forward to many seasons of reliable performance from this machine.

We, as a Company, have invested a great deal of time and effort in developing our lines of agricultural and industrial equipment.

This manual was developed specifically for the machine you have purchased. The information, contained within, was prepared 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. in the back of the manual, for specific chapter and topic/page number references.

This GEHL equipment is provided with its Operator's Manual attached to it. After using it, please keep this Manual with the unit at all times! Furthermore, we recommend if this machine is re-sold that this Manual accompany the unit.

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 you attempt to operate lt.

Our wide Dealership network stands by to provide you with any assistance you may require, including genuine GEHL service parts. All parts should be obtained from or ordered through your GEHL Dealer. Give complete information about the part as well as the model number and serial number of your machine. Record numbers, in the spaces provided, as a handy record for quick reference.

The Mower Conditioner model and serial number is on a plate located on the left side of the Swing Frame at the Steering Post Pivot. "Right" and "Left" are determined from a position standing behind the Mower Conditioner. From this position. the Conditioner Roll Timing adjustment is on the "right" side.

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MODELNO.

MC22 (Fill In)

(ADIn)

GEHL COMPANY

WEST BEND, WIS. 53095 U.S.A.

Typical Model & Serial Number Plate

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

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

The GEHL Company, In cooperation with the Amerl· can 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 unit Itself, you are reminded to BE ALERT! Your personal safety Is Involved!

CHAPTER 2 SPECIFICAT IONS All Dimensions are in Inches (Millimeters) Unless Otherwise Noted Model/Description .......... . .. MC2240 & MC2270 Swing Frame Mower Conditioner Cutting Width 2240 ......... .. .... . ... ...... 12'3" (3733.8) 2270 .. .. .. .... .. .......... .. 14' 3" (4343.4) Machine Weight (with Tongue) 2240 .. . .... . ..... . ... . ... . 5490# (2495.5kg) 2270 .. . .......... ... ...... 5660# (2572.7kg) Overall Width 2240 ......... .. ........ .. . .. ... 13'9" (4191) 2270 . ............. . . . ...... .. 15'9" (4800.6) Overall Length .. .. .... .. ... . . . . .... . .. 22 (6705.6) Tread Width 2240 ... . .. . ...... . . . ..... .. 137-1/2 (3492.5) 2270 ..... . .. .... ...... .. ... . ... 139 (3530.6) Tire Size 2240 .. .. . ... ....... . .... .. . 9.5L X 14, 6 Ply 2270 . . .. .. .. .. ..... .. . .. .. . . IlL X 14, 6 Ply Tire Pressure . .. ............... . .. . 28 psi (196kPa) Wheel Bolts . . ... 9/16 (14.3) X 1- l/8 (28.6) Grade 5 Part Number .. .. ..... . .... .. ... . ... . . . ....550041 Torque ..... . ... . ..... . ... .. .. 90 ft.-lbs. (122 Nm) Header Lift Range . . ..... . ... . .... 3 (76.2) below to 19 (482.6) above ground Header Floatation . . . . . . laterally adjustable springs Cross Shaft Speed (Reel/Auger and Sickle Drive) ... .. .. . .. .. variable Sickle Speed ... . ... . .. .... .. ... . . 1500 SPM (750 CPM) Stroke . ... .. .. .. .. ... ...... . ..... .. . ... 3 (76.2) Cutting Height .. . . . ... .. . . ... 1 (25.4) to 6 (152.4) Guard Angle .. . ..... . ... .. . .... . ... . . . . 8• to 14 • Guard Spacing .. .. ..... . . . ... . . . ........ 3 (76.2) Drive ..... .. .. . .... .. . . . .. .. . • . ..... wobble arm Hay Conditioner .. .... ... Intermeshing Rubber Rolls Length .. .. .. . .. .... .. .. .. .. .... .. .. 109 (2768.6) Diameter .... .. .. ... .... .... .. .. .. . 7-3/4 (196.9) Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 RPM Reel ........ ... . .. . . . . . . . .. .43 (1092.2) Diameter All Metal4 Bat w/Cam Track Actuated Tines Drive .... . .. . ..... . .... . . .. ...... .. . . .... . Belt Action Control . . . . ........... . ....... Cam Track Speed (Adjustable) .. .. ............. 71 to 98 RPM Auger .. .. ...... . ......... . ....... .. . . .. All Metal Drive .... . .... . .. . ... .... Chain with Shear Bolts Diameter .. .. .. .. .. . . .. . .... . .. ..... .. 22 (558.8) Speed ................ . ... . ... .. ... . ... 185 RPM

Hydraulic Drive System . .... PTO Driven Pump and Motor Combination - 540 RPM or 1000 RPM System Fluid . ... .... .. ..... Dextron II Automatic Transmission Fluid Reservoir Capacity ..... 27.5 U.S. Gallons (104.11) System Relief Pressure .. ..... . ... . ... .. . .4000psi Filter Assembly ........... Full Flow, No By-Pass Filter Assembly ... . . . . .. .. Screw On, Throwaway Filtering Material ... . . . .. .. .... 10 Micron Phenol Resin Treated Paper Operating Temp ................. -3o· to +210. F. Motor Displacement .... .. ... . .. . .. 5.04 Cu. In. Per Rev Operating Speed ...... . . .. . . .. ... .. .. .. 985 RPM Max. Operating Pressure .. ........ . ...... 3500psi Mounting .......................... 2 Bolt Flange Port Size (2) ............. .. .... . . 1-1/16-12 SAE Drain Port Size ..................... 9/16-18 SAE Rotation, from L~ft End as Mounted ... . Clockwise Shaft ... .. ........ . .. . ... . ... . .... . ..... Splined Bolt Torque .. .. . ...... . . . ... .. 55 ft.-lbs. (75 Nm) PUMP GEARBOX ASSEMBLY Pump ...................... . .... 540 or 1000 RPM Rotation ...... Counterclockwise from Splined End Gearbox Type .. . ..... . ... .. .... .. ............ . Planetary Input Speed . .... ... ... ... .... . . 540 or 1000 RPM Hydraulic Steering Cylinder Bore . . ........... . .. . . . ...... .. . 3-1/2 (88.9) Stroke .. .. ..... . .................. 16 (406.4) Closed Length . .....• . .... . .... . .31-1/2 (800) Port Size . .. .. .................. . 3/4-16 SAE Lift Cylinders Max Operating Pressure ..... ...... .. . 2000psi Closed Length . . .... .. .... .... . 22-3/4 (577 .9) Port Size . . . .. . .. .... .... .. .. .. .. .. 3/8 NPTF TRACTOR REQUIREMENTS Horsepower .. . ... .. ... . *60 PTO hp Recommended PTO RPM . .... . ..... . ........ . ....... 540 or 1000 Hydraulics . .... . ..... . ......... . ... . Dual Remote *Actual horsepower available at operating altitude.

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INTENTIONALLY BLANK

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CHAP TER3 CHECKLISTS PRE-DELIV ERY

DELIVERY

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After the Mower Conditioner has been completely setup, the following inspections MUST be made before delivering it to the Customer. Check off each item after prescribed action is taken.

Check that:

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.

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parts of the unit have been damaged in shipment.

0 NO Check for such things as dents and loose or missing

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Hydraulic Oil Reservoir 1s filled to the proper level; see Lubrication chapter of this manual.

The Wheels are properly mounted and securely attached and Tires are properly mounted and inflated to the appropriate pressure listed in the Service chapter.

and review with customer the Service chapter of 0 Explain this manual.

0 All bolts and fasteners are in place and tightly secured. applicable, the Hydraulic Pump, Motor, Cylinders, 0 As Hoses and Fittings are NOT damaged, leaking or loosely connected.

Gearbox is filled to proper oil level; see 0 The Lubrication chapter of this manual.

Grease Fittings have been properly lubricated, 0 All Chains oiled, and as applicable, the Self-contained

0

its contents BEFORE operating the unit.

Customer on how to use the Index of this manual 0 Direct as a quick page number locating guide .

Explain and review with Customer the SAFETY 0 information in this manual. the function and use of the Transport Locks for 0 Explain the Header Lift and Swing Frame Transport Block.

Explain and review with Customer the Controls & O Safety Equipment chapter of this manual.

Explain that regular lubrication is required for continued 0 proper operation and long life. Review with him the

parts; correct or replace components as required.

iii

the Customer his Operator's Manual. Instruct 0 Give customer to be sure to read and completely understand

All Guards, Shields and Decals are in place and securely 0 attached. and Serial numbers for this unit are recorded in O Model space provided on this page and page 2.

Hook the unit up to a 540 or 1000 RPM tractor, de~ pending on your unit, and test~run it while checking that proper operation is exhibited by all components.

Check that:

0 Hydraulic Hoses and connections do not leak.

Drives, Chains and Mechanisms are operating 0 All smoothly and properly adjusted.

Reel and Conditioning Rollers turn freely and the 0 The Tines are NOT striking the Sickle or Conditioning

Lubrication chapter of this manual.

and review with customer the Preparing for O Explain Field Operation chapter of this manual.

Completely fill out Mower Conditioner Owner's 0 Registrations, including Customer's signature, and return them to the company.

I acknowledge that the above points were reviewed with me at the time of delivery.

Customer's Signature Date Delivered

(Dealer's File Copy)

Rollers.

I acknowledge that pre-delivery service was performed on this unit as outlined.

Dealership Name Dealer Representative 's Signature Date Checklist Filled-out Model Number

Serial Number

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INTENTION ALLY BLANK

{To be removed as Dealer's File Copy)

6

CHAPTER3 CHECKLISTS PRE-DELIVERY

DELIVERY

After the Mower Conditioner has been completely setup, the following inspections MUST be made before delivering it to the Customer. Check off each item after prescribed action is taken.

Check that:

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.

0

NO parts of the unit have been damaged in shipment.

Check for such things as dents and loose or missing parts; correct or replace components as required.

0 All bolts and fasteners are in place and tightly secured. applicable, the Hydraulic Pump, Motor, Cylinders, 0 As Hoses and Fittings are NOT damaged, leaking or loosely connected.

Gearbox is filled to proper oil level; see 0 The Lubrication chapter of this manual.

All Grease Fittings have been properly lubricated, 0 Chains oiled, and as applicable, the Self-contained Hydraulic Oil Reservoir is filled to the proper level; see Lubrication chapter of this manual.

Wheels are properly mounted and securely attached 0 The and Tires are properly mounted and inflated to the appropriate pressure listed in the Service chapter.

All Guards, Shields and Decals are in place and securely 0 attached. and Serial numbers for this unit are recorded in 0 Model space provided on this page and page 2.

Hook the unit up to a 540 or 1000 RPM tractor, depending on your unit, and test-run it while checking that proper operation is exhibited by all components.

Check that:

0 Hydraulic Hoses and connections do not leak.

Drives, Chains and Mechanisms are operating 0 All smoothly and properly adjusted.

Reel and Conditioning Rollers turn freely and the 0 The Tines are NOT striking the Sickle or Conditioning Rollers.

I acknowledge that pre-delivery service was performed on this unit as outlined.

the Customer his Operator's Manual. Instruct 0 Give customer to be sure to read and completely understand its contents BEFORE operating the unit.

Customer on how to use the Index of this manual 0 asDirect a quick page number locating guide.

Explain and review with Customer the SAFETY 0 information in this manual. the function and use of the Transport Locks for 0 Explain the Header Lift and Swing Frame Transport Block.

Explain and review with Customer the Controls & 0 Safety Equipment chapter of this manual. that regular lubrication is required for continued 0 Explain proper operation and long life. Review with him the Lubrication chapter of this manual. and review with customer the Service chapter of 0 Explain this manual. and review with customer the Preparing for 0 Explain Field Operation chapter of this manual. fill out Mower Conditioner Owner's 0 Completely Registrations, including Customer's signature, and return them to the company.

I acknowledge that the above points were reviewed with me at the time of delivery.

Customer's Signature Date Delivered

(NOTE: Pages 5 & 6 Have Been Removed At Perforation)

Dealership Name Dealer Representative's Signature Date Checklist Filled-out Model Number

Serial Number

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CHAP TER 4

SAF ETY 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 INFORMATI ON. 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.

A

DANG ER

"DANGER" Indicates an Imminently hazardous situation which, If not avoided, will result In death or serious Injury.

A WARNING "WARNING" Indicates a potentially hazardous situation which, If not avoided, could result In death or serious Injury.

A CAUTION "CAUTION" Indicates a potentially hazardous situation which, If not avoided, may result In minor or moderate Injury. May also alert against unsafe practices.

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MANDATO RY SAFETY SHUTDOW N PROCEDURE BEFORE unclogging, cleaning, adjusting, lubricating or servicing the unit: 1.

Disengage the tractor PTO.

2.

Shut off the tractor engine, place the tractor 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.

S.

Disconnect the Hydraulic Pump from the PTO and Hoses from tractor.

ONLY when you have taken these precautions can you be sure it is safe to proceed. Failure to follow the above procedure, could lead to death or serious bodily injury DO NOT get near the unit until the Reel and Conditioner Rolls have stopped rotating! Both mechanisms and the Sickle can continue to operate after the PTO is disengaged!

DO NOT attempt to hand feed or kick any crop or material into this machine!

BE SURE the Hitchjack Locking Pin is completely engaged and that the machine is properly blocked and prevented from rolling BEFORE disconnecting the unit from the tractor!

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.

ADDITIONAL SAFETY REMINDERS 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.

SAFET Y (Continued) ALWAYS wear safety glasses with side shields when striking metal against metal. It is further recommended that a softer (non-chippable) 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.

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

NEVER use your hands to search for hydraulic fluid leaks; use a piece of cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause 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.

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.

Always lower Header to ground when parking.

Always use adequate lights or safety warnings when transporting machine on public roads and after dark.

Check with the local law enforcement agencies for specific requirements.

Limit towing speed to 20 mph.

ALWAYS follow state and local regulations regarding use of safety chain and auxiliary lighting when towing farm equipment on public highways. BE SURE to check with local law enforcement agencies for your own particular regulations. Unless otherwise prohibited, use a Slow-moving Vehicle Emblem.

A DANGER MAINTAIN A SAFE DISTANCE FROM EACH END OF HEADER. NEVER STAND IN FRONT OF HEADER WHEN MECHANISM IS OPERATING. FAILURE TO HEED WILL RESULT IN DEATH OR SERIOUS INJURY. 093843

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A

SA FE TY (Continued)

A WARNING THIS IMPLEMENT IS EQUIPPED TO OPERATE WITH 540 RPM TRACTOR MEETING ASAE STANDARD S203. NEVER ATTEMPT TO CONNECT OR OPERATE WITH 1000 RPM PTO TRACTOR. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

A WARNING THIS IMPLEMENT IS EQUIPPED TO OPERATE WITH 1000 RPM PTO TRACTOR MEETING ASAE STANDARD S203. NEVER ATTEMPT TO CONNECT OR OPERATE WITH 540 RPM PTO TRACTOR. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY. ..,••,

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A

SAFET Y (Continued)

A

A WARNING THIS UNIT IS OPERATED BY HYDRAULIC OIL UNDER PRESSURE. ESCAPING HYDRAULIC FLUID UNDER PRESSURE CAN BE INVISIBLE AND CAN PENETRATE THE SKIN. DO NOT USE HANDS TO SEARCH FOR LEAKS. RELIEVE PRESSURE PRIOR TO DISCONNECTING HYDRAULIC LINES. COMPONENTS CAN BE HOT. APLUGGED MACHINE WILL CAUSE OIL TO BYPASS UNDER HIGH PRESSURE UNTIL THE SOURCE OF THE PLUGGING IS REMOVED; THEN COMPONENTS WILL SUDDENLY BEGIN TO ROTATE. BEFORE UNPLUGGING, CLEANING, ADJUSTING OR SERVICING THIS UNIT, PROCEED AS SPECIFIED IN THE OPERATOR'S MANUAL. KEEP ALL GUARDS AND SHIELDS IN PLACE.

