G E H l..; L: COMPANY New Agricultural Equipment

Transcription

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2 G E H l..; L: COMPANY New Agricultural Equipment G E H l..; L: Company (Inc.), hereinafter referred to asg as G E H l..;, L:, warrants new G E H l..; L: machinery and attachments (the "Equipment") to be free from defects in material and workmanship at thetime time of delivery to the original purchaser if properly set up and operated in accordance with the recommendations set forth in G E H l..;'s L: 's Operator's Manual. G E H l..; L: 's liability for any defect shall be limited to repair or replacement of the Equipment. G E H l..; L: 's obligation shall terminate twelve (12) months after the delivery of the goods to the original retail purchaser or when the Equipment is first put into use, whichever event occurs first. This warranty shall not apply to tires which whic'h are subject to the warranty of the tire manufacturer. Please contact your G E H l..; L: dealer for further information on tire warranties. This warranty shall not apply to any item of Equipment which shall have been repaired or altered outside the G E H l..; L: factory or authorized G E H l..; L: dealership or which has been subject to misuse, negligence or accident; neither shall it apply to Equipment which has not been operated in accordance with G E H l..; L: 's printed instructions or has been operated beyond the Company's recommended machine rated capacity. EXCLUSION OF WARRANTIES Except as otherwise expressly stated herein, G E H l..; L: makes no representation or warranty of any kind, express or implied, including merchantability or fitness for particular purpose in respect to the Equipment. G E H l..; L: shall not be liable for incidental or consequential damages for any breach of warranty, including but not limited to inconvenience, rental or replacement equipment, loss of profits or other commercial loss. No agent, employee or representative of G E H l..; L: has any authority to bind G E H l..; L: to any affirmation, representation or warranty concerning its machinery and attachments except as specifically set forth herein. Certain limitations expressed herein are excludable in accordance with provisions of local law. Such provisions shall be deemed struck if such local law is applicable. All other provisions shall continue to apply.

3 TABLE OF CONTENTS Chapter Description Page Warranty... Inside Front Cover 1 Introd.uction Introduction Specifications Checklists SAFETY (Including MANDATORY SHUTDOWN PROCEDURE) Operation Adjustments Maintenance & Service Set-Up & Assembly Decal Locations Service s & Numerical Index Index Standard Hardware Torque Data Inside Back Cover 1

4 Your decision to purchase this piece of GEHL \9 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. CHAPTER 1 INTRODUCTION IMODELNO. DM160 SERIAL NO. We, as a Company, have invested a great deal of time and effort in developing our lines of agricultural and industrial equipment.. This manual completely covers the current DM160 model. Service parts information only is provided in this manual for the out-of-production DM140 model. 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. 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 it. Furthermore, we recommend if this machine is re-sold that this Manual accompany the unit. 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 model number and serial number for this unit are on a plate located on a Gusset on the Main Frame. (Fill In) GEHLCOMPANY WEST BEND, WIS 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 American Society of Agricultural Engineers and the Society of Automotive Engineers, has adopted this SAFETY ALERT SYMBOL A 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 ALERTI Your personal safetyjs Involved I "Right" and "Left" are determined from a position standing behind the unit and facing the direction of travel. From this position, the Support Leg is on the "left" side. 2

5 CHAPTER 2 SPECIFICATIONS Dimensions are In Inches (Millimeters) Unless Otherwise Noted Model & Description... DM160 Disc Mower Power Requirements From 540 RPM 45 hp (34 kw) tractor with Category II, 3-Point Hitch Operating Width (2390) Transport Width... Approximate with of Tractor Weight lb (414 kg) Disc Rotating Speed RPM at 540 PTO RPM Number of Discs... 6 Total Number of Knives Knife Overlap /4 (l08) Knife Tip Speed174 mph (78 m/sec) at 540 PTO RPM Gearbox Oil Capacity... 1/2 U.S. Pint (1/4 Liter) ofhd90 Cutterbar Oil Capacity... 4 U.S. Pint (2-1/4 Liter) of HD90 Cutting Speed... 6 mph (9.5 kmh) (or as Fast as Conditions Permit) Standard Features Hydraulic Cylinder Cutterbar Control Disc Mower is provided with a four-strand V -Belt Driven Bevel Gearbox with Telescoping PTO Coupling between the Drive Sheave and the tractor PTO shaft Oil-bathed Spur Gear Cutterbar Disc Drive Safety Tension Bolt Cutterbar Breakaway Protection Variable Cutterbar Operating Positions to 45 Above or Below Straight Horizontal. Heavy Flexible, Synthetic Sheet Guard Over the Cutterbar Cutterbar Provided with Built-in and Replaceable Stone Guard Plates Cutterbar Knives have a 15 Twist to Lift the Cut Material Over the Cutterbar 3

