OPERATOR'S MANUAL REAR ARM-TYPE MOWER

Transcription

1 SaMASZ Sp. z o.o. Poland, Białystok, ul. Trawiasta 15 Established 1984 NIP tel. (+48) (85) fax (+48) (85) samasz@samasz.pl OPERATOR'S MANUAL REAR ARM-TYPE MOWER KWT 550 (E, EP) KWT 650 (E, EP) KWT 651 (E,EP) MOWING ADAPTERS CAMEL 900 (EP) KOLIBER 400 (E, EP) KOLIBER 450 (E, EP) KW 110 LAMA 101 P KW 111 LAMA 120 P KW 125 LAMA 120 KW 126 LAMA 140 KW 140 LAMA 121 KW 141 LAMA 141 LAMA 121 HD Serial no. Original manual IN347EN EDITION NO. 11

2 DO NOT TURN THE DRIVE ON IF THE MOWER IS NOT IN ITS WORKING POSITION DO NOT OPERATE THE MOWER WITH UNAUTHORIZED PERSONNEL PRESENT WITHIN 50 M OR LESS WARNING: Keep this manual for future use. We congratulate you on the purchase of your new SaMASZ machine and wish you much pleasure and the very best experience resulting from its operation. We congratulate you on the purchase of your new SaMASZ tedder and wish you much pleasure and the very best work results through the years to come. Updated by: Bartłomiej Jaworski Łukasz Pietrewicz Marta Zalesko

3 Table of contents page 1. IDENTIFYING THE MACHINE INTRODUCTION PROPER USE Technical data Design and working principle Mounting flail heads Lama 121 and Lama Characteristics of hydraulics of arm Standard equipment and spare parts Flails applied in mowing heads SAFETY ADVICE Safety rules and regulations Conditions of mounting machine on tractor Transport Putting the machine onto another vehicle for transport Working parts PTO shaft Hydraulic assembly Residual risk Residual risk assessment Operator's qualifications OHP recommendations during operation - remarks for operator Safety decals and their meaning OPERATION Attaching the arm to the tractor Preparing machine for transport Mounting PTO shaft Switching the machine from transport to working position Operation Operating control panel Basic information on mowing MOUNTING AND ADJUSTMENTS Mounting and dismounting flail head Mounting flail heads Adjusting flail head mowing height Replacing knives in mowing adapter Operating hydraulics Oil tank with equipment Oil shut-off valve Multiplier with pump set Suction filter CCA 302 CD Control distributors Initial regulations Safety valves Hydraulic engine Operating service Daily maintenance After-season maintenance Dismounting machine from tractor Storing LUBRICATING DEFECTS AND THEIR REPAIRS REPAIR AND WITHDRAWAL FROM USE ELECTRIC DIAGRAMS WARRANTY CARD WARRANTY TERMS Warranty claim procedure Warranty repairs record

4 1. IDENTIFYING THE MACHINE Data plate is attached firmly on both long boom and flail head and placed as provided on Fig. 1, Fig. 2 and Fig. 3. Fig. 1. Data plate placement on arm KWT 550/650 Fig. 2. Data plate placement on arm KOLIBER 400 Fig. 3. Data plate placement on flail head Data plate includes: - name of the manufacturer, - weight, - machine serial number, - quality management sign, - machine symbol, - CE marking means that the machine is conform with - date of manufacture, Directive 2006/42/EC and harmonized standards. - version number, - MADE IN POLAND sign. - barcode, In case the operator's manual is unclear or illegible all necessary information can be obtained from manufacturer or the dealer