A WARNING

BE SURE MACHINE IS CLEAR OF PEOPLE, TOOLS, AND OTHER OBJECTS BEFORE STARTING. DO NOT WEAR LOOSE OR BAGGY CLOTHING AROUND THIS MACHINE AND KEEP HANDS, FEET AND CLOTHING AWAY FROM MOVING AND POWER DRIVEN PARTS. KEEP CHILDREN AND SPECTATORS OFF AND AWAY FROM MACHINE WHILE IT IS OPERATING. KEEP OFF UNIT UNLESS A SPECIFIED OPERATOR'S STATION IS PROVIDED. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

THE OWNER IS RESPONSIBLE FOR MAKING INFORMATION AVAILABLE ON THE SAFE USE AND PROPER MAINTENANCE OF THIS MACHINE. DO NOT START, OPERATE OR WORK ON THIS MACHINE UNTIL YOU HAVE CAREFULLY READ AND UNDERSTAND THE CONTENTS OF THIS MANUAL. IF YOU HAVE QUESTIONS ON OPERATION, ADJUSTMENT OR MAINTENANCE OF THIS MACHINE OR NEED AN OPERATOR'S MANUAL, CONTACT YOUR GEHL DEALER OR GEHL COMPANY, WEST BEND, WISCONSIN 53095 MODEL AND SERIAL NUMBERS WILL BE REQUIRED. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

Cle3387

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SAFETY (Continued)

A WARNING HOT LIQUID UNDER PRESSURE. ALLOW TO COOL. REMOVE CAP SLOWLY. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

A WARNING INSTALL TRANSPORT LOCK BEFORE TRANSPORTING MACHINE. LOCK LOCATES MACHINE IN PROPER POSITION BEHIND TOWING VEHICLE. FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

A WARNIN G • MECHANICAL OR HYDRAULIC FAILURE CAN CAUSE UNIT TO FALL • BEFORE TRANSPORTING INSTALL TRANSPORT LOCKS. • BEFORE WORKING ON OR UNDER MACHINE, INSTALL TRANSPORT LOCKS, BLOCK WHEELS, HEADER AND TRAILER FRAME. • FAILURE TO HEED COULD RESULT IN DEATH OR SERIOUS INJURY.

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(

SAF ETY (Continued)

A

A WARNING ROTATING COMPONENTS CAN CATCH/CUT/ PINCH HAND. KEEP HANDS OUT. CLOSE OR REPLACE GUARD BEFORE OPERATING MACHINE. FAILURE TO HEED COULD RESULT IN DEATH OR 093365 SERIOUS INJURY.

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Notes

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CHAPT ER 5 CONTRO LS & SAFETY EQUIPM ENT The Mower Conditioner is provided with several features for operator safety and convenience.

A CAUTION Become familiar with and know how to use ALL Safety Devices and Controls on the Mower Conditioner, BEFORE attempting to operate this equipment. Know how to STOP Mower Conditioner operation BEFORE startIng lt.

GUARDS & SHIELDS (Figs. 5·1 & 5·2) Whenever and wherever possible and without affecting machine operation, Guards and Shields have been used, on this equipment, to protect potentially hazardous areas. In many places, Decals are also provided to warn of potential dangers as well as to display special operating procedures.

A WARNING Read and observe ALL Warnings on the unit, BEFORE operating lt. Do NOT attempt to operate this equipment unless ALL factory Installed Guards and Shields are properly secured In place.

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1 • Left Drive Shield 2 • Right Drive Shield 3 • Transport Block 4 • SMV Emblem Attachment

Fig. 5·2 Various latched and hinged Guards, Shields and Covers are provided on both model Mower Conditioners to enable access for lubrication, service and adjustment.

A CAUTION BEFORE proceeding to perform any work on the Mower Conditioner and, BEFORE removIng any Guards and opening any Covers and Shields, BE SURE to exercise the MANDA· TORY SAFETY SHUTDOWN PROCEDURE (page 8). BE SURE also to replace ALL Guards, Shields and Covers BEFORE operatIng the unit.

HEADER LIFT & STEERING SYS· TEM(Figs. 5·1, 5·2 & 5·3) The Mower Conditioner uses a remotely controlled (from the tractor seat) hydraulic Cylinder system, to raise and lower, and position the Header. Before transporting the unit, BE SURE to raise the unit as high as possible and activate the Transport Block and the Header Lift Safety Locks on both sides of the unit.

1 • Conditioner Drive Shield 2 • Header Lift Safety Lock (Right) 3 • Large Hinged Right End Shield

Fig. 5·1

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A CAUTION

Refer to the Optional Features & Accessories Chapter for ordering information.

BEFORE transpor ting the Mower Conditioner, raise the unit as high as possible and engage both Header Lift Safety Locks and Transport Block.

0

1 • Safety Chain

Fig. 5·4

HEADER DRIVE (Fig. 5·5) The Hydraulic Motor shown in Fig. 5-5 drives the Auger, Sickle, Reel and Conditioner. It receives hydraulic power from the Pump. The Hydrauli c Pump/Gearbox Assembly slides onto the tractor 1000 or 540 rpm PTO shaft. Hydraulic Fluid is pressurized through a line mounted on the bottom of the Tongue, to the Pressure Relief Valve and then to the Motor.

Returning fluid passes through the Replaceable Cartridge Filter and into the Tongue Reservoir to be picked up and pressurized by the Pump once again. The Tongue/Reservoir also acts as a cooling basin for the Hydraulic Fluid.

A CAUTION

1 • Tractor Valve Stack 2 • Steering Valve 3 • Lift Valve 4 • Lift Cylinders 5 • Steering Cylinder

Fig. 5·3

The Mower Conditioner Is driven by the trac· tor PTO. Any time the PTO Is engaged the Header will operate.

SAFETY CHAIN (Fig. 5·4) HITCHJACK (Fig. 5·6)

A CAUTION ALWAYS follow state and local regulations regarding a safety chain (do not use a nylon or plastic rope as a safety chain) and auxiliary lighting when towing farm equipment on pub· lie highways! A safety chain should always be used to retain the connection between the towing and towed machine, In the event of separation of the primary attaching system.

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

As required or when desired, the Mower Conditioner should be equipped with a safety chain and auxiliary lighting for transporting the unit on public highways.

16

A Hitchjack is furnished with the Mower Conditioner to support the machine when the tractor is disconnected as well as to facilitate aligning the Drawbar Extension with the Tractor Drawbar for hookup. When the Jack is NOT being used to support the Mower Conditioner, it can be removed and relocated to a "storage" position on the Tongue.

A WARNING BE SURE the Locking Pin Is properly seated Into the holes through the Jack Tube and the "Suppor ting" Position Hub on the Tongue, BEFORE disconn ecting the Mower Condl· tloner from the tractor.

6 • Pump Case Drain Line 7 • Suction Line 8 • Gearbox/Pump (Attaches to Tractor's PTO Shaft) 9 • Pressure Line 10 ·Reservoir/Tongue

1 ·Motor 2 • lnllne Relief Valve 3 • Motor Case Drain Line 4 • Motor Return Line 5 • Filter

Fig. 5·5

7'

1 • Hltchjack Storage Hub 2 • Hltchjack In "Supporting" Position

Fig. 5·6

HEADER LIFT SAFETY LOCK POSITION This locks the Header for transport and work on Cutterbar or around or under Header. Fig. 5-7 shows left Header Safety Lock in position (and operating storage position in dotted lines). To lock in Safety position: Raise the Header, remove Clip and Pin from bracket, swing the Stop out and raise to engage on Safety Lock. Secure Lock with Clip Pin. Repeat procedure on the opposite side of the Header.

1 • Header Lift Safety Lock Position 2 • Operating Storage Position

Fig. 5·7

17

CHAP TER 6 OPERA TION The Mower Conditioner is easy to operate, simple to adjust for varying crop conditions and requires very little maintenance. By becoming familiar with all the information in this manual, the operator will be able to operate the Mower Conditioner with ease.

Successful operation requires in-the-field knowledge of the machine as well as careful attention to necessary maintenance and adjustments given in this manual.

Understanding the capabilities of the machine and its operation will insure proper care in achieving the satisfaction that is part of owning a GEHL Mower Conditioner.

Use of a tractor with a Remote Hydraulic "Float" is recommended for the Lift Cylinders during field operation. If your tractor doesn't have a Float Control, check that the rod ends of the Lift Cylinders are free to move in the push arm slots, this allows extra flexibility in clearing obstacles.

PRECAUTIONARY NOTES - Giving careful attention to good safety practices will act as a reminder to always follow good operating techniques and preventive maintenance.

Be on the alert for a peculiar operational sound which could indicate that some component or system is not functioning properly.

- Do not overload machine in heavy crop with excessive ground speed. Slow down!

- Disengage Header when moving from one field to another. Do not operate Header excessively without any load on it.

- Do not overload the Mower Conditioner. In heavy crop stands, slow down the machine ground speed and maintain rated PTO speed.

- During first hours of operation and regularly thereafter, check the machine for loose Bolts, overheating Bearings or damage. Check the Conditioner roll clearance and adjustment. (See Adjustments Chapter.)

- Watch the Header flotation. The Header should ride firmly on the ground without excessive bouncing. It must be light enough, however, to float over uneven ground and obstructions with-

18

out bulldozing. Adjust flotation per instructions found in the Adjustments Chapter.

- When operating in cold weather, allow the oil a few minutes to warm-up before starting to cut.

The Pump may have a tendency to surge when first started because the oil is cold.

- Refer to Troubleshooting Chapter for specific problems.

PTO AND GROUND SPEED Always operate the tractor PTO at its rated speed for field operation. PTO speed is important for efficient cutting, conditioning, and windrow formation.

Average ground speed should be between 4 and 6 mph.

Crop conditions may require slower speeds. If so, shift to a lower gear and maintain rated PTO speed.

Don't attempt to travel too fast over the field. Overtraveling the Sickle and Reel will accomplish disappointing results and can waste material.

TRANSPORTING THE MACHINE The center pivot design allows operation to either side of tractor, as well as towing directly behind the tractor.

However, during transportation of the machine, the Transport Block should be installed in its transport position as shown in Fig. 6-1 unless maneuvering during transportation is required. The Block locks the machine to tow directly behind the tractor and prevents inadvertent movement to either side due to Hydraulic failure.

1.

Install both Header Lift Safety Locks per Safety Chapter.

2.

Make sure the Hitchjack is attached to Storage Post when not in use.

3.

Install Transport Block against Swing Frame per Fig. 6-1. Secure block with Pin.

A CAUTION Air In Hydraulic Lines will allow Cylinders to move, possibly shifting Tongue or Unit, especially on an Incline or while In motion.

4.

After the Hoses are coupled to the Tractor remote Hydraulic System, cycle Cylinders several times to remove trapped air.

A CAUTION DO NOT TOW UNIT WITHOUT TRANSPORT BLOCK INSTALLED AND HYDRAULIC CVLIN· DER INSTALLED.

Steering around an obstruction

1 • Transport Block 2 • SMV Emblem Attachment 3 • Retaining Ring

Fig. 6·1 5.

Be certain that all Safety Decals, Reflectors, slow moving vehicle signs, or Safety Flashers are in place, clean and visible.

6.

Limit towing speeds to 20 mph.

7.

Remember: Practicing good road manners will help en~ure a safe drive to and from the field.

Operating on left side of tractor

STEERING Steering the 2240/2270 is controlled by the tractor remote Hydraulic System and allows the Mower Conditioner to follow directly behind the tractor or make a full cut to either side or an infinite number of positions in between.

A CAUTION Do not activate Steering system without mak· lng sure no one or thing will be hit as Frame and Header move.

Operating on right side of tractor

Fig. 6·2

19

·(/:·"' I

/

/

I .

I

•

!f' J .' ___,. . ,_ /~ . . '.·.

Fig. 6·3 • 180 Degree Turnaround By moving the tractor Control Lever forward, the Mower Conditione r steers right; by reversing the Lever, the Mower Conditioner steers left, see Fig. 10-4 for typical arrangement of Control Levers. The controls are operated momentarily for steering and must be returned to OFF or NEUTRAL position as soon as the Conditioner reaches the desired path of travel. The second Control Lever, when moved back, lifts the Header from the cutting position and when moved forward, lowers the Header.

The Center Pivot provides the operator the opportunity to move the Mower Conditioner into field position easily, allowing right angle turns in either direction, steering around objects on both sides, and straight line field cutting on either side of the tractor, as shown in Fig. 6-2.

NOTE: Do NOT use hydraulic operating pressures over 2500 psi. Check your tractor manual for system pressure.

180 Degree Turnaround When it is desired to cut back and forth on one side of the field, approximately 50 feet is required on each end of the field to make a tso· turnaround. The tum is accomplished as follows: Beginning at Position 1 in Fig. 6-3, the tractor is guided away from the uncut crop while the Mower Conditioner is guided straight ahead until cutting through the end. As soon as the Sickle cuts through, raise the Header to lift the Gauge Wheels or Skid Shoes clear of the ground and then steer the Mower Conditioner to the extreme direction away from the uncut crop. At Position 2, the tractor is guided back towards the uncut crop. In turning, exercise caution

20

that the inside tractor tire does not contact Tongue of Mower Conditioner. In Positions 3 and 4, continue the turn towards the uncut crop with the Conditione r steered towards the outside of the circle, being aware of the Tongue and tire caution, At Position 5, the tractor has completed the circle and the front wheels are turned to line up with the last cut windrow to straddle it. At this point, the Mower Conditioner direction should be changed to line up with the edge of the uncut crop. Also, be prepared to lower the Header to cutting height. At Position 6, the turn has been completed and a new cut through the field has been started.

Turning Square Corners The following procedure and diagram shown in Fig. 6-4 are intended only as a guide to aid the operator in setting up a turning procedure for the particular tractor being used. Distances are not specified due to the variance of tractor maneuverability. As the tractor approaches the corner, guide the tractor sharply away from the crop. The Header is steered to maintain a straight cut ahead as the tractor moves away from the crop. As soon as the Header cuts past where the new corner will be, steer the Mower Conditioner to the extreme direction away from the uncut crop. The Header should be raised sufficiently at this point for the Skid Shoes or Gauge Wheels to clear the ground.