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7 -c o ~ o t: CD Il. 'to > c. o o.! u:: U) i.. CD 1;; CD C ~ E CD a: - PRE-DEUVERY After the Disc Mower has been completely set-up, the following inspections should be made Defore delivering it to the Customer. Check off each item after prescrioed action is taken. Check that: D Disc Mower has been assembled correctly according to instructions in the Set-up & Assembly chapter of this manual. D All Grease Fittings have been properly lubricated and that the Gearbox and Cutterbar have been filled to their proper operating level; see the Lubrication chapter for specific details. D All Guards, Shields and Decals are in place and securely attached. D All fasteners are properly secured. D All adjustments have been made to comply with setting given in the Adjustments chapter. D Model and Serial Numbers for this unit are recorded in spaces provided on this page and page 2. Hook the unit up to a 540 RPM tractor and test-run the unit while making sure that proper operation is exhibited by all components. Check that: D The Telescoping PTO rotates freely inside the properly Chain-anchored PTO Shields. D All Blades and Discs are turning freely. D All mechanisms are operating smoothly. D All hydraulic Hose connections are NOT leaking under pressure and that Lift Mechanism is operating smoothly and properly. I acknowledge that pre-delivery procedures were performed on this unit as outlined above. CHAPTER 3 CHECKLISTS DEUVERY The following Checklist is an important reminder ofvaluable 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. Check that: D Give Operator's Manual to the Customer and instruct Customer to be sure to read and completely understand its contents BEFORE operating the unit. D Direct Customer on how to use the Index of this manual as a quick page number locating guide. D Explain and review with Customer the SAFETY chapter of this manual. D Explain that regular lubrication is required for continued proper operation and long life. Review with Customer the Lubrication chapter of this manual. D Explain the function of the Cutterbar Breakaway Mechanism. D Explain the function and value of the PTO Safety Chain and the Flexible Sheet Cutterbar Guard. D Demonstrate the proper use of the Spring -loaded PTO Locking Couplers. D Completely fill out the Owner's Registration, including Customer's signature, and return it to the company. Customer's Signature Date Delivered (Dealer's File COpy) Dealership Name Dealer Represenlative's Name Date Checklist FIlled-out Serial Number 5

8 6 INTENTIONALLY BLANK (To Be removed as Dealer's File Copy)

9 PRE-DELIVERY After the Disc Mower has been completely set-up, the following inspections should be made before delivering it to the Customer. Check off each item after prescribed action is taken. Check that: D Disc Mower has been assembled correctly according to instructions in the Set-up & Assembly chapter of this manual. D All Grease Fittings have been properly lubricated and that the Gearbox and Cutterbar have been filled to their proper operating level; see the Lubrication chapter for specific details. D All Guards, Shields and Decals are in place and securely attached. o All fasteners are properly secured. o All adjustments have been made to comply with setting given in the Adjustments chapter. D Model and Serial Numbers for this unit are recorded in spaces provided on this page and page 2. Hook the unit up to a 540 RPM tractor and test-run the unit while making sure that proper operation is exhibited by all components. Check that: D The Telescoping PTO rotates freely inside the properly Chain-anchored PTO Shields. D All Blades and Discs are turning freely. D All mechanisms are operating smoothly. D All hydraulic Hose connections are NOT leaking under pressure and that Lift Mechanism is operating smoothly and properly. I acknowledge that pre-delivery procedures were performed on this unit as outlined above. CHAPTER 3 CHECKLISTS DELIVERY The following Checklist is an important reminder of valuable informatlon 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. Check that: D Give Operator's Manual to the Customer and instruct Customer to be sure to read and completely understand its contents BEFORE operating the unit. D Direct Customer on how to use the Index of this manual as a quick page number locating guide. D Explain and review with Customer the SAFETY chapter of this manual. D Explain that regular lubrication is required for continued proper operation and long life. Review with Customer the Lubrication chapter of this manual. D Explain the function of the Cutterbar Breakaway Mechanism. D Explain the function and value of the PTO Safety Chain and the Flexible Sheet Cutterbar Guard. D Demonstrate the proper use of the Spring-IoadedPTO Locking Couplers. D Completely fill out the Owner's Registration, including Customer's signature, and return it to the company. Customer's Signature Date Delivered (NOTE: Pages 5 & 6 Have Been Removed at Perforation) Dealership Name Dealer Representative's Name Date Checklist Filled-out Serial Number 7

10 CHAPTER 4 SAFETY A The above Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN VOL VED! 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 FOL LOWING SAFETY INFORMATION. IN ADDI TION, 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 AL WAYS takes the operator's 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 DANGER "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. MANDATORY SAFETY SHUTDOWN PROCEDURE BEFORE unclogging, cleaning, adjusting, lubricating or servicing the unit: 1. Disengage the tractor PTO. 2. Place the tractor transmission in park to prevent any tractor movement and lower unit until it is resting on firm ground. 3. Shut off the tractor engine and remove the starter switch key and take it with you when leaving the tractor seat. 4. Wait for all movement to stop Disconnect PTO Driveline from the tractor. ONLY when you have taken these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious" bodily injury. 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. AL WAYS wear safety glasses with side shields when striking metal against metal. It is further recommended that a softer (non-chipable) material be used to cushion the blow. Failure to heed could lead to serious injury to the eye(s) or other parts of the body.- 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. 8

11 A SAFETY A (Continued) KEEP OUT WHILE MACHINE IS OPERATING. ROTATING BLADES BELOW PROTECTIVE COVER CAN CUT OR CATCH HANDS OR FEET. FAILURE TO HEED CAN RESULT IN DEATH OR SERIOUS INJURY FlEV REV MAINTAIN SAFE CLEARANCE FROM ELECTRIC POWER LINES AND AVOID CONTACT WITH ANY ELECTRICALLY CHARGED CONDUCTOR. CONTACT WITH ELECTRICAL POWER SOURCE CAN RESULT IN ELECTRICAL SHOCK OR ELECTROCUTION. FAILURE TO HEED CAN RESULT IN DEATH OR SERIOUS INJURY BEFORE UNCLOGGING, CLEANING, ADJUSTING, LUBRICATING OR SERVICING THE UNIT ALWAYS FOLLOW THE MANDATORY SAFETY SHUTDOWN PROCEDURE UNLESS OTHERWISE INSTRUCTED BY THE OPERATOR'S MANUAL. THE PROCEDURE IS: 1. DISENGAGE THE TRACTOR PTO. 2. SHUT OFF TRACTOR ENGINE. 3. WAIT FOR ALL MOVEMENT TO STOP. 4. DISCONNECT THE PTO DRIVELINE FROM THE TRACTOR... BE SURE PTO SHIELDS TURN FREELY AND KEEP ALL GUARDS AND SHIELDS IN PLACE. BE SURE MACHINE IS CLEAR OF PEOPLE, PEOPLE. TOOLS. AND OTHER OBJECTS BEFORE ENGAGING PTO. pnr 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

