operating manual - giltrap / home series forage wagon operating manual m90 series...

M90 Series Forage Wagon ‘Super’ Hydraulic & PTO Drive Models

Part Number: 595-0005 Giltrap Engineering Ltd P.O. Box 83, 7 Main North Rd Otorohanga, New Zealand Phone: +64 7 873 4199 Fax: +64 7 873 8131 Email: [email protected] Website: www.giltrapag.co.nz

Operating Manual

M90 Series Forage Wagon Operating Manual

M90 Series Manual_Operating_Rev10_07.doc

Disclaimer Although every attempt has been made to ensure the correctness of information and diagrams in this manual, Giltrap Engineering Limited will not be responsible for any damage or consequential loss arising out of misinterpretation or failure to follow recommended procedures; nor will it be liable for any damage caused by or arising out of modification or misuse of its product. For parts or service enquires, please contact the applicable numbers on the previous page.

First Edition (draft copy) ‘M90 Centre Feed’ printed January 1996 First Edition ‘M90 Side Delivery’ printed December 1998

Second Edition (first two books combined) amended and printed February 2003 Amended and reprinted October 2007

Copyright 2007 by Giltrap Engineering Ltd. Printed in New Zealand

All rights reserved. Reproduction or use, without express permission, of editorial or pictorial content, in any manner, is prohibited.



Table of Contents

INTRODUCTION ...................................................................................................................................................... 0H4

DELIVERY AND WARRANTY ............................................................................................................................... 1H4

PRE-SERVICE GUIDELINES FOR ALL GILTRAP WAGONS ......................................................................... 2H5

OPERATING INSTRUCTIONS FOR HYDRAULIC FORAGE WAGONS ....................................................... 3H6

OPERATING INSTRUCTIONS FOR PTO FORAGE WAGONS ....................................................................... 4H7

HYDRAULIC PERFORMANCE & OPERATING PRINCIPLES ....................................................................... 5H8

PRIORITY VALVE – DANFOSS 2F95 .................................................................................................................. 6H10

ADJUSTING THE CROSS CONVEYER BELT .................................................................................................. 7H11

GENERAL SAFETY ................................................................................................................................................ 8H12

TROUBLESHOOTING GUIDE ............................................................................................................................. 9H15

HCV1899B VALVE LAYOUT ................................................................................................................................ 10H17

PARTS BOOK SECTION ........................................................................ 11HERROR! BOOKMARK NOT DEFINED.



0BIntroduction

Thank you for purchasing a Giltrap product. Giltrap Engineering Limited has enjoyed a long-standing success with their machinery. We would like you to enjoy the benefits of owning a Giltrap too. By following the guidelines laid out in this book, you will ensure trouble free, low maintenance operating for years. Giltrap Engineering Limited is a progressive company which continually strives to satisfy your needs, so we welcome any feedback which you can provide to help us improve our products and services and to ensure that they perform to your expectations. Any constructive comments about this operator’s manual are also welcome. Your machine has been designed to perform its task efficiently and with a minimum of maintenance. This handbook provides safety guidelines, instructions, maintenance requirements and parts listings. We recommend that you read the entire handbook, before operating the machine as this will enable you to take full advantage of your new machine’s considerable potential. Please fill in the details below for future reference:

1BDelivery and Warranty

Before you begin to use your machine, please check it to make sure there is no delivery damage. If damage is evident, contact the dealer who supplied the machine so that they can make the appropriate claims. All Giltrap products are covered by a 12-month warranty on parts and labour, subject to normal use. If you have any other queries, please contact your dealer or Giltrap Engineering Limited.

Model: Serial No: Delivery Date: Dealer:



2BPre-Service Guidelines for All Giltrap Wagons

Prior to delivering your machine, your dealer should have completed a pre-delivery check. It is advantageous to you to check the following points before using the machine for the first time. Caution: Do not stand in the bin or near the shredder elevator while the machine is running.

CHECK FLOOR CHAIN TENSION. A simple check is to stand in the bin and exert a strong pull at the centre of the floor. There should be approximately 70mm of vertical movement in this area.