As the tractor passes the corner, steer it sharply back towards the corner, but be aware that the inside tractor tire does not contact the Tongue. Guide the tractor to straddle the last cut windrow. As the Mower Conditioner completes its turning, be ready to steer it towards the uncut crop and align the Header with edge of the uncut crop, then lower the Header to cutting height.

tangled, matted or wet crops, install the Stub Guard Kit listed under ''Extra Equipment' ' . Check that Sickle is always in register and alignment.

Sickle Speed The Sickle speed should not be increased above that specified under Specifications. When the Sickle cannot cut off the crop evenly or pulls the stalk, the ground speed of the machine should be reduced - or the Sickle sharpened.

Reel Position ing and Speed Factory setting of Reel and Cam should NOT be changed unless absolutely necessary. In down and tangled conditions, it may be necessary to move the Reel forward and down. If the Reel is running jerky in heavy conditions, slow the Reel down. Higher ground speed will require faster Reel speed for best cutting efficiency. When the Reel speed is changed, check Reel Drive Belt tension (see Adjustments Chapter).

Auger Position and Speed

Fig. 6·4 ·Turning a square corner

HEADER OPERATION The following paragraphs discuss the operational aspects of the subjects listed. Refer to Adjustments Chapter for adjustment details.

Guard Angle Guard angle is the angle between the Guard ledger surface and the ground. The Header on the 2240/2270 Swing Frame can be set for s· to 14 • angle. The 14• angle has the better pickup action. When rocky conditions or uneven ground exists, use the flatter s• angle to prevent the Guards from picking up rocks or digging in so readily. Intermediate settings tailor the Header to the crop conditions.

Normally no change is required in Auger position or speed. (See Adjustments Chapter if adjustment is necessary.)

Auger Paddles Standard equipment includes four Auger Paddle assemblies. The four Auger Paddles should be positioned 90 degrees apart as shown in Fig. 6-5. The Paddles are for feeding material evenly into the Conditioner. For normal hay cutting operations this is all that is required. Remove all Paddles and Paddles Brackets only if you are having a wrapping problem in the center of the Auger with the Crop Conditioner removed or when cutting grain or seed crops. Also tall lodge crops may work better with NO Paddles.

Push Bar The purpose of the Push Bar is to push the crop forward and down so it will feed through the Auger and Conditioner butt first after being cut off by the Sickle. If the Push Bar is set too high, the crop will stand up after the Push Bar passes, permitting the Reel to pull the crop across the Cutterbar and feeding it through the Header top first. When the crop goes through the Conditioner top first, the leaves and branches are torn from the main stalk.

Sickle and Guards The Sickles provided with the machine use underserrated sections which can be used for most of the crops to be harvested. For certain crops such as fine grasses of flax, use smooth Sickle sections, in place of the standard underserrated Sickle sections. For down,

1 • Auger Paddles

Fig. 6·5

21

Rear Strippe rs The Rear Strippers are two piece assemblies and can be adjusted forward to get exact Auger clearance. Removal of Stripper angles in front of the Auger may be required in heavy crop with build up problems in center of Auger, to provide a smoother flow of material to the Conditioner.

Always keep Rear Strippers adjusted to approximately l/8-inch clearance to the Auger. This prevents any material from being carried over the Auger.

Conditi oner Roll Pressu re The Conditioner Roll pressure determines the amount of conditioning done to the crop (assuming the Roll gap is properly adjusted) and should be used accordingly. For crops like alfalfa and clover (legumes), use only enough Roll pressure to crack and kink the stems.

If the leaves show dark spots and/or the tops of the plants are being clipped-off, too much Roll pressure is being used.

In grass-type crops, more Roll pressure is required than for legume-type crops.

See Adjustments Chapter.

NOTE: If the Conditioner Rolls are separated too far, NO amount of Roll pressure will do a satisfactory job, in most crop conditions.

Conditioner Roll Spacing The Conditioner Roll spacing is the distance between the top of the lug on one Roll and the root of the lug on the mating Roll. The Roll spacing should be set from 1/16 (1.6mm) to 1/8" (3.2mm) , for most crops.

However, it may be desirable to increase the Roll spacing when cutting thick-stemmed cane-type crops.

NOTE: Always check the Roll spacing at several points along the entire length of the Rolls. The space should always be maintained at a minimum of 1116" (1.6mm). Operating at closer than this minimum space may result in costly damage to the Rolls and sheet metal fatigue. Refer to Adjustments Chapter.

Windrow to Swath Adjustment The Mower Conditioner will make anything from a narrow windrow to a wide swath, by moving the adjustable Deflector up or down. Raise the Deflector for a narrow windrow and lower the Deflector for a wide swath. The Deflector can be adjusted, using the Deflector Adjustment Handle, as shown in Fig. 6-6. The maximum swath width achievable is 96" (2438.4mm).

If a particular width is required that is between the minimum and maximum settings, an intermediate hole can be used. If a setting is needed that falls between the holes provided, the Turnbuckle Assembly can disconnected and adjusted to give the desired width.

22

1 • Crop Deflector Adjustmen t Handle

Fig. 6·6

Unplugging

A WARNING DO NOT attempt to unplug the machine while the PTO Is engaged. In addition, NEVER at· tempt to manually clear debris or foreign mat· ter from any part of the Mower Conditio ner while It Is running. Failure to heed, could result In death or serious bodily Injury! AL· WAYS exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE attempting to unplug the machine or manually clearing debris from It! The Mower Conditio ner Is hydrauli cally pow· ered. When the PTO Is disengaged with a plug In the machine, pressure may be trapped be· tween the Hydraulic Pump and Motor. If the Pump Is not removed from the tractor's PTO shaft to allow the pressure to relieve, the Sickle, Auger and Reel may move when the plug Is removed , causing Injury.

A CAUTION Never stand directly behind Mower Condla tloner when It Is running. The machine may project dangerous flying objects.

NOTE:

A wrench pad is provided on the upper drive shaft near the right hand end of the main drive shaft for manually reversing the rolls to remove plugs from the Conditioner.

CHAPT ER 7 ADJUSTMENTS

A CAUTION BEFORE proceeding to perform all Malnte· nance routines on this unit, exercise the MAN· DATORY SAFETY SHUTDOWN PROCEDURE (page 8).

A CAUTION BEFORE proceeding to adjust the cutting height, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

HEADER FLOTATION The 2240 and 2270 Mower Conditioners have been designed and factory adjusted to function properly under most field operating conditions. However, due to the wide range of operating conditions encountered, some additional adjustments may be required.

CUTTING HEIGHT (Fig. 7-1) The cutting height (stubble height) can be adjusted from 1 (25.4mm) to 6" (152.4mm), using the Skid shoes, optional Center Skid Shoe, and/or Gauge Wheel, located on each end of the Cutterbar. The Skid Shoes can be raised or lowered, using the Adjustment Pins shown. BE SURE to operate the unit with both Skid Shoes or Gauge Wheels in the same position. The 1" (25.4mm) cutting height can only be obtained with a 12'-14' Guard angle.

NOTE: Any change to the cutting height requires that the flotation be checked and readjusted, as necessary. In addition, any change to the Guard angle will also affect the cutting height.

Check Header flotation with Header lowered. A force of 50 (22. 7kg) to 70 (31.8kg) pounds should lift either end of the Header. Too much weight on the Header can cause excessive Guard and Sickle Section breakage.

Adjust flotation with the Spring Bolts. Turn the Spring Bolt to adjust the tension on the Spring. Set the Header flotation to 50 (22.7kg) to 70 (31.8kg) pounds of downward pressure at each end of the Header. Readjust regularly thereafter to correct for spring tension drop.

BE SURE to adjust both Springs equally.

NOTE:

Bolts are easier to adjust with Header raised. Lower Header again to check flotation.

A CAUTION ALWAYS lock Header In up position with Header Safety Locks, when working on Cutterbar or under Header.

NOTE:

Use any combination of Skid Shoe setting and Guard angle that holds the clearance between the Sickle Drive Flywheel and Flotation Spring at no less than 1-314" (44.5mm).

1 • Hair Pin Cotter 2 • Position Adjustment Pins

1 • Flotation Springs (Both Sides) 2 ·Spring Bolts (Both Sides)

Fig. 7·2

Fig. 7·1

23

If your Header does not float properly with this flotation setting, check the Tie Rods and pinned connections on the lower Push Arms for any rust, bent pins or other restrictions. The Tie Rod Springs should be compressed to 1-7/8" (47.6mm) overall spring length to restrict Header side to side motion without interfering with flotation.

GUARD ANGLE (Fig. 7-3)

A CAUTION Exercise the MANDATORY SAFETY SHUT· DOWN PROCEDURE (page 8), BEFORE pro· ceedlng to adjust the Reel speed.

The Guard angle can be adjusted by loosening the third point header link and pivoting the Header about the lower Lift Arms. Moving the top of the Header toward the Main Frame allows a flatter Cutterbar angle to a minimum of 8' down. This flatter angle is for use in rough or rocky field conditions to protect the Guards.

Moving the top of the Header away from the Main Frame gives a steeper downward Guard angle to a maximum of 14 •. This is for faster, closer cutting under normal to smooth field conditions. You may select any position between these two extremes depending on your requirements and field conditions.

The recommended range of adjustment, center to center of Pins should be 20-13/16 (528.6mm) to 23-1/2" (596.9mm). After adjustment, lock Turnbuckle link securely with the locking device pointed up.

NOTE:

Use any combination of Skid Shoe setting and Guard angle that holds the clearance between the Sickle Drive Flywheel and Flotation Spring at no less than 1-314" (44.5mm).

1 ·Bolts 2 • Drive Sheave 3 • Drive Belt Idler 4 • Drive Belt Tensloner 5 • Spacer Storage Position

Fig. 7·4 To change Reel speed:

1 • Locking Tab 2 • 20·13/16 to 23·1/2"

Remove Belt tension and remove the four bolts from the Reel Drive Sheave.

2.

To increase Reel speed, remove the spacers from between the two halves of the Drive Sheave, and place in storage position.

3.

To decrease Reel speed, remove the spacers from the storage position and place them between the halves of the Sheave.

4.

Replace Bolts in Drive Sheave.

5.

Adjust Belt Tension.

REEL RELEASE LOCATION (Fig. 7·5) Fig. 7·3

REEL SPEED (Fig. 7-4) Reel speed should be about 20 percent faster than the ground speed. When changing the Auger speed, check Reel speed and adjust as necessary.

24

1.

To change the cam action of the Tines for proper release of material, loosen three Bolts and rotate Cam Track as required; tighten all Bolts. Proper material release is evident when the material flow is along the front of the Auger, NOT under the Auger or being carried over the Reel.

The best adjustment range for most crop conditions is within 1 (25.4mm) to 3-1/2" (88.9mm) from the Tines

to the Auger. A 3" (76.2mm) distance is usually the best position. If too much material is going over the Reel, have the Tines release (drop back) sooner. If too much material is feeding under the Auger, instead of along the front of the Auger, increase the release point to the maximum 3-1/2" (88.9mm) distance.

NOTE:

If material in the windrow is bunched-up, on a regular basis, adding two extra Reel Bats will make the windrow move more uniformly. A 6-Bat Reel package can be obtained from your GEHL dealer. See OPTIONAL FEATURES & ACCESSORIES.

1 • Reel Adjustment (Up or Down) 2 • Reel Adjustment (Ahead or Back) 3 • Auger Position

Fig. 7·6

CONDITIONER ROLL PRESSURE (Fig. 7· 7) NOTE: If the Conditioner Rolls are separated too far, there is NO amount of Roll pressure that will do a satisfactory job in most crop conditions.

1 • Adjust Cam Track so Tinea drop back at lndl·

cated Point 2 • 1 to 3·1/2" 3. 1/4" 4. 1/8"

Fig. 7·5

REEL POSITION (Fig. 7·6) Factory setting of Reel and Cam should NOT be changed unless absolutely necessary. In down and tangled conditions, it may be necessary to move the Reel forward and down. To move the Reel up or down, loosen four Bolts, then adjust the Bolt on the top. To move the Reel forward or back, slide in slots, then retighten four Bolts. Adjust cam end of Reel so Reel is parallel with Cutterbar. To adjust cam end of Reel, loosen three Bolts and four Bolts on Bearing Hanger behind Reel Drive Pulley. Then, using the screw adjustment as above, move the Reel up or down as necessary or slide forward or back in slots. Tighten Bolts.

Make certain the Reel clears the Cutterbar and Riser Pan by at least 1/8" (3 .2mm).

When adjusting the Reel position, check to make sure the left Tines on the Reel do not contact the high arc hold down clip. If necessary, shorten the Tines to prevent interference.

Any change in Reel position, check Reel Drive Belt tension.

Adjust Conditioner Roll Pressure Spring by adjusting the threaded Turnbuckle and Rod system. Spring pressure is normally adjusted from the factory at 4 7" (1193.8mm) overall spring length including hooks.

Move Turnbuckle ends together to increase Roll pressure. DO NOT over tighten! Prevent Spring Rods from rotating as Turnbuckle is tightened. Lubricate threads to ease adjustment.

When cutting thick stemmed cane-type crops, adjust Conditioner Roll Pressure Spring by adjusting the threaded Turnbuckle and Rod System to 45" (1143) to reduce strain on unit.

1 • Conditioner Roll Pressure Adjustment 2 • Grease Fitting

Fig. 7·7

25

Once Spring pressure is set, change amount of crop conditioning by varying roll spacing to greater roll separation for less crop conditioning or less roll spacing for increased crushing of crop.

CONDITIONER ROLL SPACING (Fig. 7·8) The Conditioner Roll space is the distance between the top of the lug on one Roll and the root of the lug of the mating Roll. The Roll spacing should be set from 1/16 (1.6mm) to 1/8" (3.2mm) for most crops. However, it may be desirable to increase the Roll spacing when cutting thick-stemmed cane-type crops.

equal amount of Shims to both ends of the Header, to keep the Top Conditioner Roll parallel to the Lower Conditioner Roll. It will be necessary to release the Roll pressure before attempting to change the gap. See Fig~;ue 7-9 .

DO NOT OVERLOAD CONDITIONER. In heavy hay, maintain full roller speed with slower ground travel.

NOTE: If the Conditioner Rolls are separated too far, NO amount of Roll pressure will do a satisfactory job of conditioning most crops.

NOTE: Always check the Roll space at several points along the entire length of the Rolls. The space should always be maintained at a minimum of 1116" (1.6mm). Operating at closer than this minimum space may result in costly damage to the Rolls.

On MC2240 (after SN14900) and MC2270 (after SN25100), the Conditioner Roll gap can be changed by adjusting the Roll Stop Bolt that exerts pressure against each Roll Arm. BE SURE to adjust each bolt an equal amount to both ends of the Header, to keep the Top Conditioner Roll parallel to the Lower Conditioner Roll. It is NOT necessary to release the Roll pressure before attempting to change the gap. See Figure 7-8.

1 • Conditioner Roll Shim Adjustment (Both Sides)

Fig. 7·9: MC2240 (Before SN14901) and MC2270 (Before SN25101)

AUGER SPEED (Fig. 7-10) Standard factory Headers are equipped with a 16-tooth Auger Drive Sprocket. This Auger speed provides best feeding action in most average to heavy crops. A 14tooth Drive Sprocket is available from your GEHL dealer for slowdown.