12 SAFETY (Continued) A ACAUTION THIS IMPLEMENT IS EQUIPPED TO OPERATE WITH 540 RPM PTO TRACTOR. NEVER AT TEMPT TO CONNECT OR OPERATE WITH 1000 RPM PTO TRACTOR REV. 0 INSTALL TRANSPORT P.IN ~IN BEFORE WORKING UNDER MACHINE. PIN PREVENTS MACHINE FROM FALLING DOWN ON YOU. FAILURE TO HEED CAN RESULT IN DEATH OR SERIOUS INJURY ROTATING KNIVES MAY THROW FOREIGN OBJECTS. 2. KEEP CUTTERBAR SHIELD IN DOWN POSITION AT ALL TIMES. 3. BYSTANDERS ARE TO BE KEPT AT A SAFE DISTANCE REV. a 0 10

13 A SAFETY (Continued) 1. FOR YOUR PROTECTION THIS DRIVE TUBE HAS A GUARD THAT MUST BE TIED DOWN TO PREVENT ITS ROTATION. DO NOT POUND TO REMOVE DRIVE TUBE. > 2. GREASE JOINTS AND TELESCOPING MECHANISM REGULARLY. 3. KEEP DRIVE PROPERLY ADJUSTED - SEE OPERATOR'S MANUAL FOR DETAILS. 4. U-JOINT YOKES MUST BE PROPERLY ATTACHED AND MAINTAINED REV, 0 A DANGER ROTATING DRIVE LINE DEATH WILL RESULT FROM ENTANGLEMENT KEEP PEOPLE AND CLOTHING WELL CLEAR DO NOT OPERATE WITHOUT: DRIVE LINE GUARDS INPUT SHAFT GUARDS TRACTOR MASTER SHIELD U JOINTS LOCKED TO TRACTOR AND IMPLEMENT SHAFTS 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 THOROUGHLY UNDERSTAND THE CONTENTS OF THE OPERATOR'S MANUAL. IF YOU HAVE ANY 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 MODEL AND SERIAL NUMBERS WILL BE REQUIRED FAILURE TO FOLLOW SAFETY, OPERATING AND MAINTENANCE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS, POOR OPERATION AND COSTLY BREAKDOWN. WHEN TRAVELING ON PUBLIC HIGHWAYS OBEY ALL TRAFFIC LAWS CONCERNING LIGHTING, SLOW MOVING VEHICLE SIGNS, ETC. LIMIT SPEED TO 20 MPH AND USE A LOCKING HITCH PIN

14 EMERGENCY SHUTDOWN A CAUTION BEFORE starting the tractor engine and running the Disc Mower, review and comply with ALL SAFETY recommendations set forth In the SAFETY chapter of this mctnual. In an emergency or in case material or a foreign object becomes lodged in or between the Mower Discs or Blades, stop Mower operation IMMEDIATELY by disengaging the tractor PTO and stopping forward movement. When the Discs or Blades are stopped by a foreign object, the Discs or Blade will stop when the Shear Bolt in the Cutterbar Breakaway Mechanism breaks. CHAPTER 5 OPERATION be used for operating the DM160 Disc Mower. The tractor 3-point linkage should have a freely adjustable top link and swivel cranks on the lower links. A tracking width of 59-1/2" (1510 mm) is recommended to allow sufficient space for the tractor wheels. Stabilizing bars or chains are essential. to help maintain the position of the tractor and Mower with respect to the standing crop. A CAUTION Exercise the MANDATORY SAFETY SHUT DOWN PROCEDURE before leaving the tractor seat to remedy a problem. (Page 8) GENERAL INFORMATION AL WAYS engage the tractor PTO at idle speed, when starting-up the Disc Mower to reduce unnecessary stress on the Drive Line. The GEHL DMl60 Disc Mower is designed for mowing virtually all types of crops, whether it's down and tangled alfalfa, matted grasses or crops heavy with dew or fresh rain. It is designed for attachment to the 3-point Category II hitch of a 45 hp (34 kw) 540 RPM tractor. The Disc Mower features a six (6) triangular-shaped Discs that rotate at 3000 RPM. Each Disc has three (3) specially tempered, reversible Knives that give a clean, high impact cutting action. The Transmission is Belt Driven from the PTO to an all-gear Cutterbar Gearbox. The Cutterbar Gears operate in an oil bath for smooth,continuous Disc operation. PREPARING TRACTOR (Figs. 5-1 & 5-2) In general, any 45 hp (34 kw) 540 RPM tractor, which is equipped with a hydraulically-operated 3-point hitch and a single remote hydraulic output connection, can 1 - Stabilizer Bars or Chains 2 - Tractor Lower Link Swivel Crank 3 - Ground 4 - Track Width of 59-1/2" (1500 mm) Fig. 5-1 NOTE: A wei/-oiled 3-point linkage is essential to adjusting the position of the Mower. 1 - Freely Adjustable Tractor Top Link 2 - Tractor Lower Link Swivel Crank 3 - Stabilizer Bars or Chains Fig

