OPERATORS MANUAL FOR KAFURTER ROTARY TOPPERS MODELS: TP110, TP140, TP160, TP170

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1 OPERATORS MANUAL FOR KAFURTER ROTARY TOPPERS MODELS: TP110, TP140, TP160, TP170 SAFETY WARNING: Do not use or operate this this manual and assembly instructions (where applicable) has been read and understood. equipment until

2 CONTENTS 1.1 Safety First General Safety Operating Safety Storage Safety Maintenance Safety Safety Signs CHAPTER SERVICE AND MAINTENANCE Service Maintenance Trouble-shooting Assembly Specification CHAPTER MECHANICAL 2.6 Mechanical Bolt Torque Setting Spare Parts Lists...22 THANK YOU FOR BUYING THIS KAFURTER TOPPER. THE KAFURTER SERIES OF TOPPERS HAVE BEEN DESIGNED TO CUT PADDOCKS, AREAS OF ROUGH GRASS AND OTHER PLANTS. IT IS A SIMPLE AND RELIABLE SYSTEM THAT REQUIRES MINIMAL MAINTENANCE. 1

3 CHAPTER SAFETY INFORMATION PLEASE NOTE Make sure all potential operators of this equipment read this manual and all safety messages contained within. 1.1 Safety First Read these safety rules attentively. Follow all suggested precautions to avoid potential dangers and to safeguard your health and personal safety. The purpose of this manual is to familiarise the operator with the operation and regular servicing of the machine. Remember that the time spent on maintenance extends the life of your Topper. The safety information given in this manual does not replace any other safety requirements or insurance requirements. This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. YOU are responsible for the SAFE operation and maintenance of your Topper. YOU must ensure that you and anyone else who is going to operate, maintain or work around the Topper is familiar with these operating and maintenance procedures and related SAFETY information. This manual will take you step-by-step through your working day and alerts you to all good safety practices that should be adhered to while operating the Topper. Remember, YOU are the key to safety. Good safety practices not only protect you but also the people around you. Make these practices part of your safety programme. Most accidents can be prevented. Do not risk injury of death by ignoring good safety practices. 2

4 This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. Topper owners must give operating instructions to operators or employees before allowing them to operate the machine. The most important safety feature on this equipment is a SAFE operator. It is the operator s responsibility to read and understand ALL Safety and Operating instructions in the manual and to follow these. A person who has not read and understood all operating and safety instructions is not qualified to operate the machine. An untrained operator is a danger to himself and bystanders with the possibility of serious injury or death. Do not modify the equipment in any way. ANY modification may weaken the functionality and/or safety of the machines. It can also affect the life of the equipment and will invalidate its warranty. Think SAFETY! Work SAFELY! This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. 1.2 General Safety 1. Read the operator s Manual and all safety signs carefully before operating, maintaining, adjusting or hitching / un-hitching the Topper. 2. Do not allow anyone to ride on the Topper. 3. Operate only at a safe distance from bystanders. Clear the area of pets and people, especially small children, before starting. 4. Clear working area of stones, branches or hidden obstacles that might get caught up in the blades 5. Keep hands and feet away from underside of the Topper at all times. 3

5 6. Keep all shields in place. If shield removal becomes necessary for repairs, replace the shield prior to use. 7. Do not stand between the tractor and the Topper. 8. All rotary blades have the ability to discharge objects at high speeds, which could result in serious injury to bystanders or passers-by, use with extreme caution. 9. Place all controls in neutral, stop tractor engine, set hand brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or un-hitching. 10. Review safety related items regularly with all personnel who will operate or maintain the Topper. 11. Do not operate the Topper if you feel unwell or physically unfit. Stop operation immediately if you begin to feel unwell. 12. Our Toppers are designed with safety in mind; however, there is no real substitute for caution and attention in preventing accidents. Once an accident has happened, it is too late to think about what you should have done. 13. Use a tractor equipped with a Roll Over Protective Structure (ROPS). Always wear your seat belt. Serious injury or even death could result from falling off the tractor - particularly during a turnover when the operator could be pined under the ROPS or the tractor. 14. Never exceed the limits of a piece of machinery. If its ability to do a job, or to do so safety, is in question - DON T TRY IT. This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. 1.3 Operating Safety 1. Read and understand the Operator s Manual and all safety signs before operating, servicing, adjusting, repairing or un-hitching. 2. Do not allow anyone to ride on the Topper. 3. Install and secure all guards and shields before starting or operating. 4. Keep hands, feet, hair and clothing away from moving parts. 5. Place all controls in neutral, stop tractor engine, set park brake, remove ignition key and wait for all moving parts to stop before servicing, adjusting, repairing or unplugging. 6. Place all tractor and machine controls in neutral before starting. 7. Never start or operate the Topper unless sitting on tractor seat. 4