To change: 1.

Loosen Drive Chain.

2.

Loosen Set Screw and remove Auger Drive Sprocket.

Fig. 7-8: MC2240 (After SN14900) and MC2270 (After SN25100)

3.

Remove Reel Drive Belt from Drive Sheave by releasing Idler Spring Clip.

On MC2240 (before SN14901) and MC2270 (before SN25101), the Conditioner Roll gap can be changed by adding or subtracting Shims from under each Roll Arm. Thick and thin Shims are used for the adjustment.

ALWAYS use a thick Shim as the contact with the Conditioner Roll Arm. Extra Shims are located at the Left end of the Header. BE SURE to add or subtract an

4.

Install14-tooth Sprocket and adjust Drive Chain.

5.

Adjust Reel speed to maintain 20 percent faster than ground speed rate. Refer to "Reel Speed Adjustment".

1 • Conditioner Roll Stop Adjustment Bolt (Both Sides)

26

1 • Auger Drive Sprocket 2 ·Bolts 3 • Drive Sheave 4 • Drive Belt Idler 5 • Drive Belt Tenaloner 6 • Spacer Storage Position 7 ·Set Screw (Both Sides)

Fig. 7·10

27

CHAP TER 8 LUBRI CATIO N NOTE: Regular lubrication habits are essential to the satisfactory operation of your machine.

A CAUTION NEVER attempt to lubricate the Mower Condl· tloner when any part of It Is In motion. AL· WAYS, BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding to lubricate the Mower Conditioner.

GENERAL INFORMATION Don't let excessive grease collect on or around parts, especially when operating in sandy soil.

The following pages show the location of all Lubrication Points. The frequency of lubrication is given in hours based on normal operating conditions. Severe or unusual conditions may require more frequent attention.

28

Use an SAE Multi-Purpose Type Grease for all locations shown here. Be sure to clean the Fitting thoroughly before using Grease Gun.

ROLLER CHAIN Chains should be lubricated frequently to maintain their high efficiency and give long, trouble-free service. Factors such as operating conditions (dirt and temperature), amount of power transmitted, speed of chain, and lubrication, influence the life of a Chain. To effectively lubricate Chain Joints, oil must be delivered to the spaces between the Side Bars. It is also essential that an adequate oil film be retained between the Rollers and Bushings to maintain a free and flexible Chain. When a Chain becomes stiff, it should be soaked and washed in a solvent to loosen and remove dirt and corrosion from the joints, then soaked in oil, until the lubricant penetrates between the Rollers and Bushings. Refer to the Service Chapter of this Manual for recommended Conditioner Drive Chain Oiler instructions.

SEALED BEARINGS Sealed Bearings are used throughout the machine to provide trouble-free operation with a minimum of maintenance and lubrication. Sealed bearings are lubricated for life and due to the seals, re-lubrication is not practical.

LUBRICATION POINTS Grease Every 10 Hours (or Daily) 1. Lower Wobble Arm Bearing 2.

Wobble Arm Pivot Bearing

3.

Upper Wobble Arm Bearing

4.

Lift Cylinder Header Mounting (Left)

5.

Lift Cylinder Frame Mounting (Left)

7.

Lift Cylinder Header Mounting (Right)

8.

Lift Cylinder Frame Mounting (Right)

Grease Every 50 hours 6.

Conditioner Roll Pivot (Left)

9.

Conditioner Roll Pivot (Right)

10. Conditioner Roll Pressure Turnbuckle (Not shown on this page, refer to Fig. 7-7 .)

11. Adjustable 'Deflector (Both Ends) 12. Flywheel Pivot (Under Cover) 13. Conditioner Roll Chain Tensioner Pivot

GEARBOX NOTE: On a routine basis every 200 hours of operation, check the fluid level in the Mower Conditioner Gearbox. The level should be maintained with a sufficient amount of EP 90 Gear Lube so that it just starts to run out of the Fill Plug opening in the back of the Gearbox.

The Gearbox should be checked occasionally for oil drips and dust accumulation around the Seals. Oil drips or dust accumulation indicate that Seals are leaking.

Oil which is tan in color and foams excessively indicates that it has water present. Unless rust spots appear inside the Gearbox, the fluid does NOT require replacement.

Units built after Serial Numbers 14000-2240 & 251002270 are equipped with a Dipstick to check the Gearbox fluid level.

NOTE: Do NOT overfill the Gearbox; only fill to the centerline of the Cross Shaft.

29

CHAP TER 9 SERVI CE GENERAL INFORMATION

4.

Last, tighten the Set Screw in the Locking Collar.

A CAUTION BEFORE proceeding to perform all Service routines on this unit, exercise the MANDA· TORY SAFETY SHUTDOWN PROCEDUR E (page 8).

NOTE:

The following information is also referred to in the TROUBLESHOOTING Chapter 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 by (or under the direction of) an authorized GEHL equipment dealer.

SEALED BALL BEARING REPLACEMENT (Fig. 9-1) Sealed Ball Bearings are used on various Shafts, around the unit. This type of Bearing is generally retained, in place, with a Self-locking Eccentric Collar.

The Lock Collar has a counter-bored recess, which is eccentric with the Collar bore. This eccentric recess engages or mates with an eccentric end of the Bearing inner ring, when the Bearing is assembled on the Shaft.

The Bearing is engaged, on the inner ring cam, by the Collar. This assembly grips the Shaft tightly with a positive binding action that increases with use. The Collar Set Screw provides supplementary locking.

The Bearing can be removed from the Shaft by loosening the Set Screw and tapping on a punch which is placed in the drift pin hole, to loosen the Collar. Install Bearings with self-locking Collars in the following manner: 1.

Place the Bearing and Collar on the Shaft with the cam surfaces next to each other. Tighten the bolts on the Bearing Retainers.

2.

Mate the cam of the Lock Collar, with the cam of the Bearing inner ring.

3.

Press the Locking Collar against the Bearing wide inner ring and turn it, in the direction of Shaft rotation until it tightly engages. Tighten the Collar further, by tapping on a punch inserted in the drift pin hole.

NOTE: tighten it.

30

Avoid damaging the Collar. Do not over-

1 · Bearing 2 ·Set Screw 3 • Collar Cam 4 • Wide Inner Ring Cam 5 • Drift Pin Hole 6 • Eccentric Self·Locklng Collar

Fig. 9·1

NOTE:

Always tighten Lock Collars in direction that shaft is rotating.

GIB KEY The Gib Key, a tapered key with a tang on the thick end, is a combination locking device and hub retainer.

The hub MUST have a matching tapered keyway for use with a Gib Key. The Gib Key will lock the hub in place and retain it from turning.

Removal (Fig. 9-2) 1.

Remove paint from the Shaft on both sides of the hub.

2.

Loosen the Set Screws.

3.

Drive hub away from the Key head, using a large punch or drift. Make sure that Gib Key does NOT move with hub.

4.

Pull key, using a pinch bar or tapered punch.

5.

Slide hub from Shaft.

A Gib Key has a taper of 0.0104 in/in. To check taper, when filing, put two marks on the Key, 1 inch apart, and use a caliper to measure the taper.

t-----

~

"0

Fig. 9·2

.Installation (Figs. 9-3 & 9-4) 6.

Align Sheave or Sprocket and place Key in Keyway.

7.

Reseat Key with a lead-headed hammer (or rubber mallet), without moving Hub on Shaft.

The Key does NOT have to be driven extremely hard in order to hold.

NOTE:

1 • File Evenly on this side 2 ·Sprocket 3 • Glb Key 4 · Shaft 5 • Sprocket Hub 6 • 1/16" minimum gap on all Keys 7 • 1/2" maximum or flush with Shaft

Fig. 9·4

CUTTERBAR (Fig. 9·5)

A WARNING Fig. 9·3 When installing a new Gib Key into the Sprocket hub, it may be necessary to file the Gib Key to obtain a good Key length engagement. When doing this, BE SURE to file bottom side of Key, NOT the tapered top side.

When filing, use a hand file and use a smooth even motion to take enough material off. Do NOT use any type of power grinder on the Gib Key; otherwise, a poor fit will result.

BE CAREFUL when working around the Sickle. Wear heavy gloves to protect your hands and fingers.

The majority of Mower Conditioner problems are caused by a lack of proper maintenance to the Cutterbar. The Cutterbar consists of two cutting surfaces, the Sickle Section and the ledger area of the Guard. For a clean, smooth cut, the Sickle Sections MUST operate very close to the ledger surface of the Guard.

31

NOTE: Regular washing of the Cutterbar area with water under pressure will improve performance and facilitate maintenance work.

1 • Regular Guard 2 • Hold-down Clip 3 • Sickle Section 4 • Ledger Area of Guard

Fig. 9·5

Sickle Guards The double-forged, through-hardened Guard is standard equipment on this unit. When replacing, make certain the Sickle rides freely in the Guard, and new Guards are lined up with old to get a good shearing cut.

When each Guard is aligned, tighten the Bolts. The tip of the Guard MUST be aligned with the other Guards.

Use the Guard Straightening Tool provided , to straighten the Guards per details in the General Main· tenance information. Whenever all Guards are removed from Cutterbar, the Cutterbar should be inspected for any kinks in the front edge and straightened accordingly.

Sickle Register (Fig. 9-6) The Sickle stroke is 3 inches (72mm). The Sickle Section MUST center on the center of the Guard at the end of each stroke. Check register in center of the Header.

1.

To adjust, remove the Bolts which fasten the Pitman Tube to the Wobble Arm.

2.

Loosen the Cap Screw on the Pitman Tube Clamp.

3.

Turn the Upper Wobble Arm Bearing in or out of the Pitman Tube to the proper setting. Do NOT turn too far. Threads exposed on upper and lower Bearings should be equal.

Sickle & Sickle Sections (Fig. 9·5)

A WARNING ALWAYS WEAR PROPER EYE PROTECTION, when working on Sickles and Sickle Sections.

For proper operation, the Sickle MUST be straight and without any twist. Also, the Sickle Sections should be firmly fastened to the Sickle strap. Worn or broken Sickle Sections should be replaced. When replacing Sickle Sections with rivets, shear-off the rivets rather than punching them out; punching-out rivets will enlarge the holes in the Sickle strap. When replacing Sickle Scetions with Screws & Nuts, tighten Nuts to 6-8 ft lb (8-11 Nm).

NOTE:

Tighten Clamp securely, after being sure that the Sickle is in register.

NOTE:

When tightening Guard Bolts, make sure Guards are parallel with each other and NOT cocked with Cutterbar. As you face Guard when tightening it, BE SURE to tighten the Guard Bolt on your right first, while pushing Guard rearward.

NOTE: Under-serrated Sickle Sections are NOT designed for NOR intended to be sharpened. The under-serrated Sections, with serrations parallel to the Sickle strap, are sharpened by normal wear.

Sickle Removal NOTE: If Sickle Guards are badly bent or very loaded with dirt, they will have to be straightened and cleaned before the Sickle can be removed.

1.

Remove Bolts at lower end of Wobble Arm, as shown in Fig. 7-12.

2.

Loosen Sickle Head Clamp.

3.

Oscillate Wobble Arm lower end fully to the left.

4.

Pull out Sickle, complete.

5.

Reverse procedure to install Sickle.

32

1 • Upper Wobble Arm Bearing 2 • Sickle Adjustment 3 ·Flywheel 4 · Clamp 5 • Pitman Arm

Fig. 9·6

Hold-down Clips

NOTE:

Clips MUST NOT put heavy downward pressure on Sickle Sections. Hold-down Clips keep the Section from lifting off the Guards for a good shearing action but allow the Sickle to slide easily. After Guards are aligned, set the Hold-down Clips. NEVER bend down a Clip, when a Section is under it. Clip should only have a maximum of 1/32" (.8mm) clearance to Section, when Sickle is being pressed down on Guard. After all Clips are set, oil and make sure Sickle slides freely.

Regular washing of the Cutterbar area with water under pressure will improve performance and facilitate maintenance work.

Sickle Head attaches same as Pitman Head except grease fitting is up.

SICKLE DRIVE Sickle Drive Belt (Fig. 9-7) Keep heavy belt tension on Sickle Drive Belt for improved belt life and proper machine function. Adjust tension by moving Idler Pulley at the Gearbox. Washers are used as spacers to position the Idler on the Belt center as it makes the transition from the Gearbox Sheave to the Flywheel.

1 - Upper Wobble Arm Bearing 2 ·Clamp 3 - Pitman Arm 4 • Attachment Cap Screws

Fig. 9·8

Wobble Arm Pivot Bearing Adjustment (Fig. 9-9)

1 • Sickle Drive Belt Idler

Fig. 9·7

Flywheel (Fig. 9-8) Occasionally check the Flywheel Bearings for roughness or excess play. Adjust or replace as necessary.

Lubricate as required.

Pitman Arm (Fig. 9-8) Always keep the Clamp tight and the Socket Bearing in line with the Wobble Arm. See the accompanying photograph for Pitman Arm and Bearing assembly.

Wobble Arm Bearing Replacement (Fig. 9-8) Attach Pitman Head to Wobble Arm with Ball Offset up (grease fitting on bottom side). Pitman Head must be adjusted at this time for correct Sickle Register. See Sickle Register procedure. Install two 1/2 x 2-3/4" Attachment Cap Screws with Flanged Nuts on bottom of Wobble Arm. Tighten Attachment Cap Screws to 85 ft lb (115Nm) & Clamp Screws to 35 ft lb (47Nm).

The Wobble Arm Pivot Bearings must be adjusted occasionally to remove any end play resulting from wear. Any looseness of the Bearings permit hammering which intensifies the wear. The Wobble Arm Pivot has tapered Roller Bearings which are adjusted for looseness or end play by tightening the Pivot Pin Hex Jam Nut. To check for Bearing Drag, both Pivot Bearings must be unbolted from the Wobble Arm to permit free movement. Any end play will permit the ends of the Wobble Arm to move up and down and to move back and forth without drag. Tighten Jam Nuts on bottom end of Pivot Pin until a slight drag or slight effort is required to move Wobble Arm. Tighten second Nut to secure adjustment. Recheck Bearing Drag. If satisfactory, install Heads to Wobble Arm. Reinstall Pivot Bearings.

Wobble Arm Pivot Bearing Replacement (Fig. 9-9) The Wobble Arm pivots on two tapered Roller Bearings which must be adjusted for end play upon installation and after wear. When Bearings are badly worn and adjustment is no longer possible, replace them as follows: 1.

Detach the Sickle Head and Pitman Head from the Wobble Arm. Remove two bolts attaching Wobble Arm Pivot Pin to Upper Flange

33

1 • Head Attachment Bolts (2)(Bolt heads up) 2 • Upper Wobble Arm Bearing 3 • Pivot Mounting Bolts (4 places) 4 • Upper Flange 5 • Grease Fitting 6 • Lower Wobble Arm Bearing 7 • Wobble Arm Pin with Jam Nuts 8 ·Nut 9 • Lock Washer 10 ·Washer

11 ·Wobble Arm Pivot Pin 12 • Upper Flange 13 ·Washer 14 ·Bolt (1/2 x 1·1/4" Grade 5)(2 places) 15 ·Bearing Cone (2) 16 ·Wobble Arm 17 • Bearing Cup 18 ·Washer 19 ·Jam Nuts (2)

Fig. 9·9 2.