15 MOUNTING TO TRACTOR (Figs. 5-3 through 5-8) Back the tractor up to the Disc Mower with its linkage arms lined-up with the Mounting Pins on the Mower. Connect the Lower Link with crank handle last as this can be used to make up for height differences, if needed. Mount the top link, raise the Mower several inches (millimeters) and fix the Support Leg in its "transport" position. Check the position of the Mower to insure that the tractor lower links are horizontal. To detach the Disc Mower, reverse the preceding attachment procedure. Fig. 5-4: Support Leg in "Supporting" Position Fig. 5-5: Support Leg In "Transport" Position 1 Tractor Lower Link Swivel Crank 2 - Top Link Connection 3 Category II Mounting Pins 4 - Height Above Ground 5 - Lift Cylinder Hose, 3/8 x 1-1/2 Pipe Coupler and Field-supplied Quick-disconnect Fig. 5-3 A CAUTION NEVER attempt to detach the Disc Mower from the tractor without first lowering the Cutterbar to the ground. 1 - Lift Cylinder Flow Reduction Device with 1/32" (1 mm) Opening Fig

16 / / / 1 Alternate Hole In End of Link Tube 2 Regular Mounting Hole In Link Tube 3 Hole In Ram End of Hydraulic Cylinder To use the hydraulic Lift Cylinder, a 3/8 x 1-1/2 Pipe Coupling and the appropriate quick-disconnect fitting (NOT provided) MUST be attached to the Lift Cylinder Hose. Use teflon tape (or equivalent pipe sealing compound) on all fitting connections to prevent leakage. The Lift Cylinder is furnished with a: flow reduction device to limit oil flow into the Cylinder. The opening in the flow reduction device is approximately 1/32" (1 mm); do NOT attempt to change the flow reduction. NOTE: On some tractor models, when the normal hydraulic system is regulated by only the handle of the lower linkage, it is recommended to change the connection at the end of the hydraulic Cylinger Ram. Move the Cutterbar to the horizontal position and set the arms ofthe tractor lower links 16 to 18" (400 to 450 mm) above the ground. Disconnect the MI0 x 45 Bolt which secures the Link Tube to the Ram. Then, reposition the Link Tube so that it can be secured to the Ram in the alternate hole. Then, replace and resecure the Bolt. The tractor hydraulic control will now raise the Disc Mower first, and then the Cutterbar in a single operation. When using the hydraulic control, the lift control stop should be set so that the Cutterbar does NOT come above the horizontal when the Mower is raised. Refer to the "Mowing" topic in this chapter for additional details. Fig Lower Link Setting 5 16 to 18" (405 to 455 mm) 6 Ground Fig. 5-8: Tractor Hydraulics Control TELESCOPING PTO SHAFT ATTACHMENT (Figs. 5-9 through 5-14) Raise the Disc Mower so that the tractor PTO shaft, and the Mower Drive Shaft are at the same height. Align the two halves of the Telescoping PTO (side by side) and measure the amount necessary for cutoff. For a correct adjustment, the Tubes should overlap each other allowing for a 1" (25.4 mm) clearance. If the two halves are too long, first cut the Guard Tubes to the correct length. Then, cut the same length from the PTO Shaft and Tube. BE SURE to remove any burrs, clean the Tubes, and grease them from the outsides. NOTE: The angle of the Telescoping PTO MUST NOT exceed 30'. BE SURE also to disengage the PTO when the tractor 3-point hitch is raised to the maximum height. 14

17 Fig Fig. 5 9: Shafts at Same Height 1 Grease All Three Points Regularly Fig. 5-13: NEVER Use Hammer on Drive Joint 1-1"(25mm) 2 - Cut Along the Dotted Line Fig /~ // y.... ~/,- f.'\ ~/l b\!) cis" 1 - Tube Cutoff 2 - Shaft Cutoff Should Be the Same Length as Tube Cutoff Fig Chain Attached to Tractor 2 - Front Drive Shield Fig If the Telescoping PTO Drive is left too long or the Tubes are NOT greased regularly. the Mower Drive Bearings can become permanently damaged. NEVER use a hammer on the PTO ends and keep them well lubricated with grease. Attach the Guard Tube Chain securely to the tractor. 15

18 A WARNING BEFORE operating the Disc Mower, BE SURE that the PTO Guard Tube Is properly chained to the tractor PTO guard to prevent the Tube from turning. OPERATING POSITION (Fig. 5-16) First, lower the Mower Cutterbar into the operating position (parallel to the ground) with the Lift Cylinder. Next, position the Linkage Pins approximately 16 to 18" (400 to 450 mm) from the ground. Then, turn the tractor top link to position the Mower Frame vertical. TRANSPORT POSITION (Fig. 5-15) Using the tractor 3-point hitch, raise the Mower approximately 4" (102 mm). Fold-back the front part of the Protection Sheet Support. BE SURE that the Protective Cutterbar Sheet stays clear of the Hinge. Using the Lift Cylinder, position the Cutterbar vertically. 1 Cutterbar In Vertical (Transport) Position 2 Lift Cylinder Transport Safety Lock Engaged Fig. 5-15: Disc Mower In "Transport" Position A WARNING Do NOT alter NOR remove the protective Cutterbar Sheet. BE SURE also to store the Disc Mower with the Cutterbar In the "Operating" position. NOTE: BE SURE that the high pressure Tube Safety Locking Device is properly locked in the "Transport" position. 1 Tractor Top Link Adjusted to Obtain Vertical Mower Frame 2 Linkage Pins at 16 to 18" (405 to 455 mm) from the Ground Fig. 5-16: Disc Mower In "Operating" POSition MOWING Choose the appropriate tractor speed and PTO speeds for forward travel of approximately 6 mph (9.5 kmh). As necessary, adjust the cutting height with the tractor top link. A recommended procedure for gauging the cutting height is to do so with the Mower stationary. After the cutting height is determined, the Cutterbar can be raised to a position slightly below horizontal to allow for adequate flotation of the Shoe under the Gearbox. The Cutterbar can be operated up to 45' above or below the horizontal, as desired. With the Cutterbar raised, engage the tractor PTO and let the tractor clutch out slowly while allowing the engine revolutions to build-up to the recommended speed before lowering the Cutterbar and entering the crop. A CAUTION BE SURE to check the entire area for spectators and/or obstructions BEFORE proceed Ing to mow the crop. 16

