M90 Series Forage Wagon Manual Operating & Parts - Giltrap

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: info@giltrapag.co.nz 

Website: www.giltrapag.co.nz 

M90 Series Forage Wagon 

‘Super’ Hydraulic & PTO Drive Models 

Operating Manual

M90 Series Forage Wagon Operating Manual 

Disclaimer 

M90 Series Manual_Operating_Rev10_07.doc 

Page 2 

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 


Page 3 

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 


Page 4 

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: 

Model: 

Serial No: 

Delivery Date: 

Dealer: 

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.



Page 5 

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 crossconveyer 

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.



Page 6 

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.



Page 7 

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.



Page 8 

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 


Page 9 

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



Page 10 

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



Page 11 

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 


Page 12 

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.



Page 13 

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. 


Page 14 

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 


Page 15 

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.



Page 16


10BHydraulic 

Valve - HCV1899 


Page 17 

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

M90 Series Forage Wagon Manual Operating & Parts - Giltrap

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