Remove two Jam Nuts from lower end of Wobble Arm Pivot Pin. Remove Pivot Pin while holding on to Wobble Arm. Wobble Arm will be free to fall when pin is removed.

3.

Remove Wobble Arm from Header by pulling outward. Lift out Bearing cones and drive out Bearing Cups by tapping on inside edges.

4.

Thoroughly clean Bearing Housing. Press in new Bearing Cups, placing thickest edges to the inside.

5.

Pack Bearing Housing and new Bearing Cones with gun grease and install Cones in Bearing Cups. Hold bottom Bearing Cone in place and jnstall Wobble Arm with a flat washer between each Bearing Cone and Flange as shown.

6.

Insert Wobble Arm Pivot Pin through Upper Flange, Bearings and Lower Plate. Install first Hex Nut and tighten sufficiently to compress Flanges, Washers and Bearings to remove excess grease and any looseness and end play. Continue to tighten Hex Nut while rotating Wobble Arm back and forth until slight drag is detected, and install second Hex Nut.

34

7.

Attach the Upper and Lower Wobble Arm Bearings to Wobble Arm per the "Wobble Arm Bearing Replacement" paragraph and Fig. 9-8.

8.

Check Sickle alignment and register per procedures in this section of manual. Install two Pivot Pin Attachment Bolts in Flange above Wobble Arm as shown.

CONDITIONER Conditioner Roll Alignment (Figs. 9·1 0 & 9-11 & see Figs. 7·8 & 7·9) Upper Conditioner Roll must be aligned to the lower Conditioner Roll to have proper spacing and timing of the Rolls. If timing is good at 180. from one point and bad at 90" and 270", then the Rolls aren't aligned to each other length-wise. Move either upper or lower Roll left or right until ends are flush by loosening Bearing Lock Collars and shifting Roll. Rolls should be centered in the Frame. Lock Bearing Lock Collar after aligned and check Conditioner Sprocket alignment.

Conditioner Roll Timing and Chain Tension (Figs. 9·1 0 & 9·11) To time the Conditioner Rolls, remove End Panel Cover, loosen the four 7/16" Cap Screws (MC2240

before SN14901 & MC2270 before SN25101) or the twelve M8 Socket Head Screws (MC2240 after SN14900 & MC2270 after SN25100) in the lower Roll Sprocket Hub. Align the bars on the rubber Conditioner Rolls as shown in the sketch. You may want to loosen the Conditioner Drive Chain Idler Tension to make this adjustment easier. Readjust the Chain Idler Spring to 3-5/16" (84mm) compressed length. This chain tension reduces chain whip and fluctuation under heavy load conditions. Reinstall End Panel Cover using a sufficient amount of silicone sealer on all mating surfaces.

1 • 1/16" Min. Clearance (Upper Roll Lug centered between Lugs of Lower Roll) 2 • Loosen Cap Screws and rotate to adjust Timing 3 • 1/16" Min. Clearance Shimmed here 4. 3-5/16" Compressed Spring Length

Fig. 9·11: MC2240 (Before SN14901) and MC2270 (Before SN251 01)

1 • 1/16" Min. Clearance (Upper Roll Lug centered between Lugs of Lower Roll) 2 - Loosen Socket Head Screws and rotate to adjust Timing (Retorque to 25 ft.•lb., 34Nm) 3 • 1/16" Min. Clearance adjusted here 4 • 3·5/16" Compressed Spring Length

Fig. 9·10 MC2240 (After SN14900) and MC2270 (After SN25100)

Conditioner Drive Chain Oller (Fig. 9-12) Fill Chain Oiler Reservoir with lOW engine oil or automatic transmission fluid. Before operating Conditioner, open the Oiler Valve by flipping the toggle at the top of the Reservoir upright. Adjust the flow to 20 drips per minute by flipping the toggle down and tum the top knurled nut counterclockwise to increase the flow and clockwise to decrease flow .

1 - Chain Oller Reservoir

Fig. 9·12

35

l •

AUGER DRIVE Auger Position and Shear Bolts (Fig. 913)

When a new Belt is installed or the Reel is moved to its forward position, it may be necessary to change the Upper Spring Bracket. Remove the Tightener Idler Nut and use the top hole of the Upper Spring Bracket.

Normally NO change is required in Auger position.

Clearance between Auger and Stripper Angles should be l/8" (3.2mm). Auger position can be changed by loosening the four Bolts on the right Bearing Hanger and three Bolts on left side and moving Auger as required, then tightening Bolts. Make certain both ends of the Auger are adjusted evenly so Auger is parallel with Stripper Angles. Stripper Angles can also be moved to get a constant clearance between Auger and Stripper Angles.

The Auger and Reel Drives are protected by two Shear Bolts. Make certain any replacement Shear bolts are Grade 5 quality with three radial marks on the bolt head. Do NOT use Grade 2 or Grade 8 Bolts.

1 • Auger Position Bolts

Fig. 9·13

Auger Drive Chain Tension (Fig. 9-14) Adjust Auger Drive Chain tension to obtain l/2" (12.7mm) deflection with 35 lb. (15.9lkg)force as shown.

1.

Loosen Idler Sprocket Bolts.

2.

Position Idler Sprocket until Chain has correct tension.

3.

Tighten Idler Attachment Bolt.

REEL DRIVE Reel Drive Belt Tension (Fig. 9·14) When the Reel Belt is correctly adjusted it will take 15 lb. to raise the Belt Tightener Idler.

To increase Belt tension, remove Spring Clip and fasten to the next lower hole.

36

1 • Drive Sprocket 2 • Auger Sprocket 3 • 1/2" deflection with 35 lb. of force 4 • AdJustable Idler Sprocket 5 • Reel Drive Belt Idler 6 • Drive Belt Tensloner Spring Clip 7 • Auger Idler Sprocket 8 • Idler Sprocket.Bolts

Fig. 9·14

HYDRAULIC SYSTEM

A CAUTION Before checking hydraulic system, exercise the MANDATORY SAFETY SHUTDOWN PRO· CEDURE (page 8).

The Mower Conditioner is hydraulically powered, using a self-contained Hydraulic System to operate the Header functions and the tractor remote system to operate the Header Lift Cylinder and Steering Cylinder.

The Cylinders and associated hydraulic lines for raising and lowering the Header and steering the machine are connected to the tractor remote Hydraulic System for operation. Therefore, there are no servicing instructions in this manual concerning these components.

A WARNING BEFORE removing cap, allow hydraulic oil to cool. Hot oil may be under pressure. Remove cap SLOWLY. Failure to heed may result In serious burns.

NOTE:

Oil level must be maintained for efficient operation of machine. An insufficient oil supply will damage Hydraulic Pump severely, causing costly repair and down time. ALWAYS maintain a sufficient Reservoir Oil supply.

Reservoir Draining (Fig. 9-16) Drain the Reservoir by disconnecting the Pump Supply Hose from the Pump. Be prepared to catch a large quantity of oil, as the Reservoir could have as much as 28 gallons.

Hydraulic System Filter Change at first 50 hours; thereafter every 250 hours of operation or beginning of each season, whichever comes first. Install the Filter hand tight.

Reservoir Checking (Fig. 9-15) The Mower Conditioner self-contained Hydraulic System uses the Tongue of the machine for the Hydraulic Fluid Reservoir. The Filler Neck is located near the center of the Tongue. The top surface of the Tongue must be level when checking the reservoir oil level.

See illustration for checking Tongue levelness. Check the oil level daily, using the Dipstick attached to the Filler Neck Cap. FULL oil level is at the top ring on the Stick and oil should be added when the level reaches the lower ring.

1 • Pump Supply Hose 2 • End of Reservoir

Fig. 9·16

NOTE:

It is important that the Tongue is level when checking the oil level since a very small amount of being out of level can result in several gallons of oil either over-filled or low. A low oil level can result in starving the Pump, which will damage it when going up hill.

Reservoir Filling Fill Reservoir with Dextron II Automatic Transmission Fluid to level specified in paragraph "Reservoir Checking". Total capacity of Reservoir is 28 gallons.

Hydraulic Drive System Check Out (Fig. 9-17) To check out the system, it is necessary to isolate each component and test it separately. Loss or reduction of hydraulic power can be caused by failure of any one of three components. The Relief Valve is preset at the factory so the only maintenance is removal for cleaning and installation of new 0-rings. Overhaul of the Pump and Motor units MUST NOT be attempted in the field. Precision fits in the units require White Room Care during overhaul. Therefore, when a hydraulic unit fails to perform, it should be removed from the Mower Conditioner and sent to a hydraulics overhaul facility.

Use the following procedure to check out the system:

1 ·Dipstick 2 • Filler Neck 3 ·Level

Fig. 9·15

1.

Check Reservoir Oil level.

2.

Check Inline Relief Valve. Remove Relief Valve from housing. Clean Valve and inspect it for foreign material or damage. Inspect 0-ring seal and replace if worn or damaged. Reinstall Valve and test machine. Refer to Fig. 9-17 for schematic of system.

3.

Check Relief Valve pressure. Install high pressure gauge in pressure line between pump and relief valve. Block movement of Header Jackshaft, start tractor and engage PTO. The pressure should be 3,900 to 4,000 psi.

37

1 ·Motor 2 • lnllne Relief Valve 3 • Motor Case Drain Line 4 • Motor Return Line S ·Filter 6 • Pump Case Drain Line 7 • Suction Line

8 • Reservoir/ Tongue 9 • Gearbox/ Pump (Attaches to Tractor's PTO) 10 ·Pressure Line 11 • O·Ring 12 ·Relief Valve 13 • lnllne Relief Valve

Fig. 9·17

A CAUTION

5.

Do not bypass oil through the Relief Valve for an extended period of time or tremendous heat will build up In the valve.

Check Motor Case drain oil volume. Disconnec t drain hose at Reservoir and hold hose in a measurable container. Start tractor and collect Case drain oil flow for a short period of time. If flow exceeds 1.5 gpm (gallons per minute) the Motor is worn internally .

WHEELS & TIRES

If pressure is low, install a new Relief Valve and test pressure again.

If pressure is now up (3,900 to 4,000 psi), the problem is solved.

If pressure remains low, the Pump or Motor has failed.

4.

38

Check Pump Case drain oil volume. Excessive case drain oil from Pump indicates internal wear in the Pump. With Header Jackshaft blocked, disconnect Drain and hold Hose in a measurable container. Start tractor and collect Case drain oil flow for a short period of time. If flow exceeds three gallons per minute, the Pump is worn internally.

The Wheels are attached to the hubs with Wheel Bolts installed in threaded holes in the hub flange. On installation of Wheel, clean threads with a steel brush and oil very lightly to retard corrosion. Tighten Wheel Bolts to 90 foot-pounds torque.

Wheel Bearing Replacement (Fig. 9-18) 1.

Block Tires to prevent movement.

2.

Jack Tire clear of ground and remove Wheel.

3.

Pry out Hub Cap from Hub.

4.

Remove Cotter Pin, Axle Nut and Washer.

5.

Slide Hub from Axle. Use a hub puller if necessary.

6.

Remove Bearing Cups and discard. Clean Hub and dry.

7.

Press in new Bearing Cups with thickest edges facing in.

8.

Pack Bearing Cones by machine or hand, thoroughly forcing grease between rollers, cone and cage with Universal Super Heavy Duty Wheel bearing grease (or equivalent). Fill space between bearing Cups and Hub with grease to inside diameter of Cups.

9.

Place largest Bearing Cone in place and press in new Grease Seal with lip pointing towards Bearing.

10. Clean Axle and install Hub. 11. Install smaller Bearing Cone, Washer and Axle Nut. Tighten slotted Hex Nut with a wrench while rotating Hub until there is a drag. This assures all bearing surfaces are in contact and not floating in the grease. Back off slotted Nut to nearest locking slot and install Cotter Pin. 12. Fill Hub Cap 3/4 full of wheel bearing grease and install in Hub. 13. Install Wheel and remove Jack.

Tire Pressure Tire pressure should be checked regularly and maintained as follows:

1 ·Axle 2 • Inner Bearing Cone 3 • Inner Bearing Cup 4 • Outer Bearing Cup 5 • Outer Bearing Cone 6 • 1/8 x 1·1/2" Cotter Pin 7 • Grease Seal 8 ·Hub 9 ·Washer 10 ·Castellated Hex Nut (7/8"·14) 11 ·Hub Cap 12 • Wheel Bolts (6 each Wheel)

Fig. 9·18

9.5Lxl4, 6 ply flotation ............2240- 28 psi (196kPa) 11Lx4, 6 ply flotation ................2270 - 28 psi (196kPa)

39

CHAP TER 10 PREPA RING FOR FIELD OPERA TION The use of a Hydraulic Pump mounted directly on the rated PTO Shaft eliminates mechanical drive and its restrictions. Steering and Header Lift Cylinders are supplied from the tractor remote hydraulic outlets.

Before placing the machine in operation, check settings outlined in this section. Make sure all lubrication has been performed in preparing to enter operation.

TRACTOR DRAWBAR AND PTO DIMENSIONS (Fig. 10-1)

2.

Install Hitch Pin (5) in end hole of Drawbar Extension (4). Tighten 5/8" Bolts to 100 footpounds (136 Nm) torque and 1" Nut to 480 foot-pounds (650 Nm) torque.

NOTE: DO NOT operate the machine without the Drawbar Extension. Damage to the Pump and Hose Assemblies will occur.

The Mower Conditioner operates from the PTO Shaft.

The tractor Drawbar should be adjusted to the dimensions shown in Fig. 10-1. These standards have been set up by the American Society of Agricultural Engineers (ASAE) . Tractors which do not conform to ASAE Standards may require a special PTO Adapter.

See tractor dealer for Adapter.

1 • PTO Rotation as seen from Rear of Tractor 2 • PTO Master Shield 3 • 2·1/2" (63.5mm) Minimum PTO Engagement 4 • Extend Torque Arm for proper position 5 • Drawbar 6 • After Torque Arm Is positioned, wrap Chain around Drawbar

Fig. 10·2 3.

Raise Mower Conditioner tongue to clear the Hitch Pin (5) and back tractor to align Hitch Pin (5) with hole in Hitch Ball on Tongue. Lower Tongue to rest on Hitch Pin. Install Hitch Pin Lock (6) in Hitch Pin to secure it.

4.

Slide the Hydraulic Pump Assembly onto the PTO Shaft of the Tractor. Adjust the Torque Arm so that it rests on the right side of the Drawbar.

1 - End of Tractor PTO Shaft 2- 14" (355.6mm)(540 or 1000 RPM) 3 • 6 (152.4mm) to 12" (304.8mm) 4 • Hitch Pin Hole 5 • 13 (330.2mm) to 17" (431.8mm)

Fig. 10·1

NOTE:

The 14" (355.6mm) Dimension in Fig. 10-1 is not standard for 1000 RPM tractors. The Drawbar MUST be adjusted to achieve this dimension. DO NOT operate with any other distance between the center of the Hitch Pin hole and the end of the PTO Shaft.