19 SHOCK ABSORBER (Figs. 5-17, 5-18 & 5-19) The Disc Mower is provided with a Shock Absorber which MUST be fitted to the Cylinder end and to the Vertical Tube which is attached to the tractor 3-point hitch. Raise the Mower until the Inner Shoe is approximately 8" (205 mm) above the ground. Next, extend the Cylinder to lower the Cutterbar so that the Outside Shoe just touches the ground. Then, lower the tractor linkage to a distance of 16 to 18" (400 to 450 mm) between the linkage arms and the ground. At this position, Mounting Pin should be centered in Buffer Slot to provide for adequate Outside Shoe flotation. 1 - Shock Absorber Fitted to End of LIft Cylinder 2 Mounting Pin In Center of Buffer Slot Fig NOTE: If the tractor linkage is allowed to go be/ow 16" (400 mm), the Cutter bar may be damaged due to improper or NO flotation. If the linkage is allowed to go above 18" (450 mm), excessive flotation pressure will develop causing uneven mowing. 1 - Linkage Pins 16 to 18" (405 to 455 mm) Above Ground 2 - Ground MOWING SLOPES Fig The Pin MUST be in the lowest position in the slot of the Link Tube. This can be achieved by keeping the hydraulic trailer connection lever pushed for a few seconds beyond the position where the Cutterbar is resting on the ground. SWATHBOARD (Fig. 5-20) The Outside Swathboard is attached to the end of the Cutterbar. The angle of the Swathboard can be changed by tightening or loosening the Nut. The Swathstick can be arranged in anyone of four positions or removed entirely, if desired. The actual position of the Swathstick should always be adjusted according to the circumstances required, such as long, short or flattened crops. 1 Gearbox 8" (204 mm) Above Ground 2 - Ground Fig When mowing below the horizontal, the Cylinder Rod MUST be attached in the position shown. When raising or lowering the Cutterbar at the ends of the field, only the tractor linkage has to be used (and NOT the Lift Cylinder). If the Cylinder is used accidentally, the Cutterbar will again have to be replaced to the horizontal position. 1 - Swaths tick 2 - Swathboard 3 - Angle Adjustment Nut Fig

20 OVERLOAD PROTECTION (Figs & 5-22) The Disc Mower Cutterbar is protected against obstacles by a single Cutterbar Breakaway Bolt. If the Bolt breaks, while operating the unit, attempt to determine the cause of the Bolt failure before replacing it and attempting to re-secure operation. The Bolt is equipped with two Nuts. To properly install the Bolt, first attach the one Nut, using finger-tight pressure. Then, install and tighten the second Nut using a wrench. NOTE: A package of eight additional Cutter bar Breakaway Bolts is available by GEHL part number Fig Fig

21 A CAUTION BEFORE proceeding to perform any adjust ments on the Disc Mower, exercise the MAN DATORY SAFETY SHUTDOWN PROCEDURE (page 8) BEFORE proceeding. CHAPTER 6 ADJUSTMENTS DRIVE BELT TENSION (Figs. 6-1 & 6-2) The Drive V -Belt tension, between both Pulleys, should be checked before each day of operation. The tension should be maintained at approximately 5/8" (16 mm) deflection for a hand pressure applied at the midpoint of the Belt span. To adjust the tension, first loosen the Bolts on the Bearing Plate. Then, rotate the outside Nylon-insert Lock Nut to obtain the correct tension. Tap the Tension Plate with a hammer (ifnecessary), in the direction of the Hookbolt. After proper tension is adjusted, tighten the Bearing Plate hardware. NOTE: When a V-Belt becomes worn excessively and requires replacement, BE SURE to replace all of the Belts so as to maintain correct Belt lengths. 1-5/8" (16 mm) 01 Fig. 6 1 KNIFE CHANGING (Figs. 6-3, 6-4 & 6-5) This GEHL Disc Mower is equipped with twisted Knives which are designed to provide the lowest cutting level. In general, the Knives can be operated when the Cutterbar is in the flat horizontal position. Both clockwise rotating and counterclockwise rotating Knives are used. Knives are marked with direction of rotation arrows. All GEHL Knives are double-edged and reversible. As the Discs are rotating in opposite directions, next to each other, the direction of rotation of all Knives MUST be followed exactly to insure the best cutting action. The Knife Bolts can be loosened with the wrench provided, after the area around the Nut is cleaned-off. To facilitate Knife assembly or removal, place the Cutterbar in the "Transport" position. 1 - Belt Tension Adjustment Locknut 2 - Bearing Plate Attachment Bolts (2) Fig. 6 2 Fig