6 8. Clear the area of bystanders, especially small children, before starting 9. Stay away from PTO shaft and machine when engaging PTO. ENGAGE PTO AT LOW REVS. Once engaged, bring revs up to 540 RPM. 10. Clean reflectors, and lights before transporting. 11. Use hazard lights on tractor when transporting. 12. Do not operate the Topper in the raised position. 13. Objects can be thrown out from under machine with sufficient force to severely injure people and animals. Stay away from the Topper when it is running. Keep others away. 14. Always know what you are cutting. Never operate the Topper in an area that has hidden obstacles. Remove sticks, stones, wire or other objects from working area before starting. 15. Review safety instructions with all operators regularly. This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. 1.4 Storage Safety 1. Store the Topper in an area away from pedestrians. 2. Do not permit children to play on or near the stored Topper. 3. Store the machine in a dry, level area. Support the frame with wooden planks if required. This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. 1.5 Maintenance Safety 1. Good maintenance is your responsibility. Poor maintenance is an invitation to trouble. 2. Follow good workshop practices. Keep service area clean and dry. Be sure electrical outlets and tools are properly grounded. Use adequate light for the job at hand. 3. Make sure there is plenty of ventilation. Never operate the engine of the 5

7 towing vehicle in a closed building. The exhaust fumes may cause asphyxiation. 4. Before working on this Topper, shut off the engine, set the hand brake, and remove the ignition key. 5. Never work under equipment unless it is supported securely. 6. Use personal protection Equipment such as eye, hand and hearing protectors when performing any service or maintenance work. Use heavy gloves when handling blades. 7. When replacement parts are necessary for periodic maintenance and servicing, genuine factory replacement parts must be used to restore your equipment to original specifications. KAFURTER.com Limited will not be responsible for injuries or damages caused by use of unapproved parts and/or accessories. 8. A fire extinguisher and first aid kit should be kept readily accessible while performing maintenance on this equipment. 9. Periodically tighten all bolts, nuts and screws and check that all pins are properly installed to ensure unit is in a safe condition. 10. When carrying out maintenance or servicing, make sure all safety shields and devices are installed before putting the Topper back into service. This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death. 1.6 Safety Signs Care of Safety Signs 1. Keep safety signs clean and readable at all times. 2. Replace safety signs that are missing or have become illegible. 3. If a component with a safety sign(s) affixed is replaced with a new part, make sure that new safety sign(s) are attached in the same locations as the replaced components. 4. Safety signs are available from your authorised Distributor or Dealer Parts Department. 6

8 This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read this message that follows and be alert to the possibility of personal injury or death Safety Signs locations The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarise yourself with the various safety signs, the type of warning and the area, or particular function related to that area. Two of the following warning signs are located on either side of the topper headstock just inside the skids - Danger of severe injury from rotating blades. Keep hands & feet away from the underside of the topper. Two of the following warning signs are located on the left and right hand corners towards the back of the topper just inside the skids. Danger of severe injury from rotating blades. Keep hands & feet away from the underside of the topper. The following warning sign is located towards the back edge of the topper directly opposite the gearbox. Danger of severe injury, DO NOT RIDE ON THE MACHINE. DO NOT STAND BETWEEN THE MACHINE AND THE TRACTOR 7

9 One of the following safety signs is located on the flail deck in front of the P.T.O. shaft. DO NOT OPERATE THIS MACHINE IN EXCESS OF 540R.P.M. Failure to comply will put yourself and others at risk. Your flail mower may fail and your warranty will become void. Chapter 2. SERVICE AND MAINTENANCE SERVICE 2.1 FLUIDS AND LUBRICANTS Grease: Use SAE multi-purpose high temperature grease with extreme pressure (EP) performance. An SAE multi-purpose lithium base grease. Gear Box Oil: Use EP90 gear oil. Fill gearbox to side bung level. Regularly check this level. Storing Lubricants: Your Topper can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants. Store them in an area protected from dust, moisture and other contaminants. GREASING 1. Use the Maintenance Checklist provided to keep a record of all scheduled maintenance. 2. Use a hand-held grease gun for all greasing. 3. Wipe grease nipples with a clean cloth before greasing, to avoid injecting dirt and grit. 4. Replace and repair broken grease nipples immediately, If grease nipples will not take grease, remove and clean thoroughly. Also clean lubricant passageway. 8