TRACTOR HOOKUP (Figs. 10-1, 10-2 & 10-3) 1.

40

Set Tractor Drawbar to specifications shown in Fig. 10-1.

NOTE:

Pump outlets must be vertical. Circle the Drawbar with the Chain. Place end of Chain through slotted hole on Torque Arm.

NOTE:

THE PUMP MUST NEVER BE KEYED OR FASTENED TO THE PTOSHAFT.IFTHE DRAWBAR PIN SHOULD BREAK OR LOSE OUT, THE PUMP MUST BE FREE TO SLIP OFF.

.....•• .. . .....

•'

9 • Tractor Drawbar 10 • 5/8" Flat Washer (3). Use as Required 11 • 5/8 x 4" Cap Screw 12 ·Remove Hydraulic Hoses, Right Hose · Header Lift, Two Left Hosea • Steering 13 • 1·1/8" Hex Nut & Lock Washer· 14 · 1" Flat Washer (3). Use as Required 15 • 1 x 4" Cap Screw

1 • Jack Stand 2 • Hitch Pin Lock 3 ·Hitch Pin 4 • Drawbar Extension 5 • 1" (25.4mm) Slotted Hex Nut, Lock Washer 6 • 3/16 x 2" Cotter Pin 7 • 5/32 x 1·3/4" Cotter Pin 8 • 5/8" Slotted Hex Nut, Lock Washer

Fig. 10-3

NOTE:

TRACTORS WITH GROUND DRIVE PTO - The PTO must be disengaged before backing the machine. Running the PTO in reverse can damage the Hydraulic Pump and Motor.

5.

Connect the remote Hydraulic Hoses (2) on the Mower Conditioner to the Tractor remote outlets per the following procedure, "Steering and Lift Cylinder Hookup".

NOTE:

Check all Hardware for tightness within the first 3 to 4 hours of operation and weekly thereafter.

SAFETY CHAIN (Fig. 10·4) 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 .

1 • Safety Chain

Fig. 10·4

41

STEERING AND LIFT CYLINDER HOOKUP (Fig. 10-5) The two hoses from the Steering cylinder should be hooked up so that when the tractor Control Handle is moved to the forward position the Header will move to the right. (Pressure from this line will retract the Steering Cylinder) . Moving the Control Handle to the rearward position will move the Header to the left.

(Pressure on this line will extend the Steering Cylinder.) The Lift Cylinder Hose should be connected to the other valve so when the Control Handle is pulled to rear position the Header will raise. (The operator may prefer to position the Lift Cylinder connection differently for more efficient use of the Control Handle during field operation)

BREAK-IN Before starting to cut and condition, it is recommended that the Mower Conditioner be broke-in, by running it empty for approximately 30 minutes. This initial runin should be done with the Header on the ground and the Tongue in the cutting position . Before running the unit however, perform the daily (10 hour) maintenance routines listed in the beginning of the Operation chapter.

The Break-in should consist of a twenty five minute and a five minute running period. First, run the unit at idle PTO speed for twenty five minutes. Next, stop the unit and exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8) before leaving the tractor seat to reinspect the unit. After inspection is complete, reconnect the PTO, restart the tractor, engage the PTO at idle PTO speed and gradually increase the speed to 540 RPM and continue running the machine for 5 minutes. After another inspection, the Mower Conditioner is ready for the field.

TRANSPORTING BEFORE transporting the Mower conditioner, perform the following:

1 - Remote Hydraulic Levers - Typical Arrangement 2 • Lower Header 3 • Steer Right 4 • Right Hydraulic Lever 5 • Raise Header 6 • Steer Left

Fig. 10·5.

42

1.

Raise the unit as high as possible with the Hydraulic Lift. Next, flip the two Header Lift Safety Locks (one on each side of Frame) up into the locking position. Then, slowly lower the weight of the unit onto the Safety Locks.

2.

Move the Tongue to the transport position. Install the Transport Block against Swing Frame Tongue over pin and secure with Retaining Ring.

Refer to the Transporting Chapter for additional transporting information.

CHAPTER 11 TRANSPORTING TRANSPORT LOCKS (Figs. 11·1 & 11-2} When Mower Conditioner is going to be transported on a public highway, BE SURE to raise the unit all the way up and activate both Header Lift Safety Locks. BE SURE also to swing the Drawbar to the Transport position and install the Transport Block against Swing Frame Tongue and secure with Retaining Ring. See also Operation Chapter.

1 • Header Lift Safety Lock Position 2 • Operating Storage Position

Fig. 11·1

SAFETY CHAIN & AUXILIARY LIGHTING (Fig. 11-3}

A CAUTION ALWAYS follow state and local regulations, regarding a safety chain and auxiliary light· lng, when towing farm equipment on public highways! A safety ~ (NOT an elastic or nylon/plastic tow strap) should always be used to retain the connection between the towing and towed machine, In the event of separation of the primary attaching system.

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

NEVER transport the Mower Conditioner at speeds greater than 20 mph. Unless otherwise prohibited, use a Slow-moving Vehicle Em· blem.

Mower Conditioner should be equipped with a safety chain for operation on public highways. The safety chain, when attached in this manner, has the following characteristics: 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 of the road.

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.

,,

..

'

1 • Transport Block 2 • SMV Emblem Attachment Bracket 3 • Retaining Ring

Fig. 11·2

SMV EMBLEM & REFLECTORS (Fig. 11· 2) Mower Conditioner is provided with a Slow-moving Vehicle Emblem on Swing Frame rear. Red Reflector Strips are also provided at the rear corners of the Main Frame.

1 • Safety Chain

Fig. 11·3

43

CHA PTE R 12 STOR AGE IN-STORAGE SERVICE

OUT-OF-SEASON SERVICE

When it is possible, store Mower Conditioner in a dry, sheltered place.

Remove any trash accumulated during the off-season.

Before storing:

Replace Drive Belts. Align and tension the belts according to instructions given in the Operation and Maintenance sections of this manual.

Release the tension from the Drive Belts. If possible, remove, clean and store in a cool, dark, dry place. DO NOT store in the vicinity of electrical equipment.

Wash the entire machine. Take special care to remove gum from the Cutterbar and accumulated dirt from the Auger Pan. Remove trash wrapped on shafts and lodged against bearings.

Brush oil on the *Cutterbar and Roller Drive Chains.

(Roller Chain can be removed and stored in oil during off-season.)

Check the Cutterbar for bent or broken Guards and also for Sickle Sections that need to be replaced.

Lubricate the unit completely.

Run the unit at half speed for several minutes and check operation.

Turn the tractor engine off. Check the Conditioner for: • overheated Bearings.

• loose Bearing collars or flanges.

• Bearings with excessive wear.

Lubricate machine and apply oil to *Adjusting Bolt threads.

• loose Bolts.

Release Spring tension on Conditioner Rolls.

• missing Cotter Pins.

Replace paint on areas where paint has been damaged or rubbed off.

To store unit: Raise Header and lock it up with the Header Safety Stops.

Block the Mower Conditioner with the Wheels off the ground. DO NOT deflate the Tires. If storing outside, remove the Wheels and store with the belts.

Make notes of replacemen t parts needed for next season and order them early.

Replace any damaged or worn parts.

44

Install all safety shields and review the Safety Precautions, Checklists, and Operation sections of your manual.

*All items marked with an asterisk may be coated with a rust or corrosion preventive spray which is available in a pressurized container at most implement dealers.

CHAPTER 13 TROUBLESH OOTING 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. BE SURE to exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8), BEFORE making any adjustments of repairs.

MISCELLANEOUS PROBLEMS PROBLEM Leaving ragged or long stubble

CAUSE Ground speed too fast

Operating speed should NOT exceed 8mph

Improper Hold-down Clip adjustments Bent Guards Worn out or broken Guards Worn out or broken Sickle Sections Bent Sickle Strap Sickle Register off PTO RPM too slow

Adjust or replace the Hold-down Clips Straighten Replace Guards Replace Sickle Sections Straighten Readjust Sickle Register Maintain 540 or 1000 RPM PTO speed Increase Reel speed Adjust Reel Belt tension Increase the Header wei~ht on the Skid Shoes when operatrng in smooth ground conditions Raise Skid Shoes to lower Header

Reel speed too slow for ground speed Reel Drive Belt too loose and slipping Header flotation too light Cutting height too high Stubble too long in down crop

Ground speed too fast Guard Angle too flat Reel speed too slow Reel location NOT correct PTO RPM too slow Cutting height too high Header flotation too light

Leaving a small strip of run down uncut crop

REMEDY

Plugged Cutterbar

Broken Sickle Section Crowding the uncut material at the left Divider Not using a tall Crop Divider NOT using the tall Crop Divider properly

Reduce ground speed Increase Guard Angle Speed Reel up Check Reel location Maintain 540 or 1000 RPM PTO speed Raise Skid Shoes to lower Header Increase the Header weight on the Skid Shoes when operating in smooth ground conditions Unplug Cutterbar. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE on page 8.

Replace Sickle Section Allow enough room for left Crop Divider to gather crop.

A tall Crop Divider should be used in crop over 3' (.91 m) tall Adjust tall Crop Divider point to be even with inside of the end Panel Divider

45

PROBLEM

Plugging on the Guards

CAUSE

Cutting crop having a wet or heavy undergrowth

Cut when undergrowth is dry

Mud build-up

Lower Skid Shoes to raise the cutting height and get above the wet or heavy undergrowth Install cmtional Stub Guards - see your G HL dealer Lower Skid Shoes to raise the cutting height to clear most mounds of dirt Decrease the Header weight on the Skid Shoes to lighten flotation Replace necessary parts Check Reel location

Dull Cutterbar parts Reel location NOT correct Excessive breaka~e of Guards or Sickle actions

Excessive machine noise and/or vibration

Knocking noise or excessive vibration in the Sickle Drive

Cutting too low in rocky or rough conditions Guards, Sickle Sections and Hold-down Clips NOT properly aligned Guard Angle too steeR in rough or rocky conditions • Header flotation too heavy in rough or rocky conditions Ground speed too fast for rough or rocky conditions Tractor Drawbar NOT adjusted property

Decrease the Header weight on the Skid Shoes to lighten flotation Reduce ground speed

Conditioner Rolls NOT in time

Retlme Conditioner Rolls

PTO RPM too fast

Maintain 540 or 1000 RPM PTO speed

Bearings loose or worn

Check all Bearings - tighten or replace if needed Tighten

Cam track out of adjustment

Header is cutting more than can be handled by Auger and Conditioner

46

Decrease Guard Angle

Conditioner Rolls too close together

Auger to cleaning angles and straps clearance too wide

Conditioner Roll plugging

Lower the Skid Shoes to raise the cutting height Align the Cutterbar components

Check Drawbar dimensions per details in Preparing for Field Operation chapter Check Conditioner Roll spacing

Bolts holding Ball Joint to Wobble Arm loose Guards turned to one side Bent Guards Auger plugging or wrapping

REMEDY

Conditioner Rolls pulling in uncut crop

Straighten or replace Straighten or replace Adjust clearance between cleaning an~les or straps and Auger Flighting to /8" (3.2mm) Adjust clearance between cleaning angles or straps and Auger Flighting to 1/8" (3.2mm) Reduce ground speed See next category

PROBLEM Pulling crop bh the roots when cutting t e back swath or tall crop leaning into the machine

CAUSE

REMEDY

Push Bar too high

Lower the Push Bar

Conditioner Rolls too aggressive

Increase Roll spacing and/or decrease Roll pressure Increase the ground speed

Ground speed too slow Slow crop drying

Excessive Conditioner Roll spacing Low Conditioner Roll pressure Insufficient air circulation through windrow

Check Roll spacing Check Roll pressure Tractor tire running down windrow.

Consider making a wider windrow or swath

Depositing conditioned material in bunches or piles when swathing, or forming poor and bunchy windrows

PTO RPM too slow

Maintain 540 or 1000 RPM PTO speed

Reel speed too slow for ground speed Reel location NOT correct Excessive Conditioner Roll spacing Ground speed too slow in light crop

Crop may require 6 Bats on Reel

Increase Reel speed Check Reel location Check Roll spacing Increase ground speed in smooth cutting conditions Check Paddle installation or add additional Paddles to Auger lnstall2 additional Bats to Reel

Windrow too wide

Crop Deflector partly down Narrow Windrow Guides required

Raise Crop Deflector Install Left and right Directors

Windrow too narrow

Auger moving too much crop to center Crop Deflector partly up

Remove front Auger Cleaning An~es and raise Auger to maximum heig t Raise Crop Deflector

Leaves damaged or stripped off stems

Excessive Conditioner Roll pressure

Reduce Roll pressure

Reel speed too fast for ground speed

Decrease Reel speed or increase ground speed

Reel Drive Belt too loose Plugged Cutterbar

Check belt tension Unplug Cutterbar. Exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8).

Reduce Reel speed

Auger Paddles installed incorrectly

Reel slipping or jerking

Reel speed too fast In heavy and/or tall crop Reel pushing down too much crop In heavy and/or tall crop Too much crop for Reel to handle Reel carrying over crop

Reel speed too fast Reel release location NOT correct PTO RPM too fast

Lower Push Bar Add Additional Bats to Reel Decrease Reel speed Rotate Cam Track so Reel release location is moved toward Cutterbar.

Maintain 540 or 1000 RPM PTO speed

47

PROBLEM Header turns while unloaded but slows or stops when starting to cut

Excessive noise in Hydraulic Drive

CAUSE

REMEDY

Low Reservoir oil level

Service Hydraulic Reservoir

Defective 0-ring inside Relief Valve Defective Relief Valve Defective Motor

Replace 0-ring Repair Relief Valve Repair Motor

Defective Pump

Repair Pump

PTO slipping on tractor

Repair tractor PTO system

Air in system

Open Reservoir Cap and operate Drive until air is purged (flutd clear not milky) Check Inlet (suction) lines and fittings for air leaks or kinked Suction Hose Run Hydraulic System at half speed until system warms up and noise ends

Vacuum condition Cold weather

NOTE: In troubleshooting a pump-motor system, It Is necessary to Isolate the pump from the motor to determine which unit Is actually malfunctioning. A worn pump or worn motor will both give the same system Indication. Therefore, It Is advisable to first run a pressure and flow check on the pump to make sure that It Is performing within Its operating specifications. The following troubleshooting suggestions are based on the assumption that the pump has been flow and pressure checked and has been found to be within operating specifications. System pressure Is 4000 PSI with minimum pump outputs of 19.5 gpm (540 rpm PTO) and 23.7 gpm (1000 rpm PTO).

PROBLEM Oil heating

CAUSE

REMEDY

Oil supply low

Fill Reservoir

Contaminated oil Setting of Relief Valve too high or too low Oil in system too light

Drain Reservoir and fill with clean oil Set to correct pressure Drain Reservoir and refill with proper viscosity oil

Shaft Seal leakage

Worn Shaft Seal Excessive internal wear

Replace Shaft Seal Disassemble Pump and repair

Foaming oil

Low oil Reservoir

Fill Reservoir

48

CHAPT ER 14 SET-UP AND ASSEMB LY NOTE:

This Trailer Frame, Header and Conditioner package weighs approximately 4000 lbs. (1800 kg) in the crate. Do not exceed the rated capacity of your lifting device/

UNLOADING WITH A FORK LIFT (Fig. 14· 1) 1.