CHECK ELEVATOR CHAIN TENSION. Exert a pull at the mid-point of the elevator face. If necessary adjust for approximately 30mm of movement from rest towards the rear of the wagon.

CHECK ALL TRANSMISSION CHAINS. These should have some slack. The factory settings should be okay.

CHECK ALL WHEEL NUTS ARE SUFFICIENTLY TIGHT.

CHECK ALL AXLE MOUNTING BOLTS AND NUTS ARE SUFFICIENTLY TIGHT.

THE FLAPS on Centre Feed wagons are normally tied closed for delivery purposes. Make sure the flaps are opened sufficiently to allow material to pass through without blocking. Hay requires a larger opening than chopped silage.

THE BELT ON CROSS-CONVEYER MODELS should be checked for alignment, and adjusted if necessary to ensure it is tracking correctly. See the notes on cross-conveyer belt adjustment.

THERE ARE SEVERAL GREASE POINTS on all Giltrap wagons. Check the yellow label on the side of your machine to see how many grease points there are. You should fully grease everything before running it for the first time.



3BOperating Instructions for Hydraulic Forage Wagons

GREASE daily for the first week, then at weekly intervals during each feeding out season. Always grease and oil the machine after it has been in storage or not used for a long period of time.

OIL the transmission chains at regular intervals.

LOAD the wagon from the rear to the front. When difficult material has to be handled, eg long, wet silage, load the material in sections. It may sometimes be necessary to reverse the load a short distance and then bring it forward again to present a new face to the elevator. Note: reverse the floor by pushing the hydraulic lever on your tractor in the opposite direction.

BEST FEEDING OUT CONDITIONS occur when the wagon is freshly loaded. If left loaded overnight, the material can settle into a hard mass that becomes difficult to feed out. The practice of leaving a load in the machine for hours before feeding out will also accelerate the deterioration of the wagon because of the acidic nature of silage.

CONTROLLING THE FEED-OUT RATE is done by using the control rod mounted on the drawbar. This adjusts the load pressure that the ‘Super’ valve uses to start and stop the floor automatically. When you have adjusted the feed-out rate to your requirements, the ‘Super’ valve will maintain an even flow of material to the elevator by automatically adjusting the floor speed.



4BOperating Instructions for PTO Forage Wagons

GREASE daily for the first week, then at weekly intervals during each feeding out season. Always grease and oil the machine after it has been in storage or not used for a long period of time.

OIL the transmission chains at regular intervals.

CHECK ALL SHEARBOLTS are in position and that you have spare bolts before you start to feed out.

LOAD the wagon from the rear to the front. When difficult material has to be handled, e.g. long, wet silage, load the material in sections. It may sometimes be necessary to reverse the load a short distance, and then bring it forward again to present a new face to the elevator.

THE MACHINE SHOULD BE RUN AT 400 - 500 RPM with the floor set at a slow speed. When the wagon is about ¾ unloaded the floor speed can increased to empty the rest of the material.

BEST FEEDING OUT CONDITIONS occur when the wagon is freshly loaded. If left loaded overnight, the material can settle into a hard mass that becomes difficult to feed out. The practice of leaving a load in the machine for hours before feeding out will also accelerate the deterioration of the wagon because of the acidic nature of silage.

WHEN OPERATING THE WAGON IN FAST FLOOR REVERSE always ensure that the gear selector arm is bolted in the lock-hole position.



5BHydraulic Performance & Operating Principles All models from February 1996 onwards All new Giltrap hydraulic feed-out wagons are fitted with a comprehensive hydraulic system, which when tuned correctly will maximise the efficiency of the hydraulic power available from your tractor. The main components in every Giltrap system are; 1. 3 hydraulic motors on all cross conveyer wagons or 2 hydraulic motors on centre

feed wagons. These are different sizes according to the application. The elevator and conveyer belt motors are coupled directly to their respective drive shafts. The floor is driven by a hydraulic motor through a series of reduction boxes or chain and sprocket sets, determined by the size of the wagon.