22 3. Check and readjust the cutting height with the tractor top link. 4. Maintain as high a ground travel speed as comfortable to avoid second and third cutting. 5. lf a build-up of dirt, grass or trash exists, remove it and wash-down the Cutterbar before or after each operation. 1 - Clean-off Area Around Knife Bolt Nut Fig. 6-4 A WARNING Exercise the MANDATORY SAFETY SHUTa DOWN PROCEDURE (page 8) BEFORE clean Ing the Cutterbar area. Use a screwdriver (NOT your hands) to break-up any dirt buildup or to loosen twisted grass. PROTECTIVE SHEET (Fig. 6-6) The Protective Sheet Support Frame can be adjusted by means of Bolts and appropriate mounting holes to match various crop heights. The Protective Frame can quickly be removed for maintenance, as required. Remove the Bolt with Nylon-insert Lock Nut and loosen the top Nut. The Bolt is mounted in a sleeve hole. By raising the Frame, the entire assembly can be removed. 1 - Place Cutter bar In "Transport" Position to Facilitate Changing Knives 2 - Clean-off Knife Bolt Fig. 6-5 NOTE: BE SURE to use only GEHL replacement Knives, to insure the best possible cutting action and promote long life. To make the Disc stationary, while loosening the Knife Bolts, temporarily stop the Disc with a wooden wedge or hammer handle. lf the cutting quality decreases, make the following inspections: 1. Check that the Discs are running at full speed, that the tractor PTO speed is proper and that the Drive Belts are properly adjusted. 2. Check that the Knives are the proper rotation, full-sized and sharp. 1 - Protective Sheet Support Frame Adjustment Bolt 2 Support Frame Attachment Bolts Fig

23 CHAPTER 7 MAINTENANCE & SERVICE A CAUTION BEFORE proceeding to perform ALL service and maintenance routines on this unit, exercise the MANDATORY SAFETY. SHUTDOWN PROCEDURE (page 8). NOTE: Because the Cutting Knives rotate at a speed of 3000 RPM, proper Knife Bolt torque MUST be maintained at 65 ft-ib (90 N-m). Check also that the Gearbox Bolts are torqued to 185 ft-ib (250 N-m) and that the Bolts on the Mower Discs are also torqued to 65 ft-ib (90 N-m). LUBRICATION HARDWARE (Fig. 7-1) After the first hour of operation, check all attaching hardware. Hardware torques should be checked on a routine basis after every 10 hours of operation. A CAUTION BEFORE proceeding to lubricate this unit, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (page 8). Oil Level (Fig. 7-3) Both the Disc Mower Gearbox and the Cutterbar are filled with HD90 oil before shipment. The oil should be drained and replaced at the start of each season of operation. Check the Cutterbar oil level at the beginning of each day before starting operation, with the Cutterbar in the "Transport" position. It is desireable to always allow the oil to settle overnight to obtain a most accurate level indication. Check the Gearbox oil level with the Cutterbar in the horizontal or operating position. Fig. 7-1: Cutting Disc & Knife Bolt 1 - Gearbox Attachment Bolts Fig Gearbox Fill & Inspection Plug 2 - Cutterbar Drain Plug 3 - Gearbox Ventilation Plug Fig. 7 3: Gearbox & Cutterbar 21

24 Filling Plugs & Oil Contents (Fig. 7-4 & 7-5) The Gearbox is provided with a Plug for leveling, ventilation, draining and filling. The Gearbox oil contents of the DM160 is 1/2 U.S. Pint (0.25 liter). The Cutterbar is provided with a Plug for filling or draining. The Cutterbar oil contents of the DM160 is 4 U.S. Pints (2.25 liters). The Cutterbar should be placed in the horizontal operating position when adding oil to the Gearbox. A Plug is provided on the back of the Cutterbar to facilitate checking the oil level. At night, the Mower should be left parked in the "Transport" position. Then, in the morning, the oil level should reach the Plug opening. If necessary, replenish the level using HD90 oil. Telescoping PTO & Main Unit Lubrication (Figs. 7-6 & 7-7) The GEHL Disc Mower MUST be routinely lubricated to promote long life and smooth operation. All points illustrated, should be lubricated after every 10 hours of operation. The Main Frame is provided with two (2) Grease Fittings and the Telescoping Drive is also provided with four (4) Grease Fittings. In addition to the Fittings, the Telescoping PTO Drive Tube should be greased regularly so that the mating members slide freely. Apply oil, to the following points, every 10 hours; the Pressure Thrust Ball Bearing and the Pivot point for the Limitation Block and the Locking Pin Fill Hole 2 Breather Hole 3 - Gearbox Fig. 7 4 Fig. 7 6: Telescoping PTO Drive Fig Cutterbar Fill & Check Plug Hole 2 Cutterbar Fig

25 Procedures established in these set-up instructions are given in a step-by-step manner, with various parts of the process listed in such a way as to make it possible for two people to do the sequence, without having to remove parts in order to make other component attachments. The Disc Mower is packed in two crates; one crate contains the Hitch and Lift Cylinder and the other crate contains the Cutterbar and Safety Frame. Disc Mower set-up should be performed on a concrete floor, inside an enclosed workshop, which is equipped with the proper tools and an overhead hoist. NOTE: herein: CB CS HHMS PB RHMS SDS N LN NILN WN CHAPTER 8 SET-UP & ASSEMBLY The following abbreviations are used - Carriage Bolt - Cap Screw (Hexagon Head) - Hexagon Head Machine Screw - Plow Bolt - Round Head Machine Screw - Self~dril1ing Screw - Nut (Hexagon) - Lock Nut (Hexagon) - Nylon-insert Lock Nut - Wing Nut L P NPT - Lock (Washer) - Plain (Washer) - National Pipe Thread Unless otherwise noted, the standard fastening procedure is to secure two parts with a CS, Land N. A part with a mounting slot should be secured with a P against the slotted surfaces. LN's are sometimes used to prevent two parts from separating but still to allow one part to move or rotate next to the other. Attaching hardware, which will require installation in the path of cut crop, should always be installed with the head of the screw on the same side of part which will be in contact with the material. NOTE: Before proceeding, remove all components which are shipped in the two separate crates. 1. Referring to the illustration provided, remove the V -Belt Outer Cover and slide the Hitch assembly over the Gearbox Tube and secure it with the Snap Ring. 2. Referring to the illustration provided, place the V -Belts over the Pulley and mount the Pulley onto the Hub using the four (4) Bolts which are already in the Hub. 1 Gearbox Tube 2 Cutterbar Assembly 3 Hitch Assembly 4 Snap Ring 5 Pulley 6 Pulley Attachment Bolts (4) 7 Pulley Hub Fig. 8 1 :Pulley & Hub, Cutterbar Assembly & Hitch Assembly 23