Lift beneath the crate at the points shown.

2.

Be certain that your Forks are long enough to fully support both Cross Members as shown. (48" - 1219.2 mm)

3.

Chain the load to fork lift mast at the points indicated to help keep the load from tipping off the forks, especially on rough ground. Be certain to chain only that pan of the mast which moves with the load, otherwise injury to yourself or damage to equipment may result.

4.

Spread Forks as wide as possible and balance the load carefully both side to side and front to back.

1 • Chain Attachment Points 2 ·Fork Lift

TONGUE ASSEMBLY UNLOADING (Fig. 14-1) The Tongue Assembly (approximate weight, 1000 lbs.

- 454.55 kg - with oil) may be lifted off the truck using a chain at the Hook Point indicated with a stabilizing chain hooked on the point shown.

A WARNING The Tongue Assembly Is free to rotate and may do so as It Is moved. Do not get caught between the Tongue and any other obstruc· tlon. Do not allow any person to stand be· neath the Tongue at any time. If the Tongue Is to be guided Into position by hand, DO NOT attempt to lift, but control Its motion side to side by pulling on the Pump or rear cylinder Mount while standing well clear of the Tongue assembly In case It may drop suddenly.

3 • Stabilizer Chain 4 • Lift Point

Fig. 14·1

49

Use a safety chain looped around the Tongue assembly and independent of the lifting chain.

2.

Lift Unit slowly and carefully at all times.

3.

Transport slowly and with Unit close to the ground. Always look for others around who may not be aware Unit is being moved or who may be pinched between the Unit and other equipment, structures, trailer, etc.

Check all attachment points for damage, loose hardware, etc.

Protect the hydraulic tubing, hoses and components during handling.

Store the Tongue in an upright position firmly attached to some stationary, immovable object. Place wood or some other flat support under each end.

UNLOADING WITH A CRANE OR SIMILAR LIFTING DEVICE (Fig. 14-1) 1.

Lift at the chain attachment points shown. These are the strongest high points on the unit as it sits in the crate.

DO NOT UNLOAD BY LIFTING ON THE PUSH BAR.

A cAUTION

CARRY THE LOAD LOW! DO NOT LIFT NEAR THE CENTER OF THE PUSH BAR.

ASSEMBLY 1.

Remove Forming Chamber parts from Unit and set aside. See Fig. 14-2.

2.

In an open area free from obstructions, slowly tip the crated Unit down on the ground. This may be done with Chains as shown in Fig. 14-3, using · two front-end loaders or fork lifts to pull and lift simultaneously on the Chain attachment points AT THE HEADER END PANELS ONLY.

A CAUTION The center of gravity of this Unit Is NOT In line with these lift points. When you raise the Unit, It will move toward the Chain Attachment Points. DO NOT PLACE ANYONE BETWEEN THE UNIT AND THE LIFTING DEVICE! Use a stabilizing chain to the rear Header Frame or Trailer Frame or rear Crate Supports. Be care· ful not to damage the shielding and Tongue Pivot Pin during this operation.

1 ·Header Lock Shipping Bracket (Remove)

A cAUTION

Do not allow anyone near Unit during this operation. Also, be certain chains or cables are long and strong enough to do the job. The Crate may have been damaged during ship· ping or handling, causing Unit to move to the side as It tips down. Keep everyone well clear.

2 • Windrow Forming Chamber Parts Located Here

Flg.14-2

50

A CAUTION Chain or cables MUST NOT be secured to Push Bar In such a way that they can NOT slide toward the center of the Header, as this could damage the Header component parts.

3.

When Unit is down on the ground, assemble Tongue onto the main pin. Lift the Tongue Assembly as indicated in the unloading process.

NOT use a grinder or undercut the pin during this operation.

5.

Grease the inside of the Housing and Bearing Liner. Position Tongue over the Pivot Pin, then carefully lower the Tongue until the Tongue is fully onto the Pivot Pin.

NOTE:

This operation requires at least two persons, preferably three, with one operator always on the lifting device. Move Tongue slightly side to side as it is lowered. The person at the rear must be sure that the Pin is going in straight and may push down on the rear of the Tongue, where Cylinder will be attached, during this operation. Apply a film of grease to the Pin before assembly.

1- - - - - 9 Feet----~

• WARNING: Stand clear of this area

1 • Lift Bracket • Remove and discard after lowering

Header to the ground

2 ·Pull 3 • Pull and Lift 4. Lift

Fig. 14· 3A 4.

Before assembly, remove 5/8" (15.9mm) bolt and Slide 040-33054 from the top of the Tongue.

Check the Bearing Liner to be certain that it is securely in place in the Tongue. If the Bearing Liner was lost or damaged during shipment, it MUST replaced with a new one, NOT discarded.

Check the Pivot Pin for rust, handling damage, etc. after wiping off the excess protective grease.

All dents, rust, pitting, etc. must be removed or carefully sanded smooth with emery cloth. DO

Fig. 14·38

A CAUTION Keep fingers and hands away from Pivot Pin and Tongue area to avoid being crushed, pinched or squeezed.

51

6.

When the Tongue is fully down on Pin, use two 15/16" sockets on extensions and locate Slide 040-33054 on top of Pin. Install5/8 x 2-1/4 Bolt and Lock Washer and Nut. Tighten securely. Install Caps into access holes.

7.

Referring to Figure 14-4, install Hydraulic Hose Assemblies 124130, 124131 and 092032 to the 3/8" Steel Lines on the back of the Tongue. Use the single 075505 and double 067849 Hose Clamps with self-tapping Screw 072330 to secure the three hoses to the right side of the Tongue.

8.

Bolt Hydraulic Motor into the Motor Mount.

Check that Gearbox and Motor are properly aligned through Chain Coupler. Double 50 Chain should move from side to side freely. Also check that three Motor Hoses have been banded with cable ties and are not twisted or kinked in any position of the Header.

9.

Check Wheel Axles mounting position in Frame.

For 2240, Spindles should be secured in inner most holes. For 2270, Spindles should be secured in holes closest to Frame.

Assemble Steering Cylinder to hoses as shown.

Assemble 117098 Swivel Union Adapter to tractor end of head of Cylinder Hose. Assemble 092032 Hose, 087393 Tube Tee, 092037 Hydraulic Line and 092036 Hydraulic Line. When the Forming Chamber has been attached, secure Hydraulic Line/Tee Assembly to the front top surface of the Forming Chamber Cover with 076078 Hose Clamps.

Attach 092035 Hydraulic Hose Assemblies to 90• Elbows on lower back of Header Lift Cylinders.

Run hose through Rubber Grommet on Trailer Leg and attach to Hydraulic Line/Tee Assembly.

Assemble the two 70" (1778mm) Hoses 17033167 to the 3/8" Steel Lines on the front of the Tongue connected to the Steering Cylinder.

A CAUTION DO NOT TOW UNIT WITH OPEN HYDRAULIC LINES CONNECTED TO THE STEERING CYL· INDER! Unit has no control and will move freely from side to side.

10. Carefully remove Shipping Locks next to the Header Lift Cylinders. Cautiously lift or jack, then block the trailer frame one side at a time to assemble wheels. Tongue weight at the Drawbar is approximately 900 lb. (409kg), so carefully lift or jack Tongue high enough to put jack on. Use blocks as necessary and do not get under the Unit at any time.

Install 098368 Hose, 098369 Throttle Valve and 062910 Nipple to remaining Steel Line.

1 • 170·33167 Hydraulic Hose Assy (2)(70") 2 • 124130 Hydraulic Hose Assy (80") 3 • 124131 Hydraulic Hose Assy (60") 4 • 092032 Hydraulic Hose Assy (60") 5 - 087393 Hydraulic Tube Tee 6 • 092037 Hydraulic Tube Assy 7 • 092036 Hydraulic Tube Assy

8 • 092035 Hydraulic Hose Asay (42") 9 • 098368 Hydraulic Hose Assy (70") 10 • 062910 Steel Nipple Adapter 11 • 098369 Unidirectional Throttle Valve 12 • 117098 Swivel Union Adapter 13 • Connect to Head End of Cylinder 14 • Connect to Lift Circuit

Fig. 14·4

52

A CAUTION Air In Hydraulic Lines will allow Cylinders to move, possibly shifting Tongue or Unit, especially on an Incline or while In motion.

After the Hoses are coupled to the Tractor remote Hydraulic System, cycle Cylinders SEVERAL TIMES to remove trapped air.

The Wheels are attached to the hubs with Wheel Bolts installed in threaded holes in the hub flange. On installation of Wheel, clean threads with a steel brush and oil very lightly to retard corrosion. Tighten Wheel Bolts to 90 foot-pounds torque.

Fig. 14·5

11. Referring to Figure 14-6, attach 092197 Forming Chamber Cover assembly to angles on rear of Trailer Frame. Be sure to locate Hydraulic Line/Tee Assembly on top front of Cover. Use four 076078 Tube Clamps, 5/16 x 1 Carriage Bolts with small Flange Nuts to secure Hydraulic Line/Tee Assembly and Cover Assembly to the Trailer Frame. For the remainder of Forming Chamber use large Flange Nuts and 5/16 x 3/4 Carriage Bolts.

12. Install 092242 Windrower Edging to top edge of Windrowers . Also install 092406 Director Edging on top edge of Directors (see Figure 14-7).

13. Attach 092200 Left Windrower and 092199 Right Windrower to Trailer Frame and Cover Assembly. Secure with 5/16 x 3/4" Carriage Bolts and Flanged Nuts.

14. Attach 092204 Left Support and 092201 Right Support Assemblies to the Cover Assembly. Secure with 5/16 x 3/4 Carriage Bolts and large Flanged Nuts.

15. Insert lower tails of 092208 Left Director and 092207 Right Director between Windrower and support assemblies. Install 5/16 x 5/8 Carriage Bolts with large Flange Nuts to loosely hold assemblies together.

1 • 092197 Forming Chamber Cover Aasy 2 • 092242 Windrow Edging 3 • 092200 Wlndrower (Left) 092199 Wlndrower (Right) 4 • 092406 Director Edging 5 • 092208 Director (Left) 092207 Director (Right 6 • 092204 Support Assy (Left 092201 Support Aasy (Right) 7 • Tube Clamp Locations

Fig. 14·6

16. Curl the top edge of Directors down to the square holes in the rear of the Cover Assembly. Install 5/16 x 5/8" Carriage Bolts from inside of Cover.

Align top edge of Director and secure in place with Flat Washers and Nylon Insert Lock Nuts.

17. Tighten all bolts securely.

18. Adjust Top Link Turnbuckle to Pin center distance of 23" (584.2mm).

1 • 092406 Director Edging 2 - 092208 Director (Left) 092207 Director (Right)

Fig. 14·7

53

CHAP TER 15 OPTIO NAL FEATU RES & ACCES SORIE S FULL CUTTERBAR WEAR PROTECTION Kits (2240- 804157, 2270- 803624} Flg.15·1

3.

Loosen the Bearing Lock Collars on the Gauge Wheel Shafts. Tighten the bolts holding the Brackets to the Header Support Brackets at the height you want. Then center the Gauge Wheels between the Brackets and tighten the Lock Collars in the direction of their rotation. Tighten the set screws.

4.

Once these Lock Collars are set, only the bolts on each Gauge Wheel Mounting Brackets need be removed for height adjustment.

5.

Close cutting can normally be accomplished with the Gauge Wheels set at 2 (50.8mm) to 4" (101.6mm) below the Cutterbar. Crop and ground conditions may vary and you will be able to select the best Gauge Wheel height for your field after observing the unit in operation.

These kits give full Cutterbar wear protection with NO height adjustment. Gauge Wheels can be used but NOT Skid Shoes.

NOTE: If using Gauge Wheels and Skid Shoes, Gauge Wheels should be set slightly lower than the Skid Shoes, 112 (12.7mm) to 1-112" (38.1mm) for best effect.

Fig. 15·1

GAUGE WHEEL KIT (803576 - Two included} Fig. 15-2 Gauge Wheel Installation 1.

Block the unit and place Header Safety Locks in lock position before working on or under the Header.

2.

Install the Gauge Wheels and Brackets as shown in the photograph. Note the direction in which the Brackets are mounted as this affects your range of height adjustment.

1 • Adjustment Bolts 2 • Bearing Lock Collar Set Screw 3 • Header Support Bracket 4 • Gauge Wheel Bracket 5 • Gauge Wheel

Fig. 15·2

54

CENTER SKID SHOE KIT (803619) (Fig.15·3

3.

Insert the "L" shaped pin through Mounting Plate in back of Cutterbar and Skid Shoe holes with height selected.

4.

Insert the hair pin to retain "L" pin in position.

Center Skid Shoe Installation 1.

Remove carriage bolts where necessary.

2.

Hold Skid Shoe up in place and insert the Clip through slot and use the longer carriage bolts to hold Clip and Guard on.

,_ ·------~

~

- - - - ~i,___ _

,, ,, ~!

1 • Cutterbar 2 • Right End of Header

3 • Front VIew 4 ·Side VIew

Flg.15-3

55

REEL CONVERSION KITS (2240 -804127, 2270 - 803626)

2.

Kit allows installation of extra Reel Bats for heavy standing crop, raising number of Bats from 4 to 6.

Reel Conversi on Instructio ns - Figs. 154 through 15-9) 1.

Mount the Tine Bar Supports to the Reel Discs.

The Whiz Lock Screws must be assembled as shown, with the flat washer, lock washer and hex nut on the tine Bar Support side.

NOTE: Assemble heavier Gauge Supports with 314" (19.1mm) center hole on right hand cam Reel Disc.

Reposition the existing Tine Bar assemblies as shown.

Fig. 15·5 • Step 2 3.

1 o Remove Bolts. Reposition per Arrows

Fig. 15o4 • Step 1

56

See figure to identify the long and short Tine Bars. Tine Bars should alternate, long-short, when mounted on the Reel. Install the Tine Bar assemblies in their proper location, bolting the Bearing Housings to the Tine Bar Supports.

1 o Long Tine Bar 2 o Short Tine Bar

Fig. 15·6 ·Step 3

4.

Loosely assemble the Reel Bats to the Tine Bar Supports to dimension shown. Align Reel Bats and tighten hardware.

5.

Check Tine Bars to verify that Cam Bearings extend the correct distance into the Cam Track.

Cam Bearings must not touch inside surface of Cam Track.

1 • Install Split Washers here to adjust clearance 2 • Cam Bearing must NOT hit this surface 3 • 0 to 1/8" (3.2mm)

Fig . 15·8 ·Step 5

6.

1 · Reel Bat 2 • Tine bar Support

Fig. 15·7 ·Step 4

Install special Washers as required on left end of the Tine Bar to eliminate end play and secure with Cotter Key.

1 • Special Washer 2 • Cotter Key 3 • Bearing Housing

Fig. 15·9 ·Step 6

57

STUB GUARD KITS (2240 - 190-32408, 2270 - 190-32481) Stub Guards are recommended for use only where extreme down, wet, tangled conditions cause Standard Guards to ball up on the bottom and on the points.