2. One Hydraulic ‘Super Valve’. This aluminium block houses the circuitry necessary to

coordinate the efforts of all the hydraulic motors. It includes a load sensing system that constantly monitors the load on the shredder elevator. If the load reaches a predetermined set point, the floor is automatically slowed or stopped to allow the elevator a chance to clear rather than stall. If a stall situation does develop occasionally, simply reverse the floor slightly then bring the load forward again to continue feeding out. If the elevator is stalling constantly and causing problems, please ring Giltrap Engineering for advice.

The Super Valve also controls the floor and conveyer belt speeds via remote control knobs. The floor speed control is located at the front of the wagon above the drawbar. The conveyer belt speed control is located on the same side of the wagon as the belt discharge, slightly to the rear. The system is such that the cross conveyer motor on all side feed wagons have priority oil flow. This means that the belt will run at a constant speed that is determined by the operator, to place the feed material precisely where it is required. The cross conveyer speed control delivers an adjustable flow of oil to it’s motor. The remaining oil flow produced by the tractor bypasses the conveyer motor and is used in the floor and elevator motors. Imagine then, that the tractor is producing 10 litres/min, with the conveyer speed control set to deliver 12 litres/min to its motor - obviously in this case there is only enough oil to drive the cross conveyer belt, with the floor and the shredder elevator standing idle. This means that you can run the belt to clear it without running the rest of the wagon. To increase the tractor oil flow, simply increase engine revs. In the example stated, as the tractor oil delivery exceeds 12 litres/min the floor and elevator will begin to run, achieving maximum speed at maximum oil flow - usually produced at maximum tractor engine revs. Conversely, as tractor revs decrease, the elevator and then the floor will slow down, with the belt remaining at a constant speed. This is useful in feedlot situations, especially to clear an extension belt at the end of a row.



CENTRE FEED VALVE HCV 1918

Remember that the floor speed is also controllable, independent of the other motors in the system. This applies to cross conveyer wagons as well as centre feed wagons. The floor speed is infinitely variable in the forward direction, providing the tractor is delivering enough oil to drive it. In the reverse direction, the belt and/or elevator conveyors are stopped, with the floor motor receiving full tractor oil flow, ie. Full speed. You cannot adjust the floor speed in reverse. If you are using a relatively low oil flow tractor, you should adjust the belt to run as slowly as possible. This will increase the elevator speed, therefore increasing the speed of feeding out.

The tractor remote hydraulic lever must be disengaged before attempting to adjust the cross conveyer belt speed.

The floor speed can be adjusted with the machine running.

High tractor revs (especially on low flow tractors) = fast machine speed Note: Due to the different specifications of tractor hydraulics between manufacturers, sometimes a minor adjustment to the load sensing pressure in the Super Valve is necessary to tune the wagon to exactly suit the tractor being used. In this case Giltrap Engineering will advise the adjustment to be made, since it may vary between valve types.

SIDE DELIVERY VALVE HCV 1899



6BPriority Valve – Danfoss 2F95 The two largest Giltrap side delivery wagons (M90-100X and M90-125X) have an extra valve fitted to drive the side delivery belt. This is a priority valve and prior to Feb 1996 is fitted separately to the super valve. This valve is set with the tractor running and with the wagon in the feed-out mode. The valve is adjusted to give the side delivery belt enough speed to place the material correctly to where it is required. On special request, the smaller wagons can be fitted with this valve. When the trailer is empty, but running in the forward mode there may be a gradual creeping with the floor chains or elevator. This is quite normal. Remember high tractor engine revs should be used to ensure adequate hydraulic oil flow. When tractor speed is reduced to an idle, the side delivery belt will still run but the floor and elevator will stop. An important feature with this valve is that the side delivery belt (and extension belt if fitted) can be completely cleared by reducing the tractor to an idle.

Adjuster Lock nut

Inlet port

Bypass port to main

wagon valve

Regulated priority port to conveyor

motor



7BAdjusting the Side Delivery Belt

The side delivery belt is set up and adjusted at the factory before delivery; however it is usual after a period of time to notice the belt running off centre. This is normal and is caused by belt stretch or movement under load. Simply adjust the take-up bearings a little at a time using the adjusting bolts, until the belt runs true again. You usually only need to work at one end (the discharge end has the easiest access), where you should either loosen one adjuster slightly, or tighten the other, or a combination of both. All adjustments must be made with wagon running, preferably empty. Only adjust ¼ of a turn at a time and run for at least 5 minutes between adjustments. THE BELT WILL RUN TO THE LOOSE SIDE. DO NOT OVERTIGHTEN - THIS WILL CAUSE A POWER LOSS!