10 2.2 BLADE REPLACEMENT A blade may become bent, chipped or broken when using and will have to be replaced, when replacing a blade, follow this procedure: STOP PTO AND WAIT FOR THE BLADES TO STOP ROTATING. Raise the machine above the ground to provide access to the blades. Stop engine, set hand brake, remove ignition key and wait for all moving parts to stop before dismounting. Support the machine with large wooden blocks or safety stands. Remove the nut through the access hole. Push or tap the blade pin down. Remove the old blade and replace with a new one Tap or drive the blade bolt back into position. Tighten the mounting bolt to its specified torque. ALWAYS replace blades in pairs to maintain balance. NEVER try to straighten or weld blades. Unbalanced blades are dangerous. ALWAYS keep the blade carrier and blade bolts tight. Loose blades can easily pierce the steel plate housing and or cause injury. 9

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20 GEARBOX MAINTENANCE The heavy duty gearbox used on the KAFURTER range of Toppers will give many years of trouble-free service with minimal maintenance requirements. Maintain the gearbox by following this simple procedure: OIL LEVEL: IMPORTANT: The oil level should only EVER be checked when the machine is cold and on a level surface * Remove the level plug from the side of the gearbox. * The oil level should be just below bottom lip of the thread. * Add oil through the top fill plug if required. REPAIR: When the gearbox noise level is unusually high, it may be necessary to replace worn components or the entire gearbox (depending on its condition). CONTACT YOUR LOCAL DEALER IMMEDIATLEY. 19

21 2.3 TROUBLE SHOOTING This Topper is designed to cut grass or other plants. It is a simple and reliable system that requires minimal maintenance. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter. Problem and Possible cause Cutter does not turn PTO shaft slips Poor cutting job Blades dull. Grooves in grass. Scalping. Grass being left un-cut. Vibration Out of balance. Solution Repair tractor PTO clutch Traveling too fast, slow down and sharpen blades. Bent blade. Straighten or replace blade. Machine too low. Raise machine. Traveling too fast. Slow down. Top link too short. Extend top link. Check for bent, damaged or broken blades. Repair or replace as required 2.4. ASSEMBLY The machine is shipped from the factory in a partially assembled form that allows easy and convenient shipping. Your dealer should assemble the topper, but you may have opted for self assembly the topper yourself. In order to ensure optimum performance and safety integrity, the following procedures MUST be followed. BEFORE ASSEMBLY, ADOPT SAFE WORKING PRACTICES. CLEAR THE WORKING AREA, ENSURE YOU HAVE THE CORRECT TOOLS AND WEAR PROTECTIVE GLOVES AND PROTECTIVE CLOTHING. 20

22 Slowly lower the topper to the ground. Carefully remove the mounting frame, pins and driveline from the frame and lay to these to one side. Using suitable lifting equipment place the topper on secure blocks and attach the side skids securely at the required cutting height using the bolts provided. Remove the bung on the side of the gearbox and top breather cap. Pour in the correct oil as specified until it reaches the lower level of the side bung hole. When this occurs, replace bung and top breather cap. Remove the split pins from the P.T.O. guard supports on either side of the gearbox. Place the P.T.O. guard in position and re-insert the supports through the holes provided at the bottom of the P.T.O. guard. Re-insert the split pins. Install the PTO driveline Remove the bolts from the input yoke. Attach driveline to yoke. Tighten mounting bolts to their specified torque. Attach 3 point hitch A frame to the front of the machine. Be sure to position 3 point mounting pin to the front. The topper is now ready to attach to your tractor. 2.6 Mechanical CHAPTER 11 MODEL TP110 TP140 TP160 Dimensions (L x W x H) mm 1100 x 1100 x x 1400 x x 1600 x 900 Weight (Kg) Cutting Width (mm) Cutting Height (mm) 50 to to to 200 Input Turning Speed (RPM) Power Required (HP) 16~30 20~35 25~40 21

23 KAFURTER TOPPER MOWER - EXPLODED VIEW Ser.N o Part No SL GB GB93-87 Topping Mower Assembly Name Quantity Specification Pin Plain washier spring washier GB Hex.nut M Circle Steel 1 6 SL Mounting bracket 1 Remarks 23

24 for front supporting 7 Link 3 8 GB Screw M16?0 5 9 GB Plain washier GB Lock nut M SL Blade 2 12 SL Screw 2 13 GB Plain washier GB93-87 spring washier GB Hex.nut M SL Supporting board 1 for Blade 17 Litter R pin 1 18 SL Blade seat 1 19 GB Hex.nut M GB Plain washier SL Adjusting Board 2 22 GB93-87 spring washier18 4 Bigger 23 SL Protecting plate 1 24 GB70-85 Screw M10? GB Hex.nut M GB Screw M18? GB Hex.nut M GB Plain washier GB Pin4 x GB93-87 Plain washier8 4 GB Plain washier GB Screw M8? SL Gearing Box 1 33 SL Gearing Box 1 Cover 34 GB Screw M16? SL Front supporting 1 36 Link Lock 2 38 SL Deck 1 24

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