26 NOTE: The threaded holes in the Pulley are for pushing the Pulley off, when necessary. 3. Referring to the illustration provided, adjust the V -Belts tension for a 5/S" (16 mm) deflection for a hand pressure applied at the midpoint between the two Sheaves. Install and secure the Rubber Strip and V -Belt Outer Cover after proper tension is adjusted. 4. Refer to the photograph (Fig. 5-3, in chapter 5) and properly orient and attach the hydraulic Lift Cylinder. 5. Refer to the appropriate parts exploded-view drawing and properly orient and secure the Breakaway Shear Arm between the 3-Point Support Frame and the Drive Mechanism using the hardware provided. 1-5/8" (16 mm) Deflection 2 - Rubber Strip 3 - V-Belt Outer Cover Fig Hydraulic Lift Cylinder 2 Break-away Mechanism 3 - Hitch Assembly Fig Frame Wings (2) 2 - Height Adjustment Bolts 3 - Bushings 4 Frame Wing Attaching Hardware 5 - Frame Fig Bracket on Gearbox 7 - Washer (Under Slot) 24

27 6. Refer to the illustration provided and assemble the Frame for the Protective Cover in the following manner: a. Remove the long Bolts from the Gearbox and mount the Bracket onto the Gearbox. Then, install the Protective Cover Frame onto the Bracket making sure to use the Special Washer where shown. b. Properly orient and attach the Frame Wings. Make sure that the attaching hardware is left loose enough to allow the Frame Wings to be moved. c. Install the Height Adjustment Bolts with the Bushings so that the Cover is leveled. 7. Refer to the illustration provided and attach the Swathboard to the end of the Cutterbar with the Carriage Bolt, Spring, Washer and Locknut. 8. Properly orient and secure the Wooden Stick to the Swathboard with the Hooded Bolt and Cap Screw as shown. Secure each fastener with a Locknut. 9. Properly orient and attach the Protective Cover to the Mount by securing the Fastener Belts. 10. After the unit is completely set-up, check the oil levels in the Cutterbar and Gearbox. In addition, BE SURE to check that all mounting hardware is tightly secured. 1 Swathboard 2 Stick 3 Hooded Bolt 4 Carriage Bolt 5 End of Cutter bar 6 Spring. Washer and Locknut Fig. 8 5 Fig. 8 6: Protective Cover 25

28 CHAPTER 9 DECAL LOCATIONS GENERAL INFORMATION Decal Locations infonnation 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). 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 checking-off 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 Decals. 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. PAINT NOTICE Use this list to order paint for refinishing: One Gallon Blaze Paint One Gallon Maize Paint (120z Spray Cans) Blaze Paint (120z Spray Cans) Maize Paint The Decal Set Number for the DM160 Disc Mower is The Set includes the following: Description & Quantity Decal- Grease Fitting Symbol (2 Places) GEHL Decal- Cylinder Float Pin & Slot Positions Decal- Check Oil Level Decal- Use Metric 8.8 Breakaway Bolts 160 DANGER - Avoid Electrical Contact WARNING - Install Transport Lock CAUTION RPM Operation ONLY CAUTION - Rotating Blades DANGER - Cutterbar & Rotating Knives CAUTION - Drive Tube Guard CAUTION - OWner's Responsibility & Read Manual CAUTION - General Safety Precautions DANGER - Rotating Drive Une 26

29 CHAPTER 10 SERVICE PARTS & NUMERICAL INDEX When ordering service parts, specify the correct part number, full description, quantity required, the unit model number and serial number. "Right" and "Left"are determined from a position standing behind the unit and facing the direction of travel. From this position, the Cutterbar is on the "Right" side. GEHL Company reserves the right to make changes or improvements in the design or construction of any part of this unit without incurring the obligation to install such changes on any unit previously delivered. Grease fittings and common attaching hardware, such as Cotter Pins, Set Screws, Woodruff Keys, Screws, Nuts, etc., are included in the parts lists, indented below the part it is (they are) associated with, but NOT illustrated, except where a particular routing or special fastening arrangement MUST be maintained. The hardware listed is for mounting purposes and is NOT included when the part is ordered for replacement. Refer to the abbreviations table, located on this page or on the inside back cover of this manual, for the various fastener descriptions. For the part number of related fasteners, refer to the Attaching Hardware Table on the inside back cover of this manual. Standard attaching hardware torque values are also provided on the inside back cover. NOTE: Because the majority of the fasteners and components used on this machine are metric, dimensions or sizes given in the description are in millimeters unless otherwise noted. NOTE: The fof/owing abbreviations are used herein: CS - Cap Screw (Hexagon Head) HD - Heavy Duty NILN - Nylon Inset Lock Nut PC - Piece PTO - Power Take Off QID - Quick Disconnect SHCS - Socket Head Cap Screw T - Tooth THO - Thread WI - With 27

30 160 - TRACTOR LINKAGE & LIFT MECHANISM 38 \ ~ 29 ~ ti 1~ /1 P Printed In U.S.A.