Stub Guard Installation 1.

To properly install the Guards, snug up bolts tightly, tap Guard back squarely against Cutterbar. As you face Cutterbar, tighten the right hand bolt first and then the left hand bolt to keep Guard from cocking on Cutterbar.

1 • 11 0·32409 Special Guard (Left) 2 • 110·32410 Special Guard (Right)

Fig. 15·10

58

1 • Cutterbar 2 ·Skid Shoe 3 ·Sickle 4 • 110·32349 Adjustment Clip 5 ·Lock Nut 6 • 360·32404 Spacer 7 • 360·32514 Spacer 8 • 390·32659 Stub Guard Clip 9 • 1/2 x 1·3/4" Carriage Bolt 10 • 1/2 x 2·1/2" Carriage Bolt 11 • 1/2 x 1·1/2" Carriage Bolt 12 ·110·32330 Stub Guard 13 • 110·32341 High Arc Hold·down Clip 14 ·110·32334 Hold·down Clip 15 ·Special Guard 16 • 3/32" (2.4mm) 17 • 1/64" (.4mm)

Fig. 15·11

v

2.

3.

Sickle Sections must lie flat on Guard Ledger surface, or Cutterbar, Sickle or Guards must be straightened until the Sections do rest flat on the Guard Ledger.

Front of Hold-down Clip should just touch Sections, or have a slight (.015-inch) clearance.

(High arc Clips need 3/32-inch clearance.)

4.

Use the Adjustment Clip to hold down the Holddown Clip to proper clearance.

5.

Replace the Clips that hold Skid Shoes to Cutterbar.

REGULAR GUARD KIT (2240 • 088744, 2270 - 088745) These Guards are normally installed. Use this Kit to convert from Stub Guards to Regular Guards.

CROP DIVIDER KIT (803620) The Crop Dividers are recommended for tall crops. The Dividers are attached over the Push Bar at each end of the Header.

TOP SERRATED SICKLE (2240 • 091804, 2270 - 091805) The standard Sickle with top serrated Sections less Head.

AUGER SLOW-DOWN SPROCKET (370· 14117) A 14 tooth Sprocket is available to slow down the Auger. The Reel is also slowed down and its speed should be readjusted according to the ground speed.

CHAIN/SAFETY TOW (15 TON) (803099) 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.

/ ,. ,

Fig. 15·13

1 • Safety Chain

Fig. 15-12

59

CHAPTER16 DECAL LOCATIO NS GENERAL INFORMATION Decal Locations information is provided to assist in the proper selection and application of new decals, in the event the original decal(s) become damaged or the machine is repainted. Refer to the listing for the illustration reference number, part number, description and quantity of each decal provided in the Kit. Refer to the appropriate illustration(s) for replacement location(s).

NOTE: Refer to the SAFETY Chapter for the specific Information provided on all of the various Safety Decals furnished in the Decal Kit(s).

To insure proper selection of the correct replacement decals, compare all of the various closeup location photographs to your machine, before ·starting to refinish the unit. Then, circle each pictured decal (on or otherwise applicable to your machine) while checkingoff its part number in the listing. After you have verified all the decals needed for replacement, place any extra unnecessary decals aside for disposal.

NEW DECAL APPLICATION Surfaces MUST be free from dirt, dust, grease and other foreign material before applying the new Decal.

To apply, 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. Peel the other portion of the backing paper off slowly while applying hand pressure to smooth-out Decal surface.

A CAUTION ALWAYS observe Safety Rules shown on De· cals. If Decals become damaged, or If the unit Is repainted, replace the Decals. If repainting, BE SURE that All Decals from the Klt(s) which apply to your machine, are affixed to your unit.

60

The Decal Set Number for the 2240 and 2270 is 117856. The Set includes the following: Ref. Part No. Number

Description & Quantity

1.

2.

3.

4.

5.

6.

7.

8.

9.

Decal • Jack Lift Position Decal • Jack Storage Position GEHL (3 Places) Red Reflector Strip (2 Places) Amber Reflector Strip (2 Places) Decal • Hydraulic 011 Decal - No Step (2 Places) Decal • Push Bar • Do NOT Lift Decal • 2240 (2 Places) Decal • 2270 (2 Places) Decal • Striping • Swing Frame Right Decal • Striping • Swing Frame Left Decal • PTO Pump Hookup Decal • Lubrication (16 Places) WARNING· Rotating Component (3 Places) Decal· Manual Location WARNING· Manual WARNING· Hydraulic 011 WARNING· Lock Pin WARNING ·1000 RPM WARNING· 540 RPM DANGER • Moving (2 Places) WARNING· Hot Liquid WARNING· Block (2 Places)

10.

11 .

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

060511 060510 061201 067493 067926 072794 080247 082666 088499 088682 088683 088684 089151 093020 093365 093366 093367 093369 093381 093465 093466 093643 093649 115974

NOTE: Order PN 090910 for 71'(21.6M) roll of replacement Striping. The Mower Conditioner requires 21-112' (6.6M) per machine.

PAINT NOTICE Use this list to order paint for refinishing: 901225 One Gallon Blaze Paint 901226 One Gallon Maize Paint 610239 6 (12oz Spray Cans) Blaze Paint 610240 6 (12oz Spray Cans) Maize Paint

61

0

INDEX Page

Page A

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 -27 Cutting Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Header Floatation . .. .. . . ... ......... . .... 23-24 Guard Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Reel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . 24 Reel Release Location ..... .. ............ . 24-25 Reel Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Conditioner Roll Pressure . . . . . • . . . . . . . . . . . . . . 25 Conditioner Roll Spacing . . . . .. .. . .. .. .. . . . .. 26 Auger Speed .. . .. .. .. .. .. . . . .. .. . .. . .. .. . 26-27

c Checklists . . .... . .. .. ·... . . ....• • •..••. • .•.... 5-7 Controls & Safety Equipment . . . . . . . . . . . . . . . 15-17 Guards & Shields ...•.. . . . ......... .... . .... 15 Header Lift & Steering System . • . . . . . . . . . . 15-16 Safety Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Header Drive . . . . . .. . .. . .. . .. . .. .. .. .. .. . 16-17 Hitchjack.. . . .. ..... . . .... ..... ... .......... 16 Header Lift Safety Lock Position • . . • . . . . . . . . . 17 D Decal Locations . . . . . . . . . . • . . . . . . . . • • • • . . . • 60-62 I Introduction .. .. ...... . ... .. .. •. ...• • •. . . . .. • .. 2 L Lubrication . • . . . • . . . . . . . . . . • • . . . . • • • . . . . . . 28-29 Lubrication Information . .. .. .. .. .. .. .. .. . . .. 28 Roller Chain . . . . • • . . . . . . • . . . . . . . • • • . . . . . . . . . 28 Sealing Bearings . • . . . . • . . . . . . . . . . . . . . . . . . . . . 29 Lubrication Points . . . • . . . . . . . . . . . . . . . . . . . . 28-29 Gearbox .......... .. ..... ... .. • .. . . . ..•. .. .. 29 M MANDATORY SAFETY SHUTDOWN PROCEDURE . ...... • .. . . ... .. 8

0 Operation . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . 18-22 Precautionary Notes . .. . . . .. . .. .. . .. . .. . .. .. . 18 PTO & Ground Speed ................. ....... 18 Transporting the Machine ..... . .... •. .... • 18- 19 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . . . 19-20 180 Degree Turnaround ..................... 20 Turning Square Corners .. .. • .. .. .. .. .. • • .. • 20 Header Operation ...... .. . . ..... . ...... .. 21-22 Guard Angle . . . . . . . . • . . . . . . . • . . . . . • • . • • . . . . 21 Push Bar ..... .. .............••...•........ 21

Sickle & Guards ....... . .... . . .... .. .. ..... 21 Sickle Speed . .. . ..... .... ........... .. ... . 21 Reel Position & Speed ......... ........ .. ... 21 Auger Position & Speed .. .... ... .. ......... 21 Auger Paddles ... • .. ·. . . .•.. .. . . . .•..•. • .• . . 21 Rear Strippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Conditioner Roll Pressure .. . . .. ..... . . ...... 22 Conditioner Roll Spacing .. . . . ... .. ..• ...... 22 Windrow to Swath Adjustment . . • . ........... 22 Unplugging . ... .. . . . ......... ..... . .... .. .. 22 Optional Features & Accessories . . . . . . . . . . . . 54-59 Full Cutterbar Wear Protection . ... .... .. .. .... 54 Gauge Wheel Kit . . . . . . . . . . . . . . . . . . . . . . . . . • . . 54 Gauge Wheel Installation .. . .. .. .. .. .. . .. .. . 54 Center Skid Shoe ... ... ....... .. • .. ......... . 55 Center Skid Shoe Installation . . . . . . . . . . . . . . . . 55 Reel Conversion Kit ......... .... .... .. .. . 56-57 Reel Conversion Installation . . . . . . . . . . . . . . 56-57 Stub Guard Kit .. . .•. ....... ........... . .. 58-59 Stub Guard Installation . . . . . . . . . . . . . . . . . . 58-59 Top Serrated Sickle Complete . . . . . . . . . . . . . . . . 59 Top Serrated Sickle . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Auger Slow-down Sprocket . . . . . . . . . . . . . . . . . . . 59 Chain/Safety Tow (15 Ton) ...... ......... .... 59 Regular Guard Kit . . . . . . . . . . . . . . . . • . . . . . . . . . . 59 Crop Divider Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

p Preparation for Field Operation • •. . . . . ....• . 40-42 Tractor Drawbar PTO Dimension .... ...... .... 40 Tractor Hookup , . . . . . . . . . . . . . • . . . . • . . . . . . 40-41 Safety Chain •• ..... ..... . ..... .. ... . .... .... 41 Steering & Lift Cylinder Hookup . ..... .. . .. . .. 42 Break-in .. .. .. ...... .... .. ...... .. • • ........ 42 Transporting . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . 42

s SAFETY . ••. . . ......... ..•.• .. .. . . . ... . . •• 8-13 Service .. ........ .. ... . ·.... .........•. .. . . 30-39 General Information . .. .. .. .. .. .. .. .. .. . .. .. . 30 Sealed Bearing Replacement . . . . . . . . . . . . . . . . . . 30 Gib Key . ........... ..• . .. ......... ...... 30-31 Removal . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . 30-31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . 31 Cutterbar . . .. ....• . .... ...... .. . . • •. . . ... 31-33 Sickle & Sickle Sections ..... .. . .. ... .. ... . . 32 Sickle Removal . . . . . . . . . . . . . . . . . • . . . . . . . . . . 32 Sickle Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . 32 Sickle Register . . . . . . . . . . . . . . . . . . • • . • . . . . . . . 32 Hold-down Clips ..••..•.....••..•• •• .. ..•.• 33 Sickle Drive . ....•.••.. . . . .. .... .. . ••.... 33-34 Sickle Drive Belt . . . . . . . . . • . . . . . . . . . • . . . • • • . 33 Flywheel . . . • . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pitman Arm . . . . . . . . . . . . . . . . . . . . . . • . . . • • . . . . 33 Wobble Arm Bearing Replacement . ..... •.... 33 Wobble Arm Pivot Bearing Replacement .. . 33-34 Conditioner .... . • . . ••... . ... . .. .......... 34-35 Conditioner Roll Alignment . . . . . . . . . . . . . . . . . 34 Conditioner Roll Timing & Chain Tension . 34-35 Conditioner Drive Chain Oiler . . . . . . . . . . . . . . . 35

63

INDEX (Cont.)

Page

Page

Auger Drive . . . . . . . . . . . . . . • . . . . • . . . . . . . . . . . . 36 Auger Position & Sheer Bolts . . . . . . . . . . . . . . . 36 Auger Drive Chain Tension . .. .. .. .. .. .. . .. . 36 Reel Drive . . . . . . . . . . . . . . . . . . . . . . . . • • • . . . . . . . 36 Reel Drive Belt Tension . . . . . . . . . . . . . . . . • . . . 36 Hydraulic System .............. .. ........ 36-38 Reservoir Checking .............• ••........ 37 Reservoir Filling .. . .. .. .. .. .. .. .. .. .. . .. .. . 3 7 Reservoir Draining ...... ......... , . , . . . . . . . 37 Hydraulic System Filter ........••. •.•.• ...• 37 Hydraulic Drive System Check Out . . • • . . . 37-38 Wheels & Tires ......•... ..•.••••••. . •••. 38-39 Wheel Bearing Replacement . . . . . . . . . . . . . 38-39 Tire Pressure ............•• ..........• • .... 39 Set-up & Assembly . . . • . . . . . . . . . . • • • • • • . . . . 49-53 Unloading with a Fork Lift . . . . . . . . . . . . . . . . . . . 49 Tongue Assembly Unloading . . • . • • • • . . . . . . 49-50

Unloading with a Crane or Similar Lifting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Assembly . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-53 Specifications ........... •. .... .... ........ . ... 3 Standard Hardware Torque Data .. Inside Back Cover Storage .............. .............. ••........ 44 In-storage Service .. .. ..• . ............ ....... 44 Out-of-Season Service .............. ......... 44 T Table of Contents . . . . . . . . . . . . . . . . . . . • • . . . . . . . . • 1

64

Transporting ............. . .... . ..... ..... .. . . 43 Transport Locks ...•..... ...... ....... ... .... 43 SMV Emblem & Reflectors .... . ........ .. .. .. 43 Safety Chain & Auxiliary Lighting • . • . . . . . . . . . 43 Troubleshooting .••...•......• . ...•.•...•.. 45-48

w Warranty ...... ••• .. ..... . .... Inside Front Cover

TORQUE SPECIFICATIONS FOR STANDARD MACHINE HARDWARE All Torque Values are In Ft·Lbs unless otherwise stated.

(Multiply ln·Lb value* by 0.113 or Ft·Lb value by 1.355 to obtain metric Nm value.)

Bolt Size

Dry

GR.8

GR.5

GR.2 Lub.

Dry

Lub.

Dry

Lub.

* ln·Lb

NOTE: These torque values are to be used for all GEHL hardware excluding: Locknuts, Self-tapping Screws, Thread Forming Screws and Sheet Metal Screws. Unless otherwise specified, all torque values must meet this specification.

TORQUE SPECIFICATIONS FOR METRIC HARDWARE Grade Metric Bolt Size

GR.12.9

GR.10.9

GR.8.8

Dry

Lub.

Dry

Lub.

Dry

Lub.

M6

8.0

6.0

11.0

8.0

13.5

10.0

M8

19.0

14.0

27.0

20.0

32.5

24.0

M10

37.5

28.0

53.0

39.0

64.0

47.0

M12

65.0

48.0

91.5

67.5

111.5

82.0

M14

103.5

76.5

145.5

108.0

176.5

131.0

M16

158.5

117.5

223.5

165.5

271.0

200.5

I

FA RM EQ UIP ME NT GEHL COMPAN Y

904987/1P1290

WEST BEND, WISCONS IN 53095 U . S . A .

@GEHL Company 1990

Printed In U.S.A.