8BGeneral Safety For the safety of others and yourself, please read and follow the precautions in this operator’s manual. Pay particular attention to the following safety aspects of operating machinery. Do not ride on or allow passengers on the machine. Always use a recognised hitch pin with a safety clip to hook trailed implements on behind the tractor. When pulling trailed implements or loads, be sure to use a tractor of greater or equal weight than the combined weight of the load and trailer.



Carry a suitable fire extinguisher. A fire can ignite under certain conditions, so please take the following precautions:

After running your machine for a short time, check for defective bearings. A faulty bearing can become very hot, eventually discolouring, requiring immediate replacement.

Do not allow combustible material to accumulate inside guards or around rollers and other moving parts.

If your machine becomes blocked, stop immediately and remove the obstruction.

Be careful when operating in hot or dry conditions or on extreme fire risk days. Never operate your machine without the safety guards in place. All chains should be properly adjusted and replaced when necessary.



Release all hydraulic pressure from implements before commencing service work. Never look for suspected oil leaks with your hands or body - use a piece of cardboard instead. Any fluid which penetrates the skin will have to be removed immediately by a medical expert. Seek specialist advice on this type of injury. Never attempt to unblock equipment while it is still operating. Always disengage power take-off, hydraulics and shut down engine before removing materials, checking or servicing. Failure to follow these precautions is likely to result in serious injury. Ensure that your PTO shaft is adequately guarded. Do not attempt to use a driveshaft without a cover. Wear proper protective clothing. Loose attire can easily be snagged by rotating machinery resulting in serious injury or death.



9BTroubleshooting Guide

This guide has been written specifically for the HCV1899 valve. Machines fitted with different valves can still use this as a reference but be aware of the valve differences. When using the guide, it has been assumed that the tractor has been checked to provide a oil flow rate of between 30 and 60 litres per minute at full working pressure, usually between 2500psi (170 bar) and 2800psi (190 bar). If these conditions are not satisfied, the forage wagon will perform poorly or not at all. Notes and other options

To allow for lower flow tractors (30l/min and below), cartridge #6a can be changed with other types of valve cartridges to change the floor and elevator motor circuit from a series to a parallel circuit to reduce the oil flow requirement. Please note that this arrangement will cause the machine to run with acceptable speed but reduced power compared to the series circuit.

Cartridge #6a (as fitted as standard) is a check valve (CXCD) for a permanent series connection between the floor and elevator motors. By replacing this with a cavity blank (XFOA) permanent parallel connection is achieved.

By replacing cartridge #6a with a free flow reverse needle valve (NCCB), it is possible to convert the circuit between series and parallel in the field by winding fully in for series or fully out for parallel.



10BHydraulic Valve - HCV1899

Position Qty Supplier Part # Description Setting

1 1 FRDA LAN Flow Control (3.6mm) 16 lpm

1(a) 1 KNOB547B-1 Tri-Knob 3/8” UNF (not shown)

2 1 LHDA XEN Flow Compensator

3 1 RDBA LAN Floor Relief Valve 1700 psi

4 1 DPBB LAN Sequencing Element N.C. 2000psi

5 (a & b) 2 CXDA XAN Check Valve 4 psi

6 (a & b) 2 CXCD XAN Check Valve 4 psi

7(a) 1 CXCD XAN (std) Check Valve (for perm. series conn.) 4 psi

7(a,i) 1 XFOA XXN Cavity Blank (for perm. parallel conn.)

7(a,ii) 1 NCCB LCN Needle Valve (for selectable conn.)

7(b) 1 CXCD XAN (std) Check Valve 4 psi

7(b,i) 1 SCCD Relief Valve (see note) 1500psi

8 1 1/16” NPT x 0.8mm Dampening Orifice

9 1 1/8” BSPT x 0.8mm Dampening Orifice

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