31 160 - TRACTOR LINKAGE & LIFT MECHANISM OS 60460S S 60461S S Qty. Description Req. HFLN 12/M WASHER... 2 SPRING TUBE (BAR)... 1 SUPPORT LEG (STAND)... 1 TRANSPORT LOCK (STRIP)... 1 SHOCK TUBE (PIPE)... 1 LINK TUBE... 1 FRAME PIVOT (UPRIGHT)... 1 SHEAR BOLT ARM... 1 SHEAR BOLT BRACKET... 1 MAIN FRAME... 1 SPRING... 1 SUPPORT SPRING... 1 SHOCK PIN WASHER (SPACER). 1 RESTRICTOR (PLATE)... 1 TOP PiN... 1 SHAFT... 1 MAIN SPRING TUBE PIN... 1 ARM HINGE PIN... 1 LIFT PiN... 1 SHOCK SPRING GUIDE (PIN)... 1 PIN... 1 SHOCK TO FRAME STEP PIN... 1 SHEAR ASSEMBLY PIN... 2 STRIP... 2 STOP PLATE... 2 HYDRAULIC HOSE... 1 SPRING CLIP... 5 SPRING CLiP... 1 Qty. Description Req TENSIONER ARM a HYDRAULIC CYLINDER. " CONNECTOR G 3/S X 3/S b ROLL PIN 5 X ROLL PIN 6 X ROLL PIN S X b ROLL PIN S X NILN 10/M S BUFFER KIT CS S.S/MS X e CS S.S/MS X CS S.S/M10 X CS S.S/M12 X CS S.S/M16 X S N SIMS NILN SIMS NILN S/M COTTER PIN 5 X S COTTER PIN 6 X PLUG/MAIN FRAME (AFTER SN294S) PLUG/TUBE (AFTER SN294S)... 1 a) For components, see separate breakdown page. b) For replacement, order # GROOVE PIN. e) For package of eight BREAKAWAY BOLTS, order part # Printed In U.S.A /1 P1289

32 160 DRIVE, SUPPORT & GUARDS 27 Before SN2949 Before SN4097 Description Qty. Req DRIVE SPLINE SHAFT SHEAVE (PULLEY) - BOLT-ON 4 BELT (AFTER SN4096) SHEAVE (PULLEY) - 4 BELT (BEFORE SN4097) BEARING MOUNT SPACER (AFTER SN4096) SPACER (BEFORE SN4097) FRONT BELT GUARD REAR BELT GUARD STRIP RUBBER STRiP DRIVE SHEAVE (PULLEY) - 4 BELT PROTECTION FUNNEL (AFTER SN2948) a PROTECTION FUNNEL (BEFORE SN2949) BELT TIGHTENER (BOLT) EXTERNAL SNAP RING WASHER 35 X 45 X CUP WASHER GREASE CAP BEARING Description Qty. Req. DRIVE BELT... 4 MAIN BEAM... 1 GREASE FITTING... 2 ROLL PIN 14 X 65 (USED ONLY BEFORE SN4097) ROLL PIN 8 X 65 (USED ONLY BEFORE SN4097) WASHER PLASTIC CAP (USED ONLY AFTER SN2504) CS 8.8/M12 X ROD/THREADED (AFTER SN4096) CS 8.8/M12 X 130 (BEFORE SN1097)... 4 _ CS 8.8/M16 X N 8/M LN 8/M PLATE/FUNNEL (AFTER SN2540) NUT/CAP LOCK (AFTER SN4096)... 4 a) For replacement, order and /1 P Printed In U.S.A.

33 160 - HYDRAULIC LIFT CYLINDER Description Qty. Req. HYDRAULIC CYLINDER - ASSEMBLED... 1 CONSISTS OF: HYDRAULIC CYLINDER GLAND.. 1 RETAINING RING... 1 HYDRAULIC CYLINDER BARREL 1 Qty. Description Req HYDRAULIC CYLINDER ROD CYLINDER SEAL KIT HYDRAULIC CYLINDER PiSTON CYLINDER PISTON RETAINING NUT M16 X Printed In U.S.A /1 P1289

34 160 GEARBOX & DRIVE ~~. 16. (ij).; / 14 r(i~/,/ ~~@' \7@ 17 1 /~ 9 9)4 ~11 ~13 Before SN OJ/ ~-11 ~ ~-13 ~-~ 22 / 24 Description Qty. Req. Description Qty. Req BEARING... 1 HFLN 12/M BEARING RETAINER WASHER.. 1 BEARING (TWO USED BEFORE SN2949) DRIVE PIVOT HOUSING PLASTIC BEARING BREATHER PLUG BEVEL GEAR SET (AFTER SN4096) BEVEL GEAR SET (AFTER SN2948 & BEFORE SN4097) a BEVEL GEAR SET (BEFORE SN2949) O-RING RETAINING RING RETAINING RING GREASE SEAL GREASE SEAL STAR WASHER BEVEL GEAR HOUSING (AFTER SN2948) BEVEL GEAR HOUSING (AFTER SN2504 & BEFORE SN2949) b BEVEL GEAR HOUSING (BEFORE SN2505) CS8.8/M14 X CS 8.8/M14 X CS 8.8/M14 X CS 8.8/M14 X PIPE PLUG ROLL PIN 14 X 80 (USED ONLY AFTER SN4096)..., HUB/SHEAVE (USED ONLY -AFTER SN4096) ROLL PIN 8 X 80 (USED ONLY AFTER SN4096) CS 8.8/M12 X 35 (USED ONLY AFTER SN4096) BEARING (AFTER SN2948)... 1 a) For replacement, order # BEVEL GEAR SET. b) For replacement, order # BEVEL GEAR HOUSING /1 P Printed In U.S.A.