5 2. INTRODUCTION This operator's manual should be considered as the machine basic equipment. If the mower is handed over to another operator, it should be in working condition, along with operator's manual, EC declaration of conformity and its basic equipment. Prior to operating the machine its user must familiarize himself with this manual as well as common work safety rules. The machine is manufactured in accordance with requirements of safety standards. Respecting recommendations herein shall ensure operation safety. If you have any questions related to commission and operation of the machine, please contact the manufacturer. This operator s manual is an indispensable part of any machine and is intended to familiarize a machine user with principles of proper operation and use of the machine as well as the risks involved. GENERAL PRECAUTION When operating the machine warnings and safety rules marked with this sign herein should be respected. Operating the machine without previous familiarizing with its content as well as by unauthorized personnel, and especially by children, is strictly forbidden. 3. PROPER USE with flail head is set on tractors with power of min (Tab. 1) Mounting the arm is performed on rear 3-point linkage, with which are farming tractors equipped as standard. Rear PTO must be set on 540 rpm (upon special order 1000 rpm). Machine are designed for treatment of land drainage ditches in particular as well as mowing of road shoulders, shredding thinner trunks (Tab. 2), small shrubs, weeds, etc. of moderate concentration as well as mowing road shoulders, slopes, counter-slopes and ground at tractor's right side. Moreover the mower can be used to trim hedges both in vertical and in horizontal position. The arm can be additionally equipped with adapters offered by the SaMASZ co. s work properly on grass (and other plants) with height up to 1.0 m. Heads are designed for shredding cut tree branches, mowing weeds, shrubs and grass. Basing on experience, upon driving onto single shrub with section up to approx. 2 cm, the tractor should be stopped for a while, until the machine shreds the shrub at the ground, and then slowly with intervals drive forward, so there occurs no cutterbar locking. Use of the machine for purposes other than mentioned herein is forbidden. Different use than the above mentioned shall be considered as improper and may lead to revoking of the warranty. The machine should be operated, maintained and repaired only by personnel familiarized with its detailed specifications and safety rules and procedures. Willful modifications to the machine may lead to revoking of the warranty

6 3.1. Technical data SaMASZ manufactured extension arms are adjusted to operate with numerous flail heads and feature the following parameters (Tab. 1, Tab.2, Tab. 3, Tab. 4): Tab. 1. Technical characteristics of extension arms type (without flail head) KWT 550 KWT 650 KWT 651 Extension arm operating reach [m] Min. tractor weight with heads KW 125, KW 126, KW 140, KW 141, LAMA 140, LAMA 141 [kg] Min. tractor weight with heads KW 110, KW 111, LAMA 120 (P), LAMA 121 [kg] point linkage category Cat. II PTO rpm [rpm] 540 standard / upon special order Min. tire load capacity index 140 A8 Transport diameters height width length [m] 3.50x1.95x0.95 Minimal tractor power [HP] from 80 from 90 Drive and control hydraulic hydraulic electric Weight [kg] Oil level (l) Pump output [kw] 33 (180 bar) / 38 (210 bar) Pump capacity [l/min.] 90 type (without flail head) KOLIBER 400 KOLIBER 450 CAMEL 900 Extension arm operating reach [m] Min. tractor weight with heads LAMA 120 i LAMA 121 [kg] point linkage category II PTO rpm [rpm] 540 standard / upon special order Min. tire load capacity index 125 A8 125 A8 173 A8 Transport diameters height width length [m] 2.65x1.75x x1.85x x1.9x1.2 Minimal tractor power [HP] from 55 from 55 from 120 Drive and control hydraulic Weight [kg] Oil level (l) Pump output [kw] 33 (180 bar) / 38 (210 bar) Pump capacity [l/min.]

7 Tab. 2. Technical data for flail heads KW type KW 110 KW 111 KW 125 KW 126 KW 140 KW 141 Operating width [m] 1,10 1,10 1,25 1,25 1,40 1,40 Number of knives [pcs] Max. diameter of shredded shoots [cm] Required pump delivery rate [L/min] Hydraulic pressure [bar] 210 PTO rpm [rears/min] 540 Drive and control hydraulic Weight [kg] Tab. 3. Technical data for flail heads LAMA type LAMA LAMA LAMA LAMA LAMA LAMA LAMA 101 P P HD Operating width [m] 1,0 1,20 1,20 1,40 1,20 1,40 1,20 Number of knives [pcs] Max. diameter of shredded shoots [cm] ,5 3,5 3,5 Required pump delivery rate [L/min] Hydraulic pressure [bar] 210 PTO rpm [rears/min] 540 Drive and control hydraulic Weight [kg] Summary and scheme of operating reach of each extension arm with flail heads along with marking are provided in Tab. 4, Fig. 4 and on Fig

8 Tab. 4. Operating reach of extension arm with flail head Operating reach of extension arm with flail head [cm] A B C D E F G KWT 550 / KW KWT 550 / KW KWT 550 / KW KWT 550 / KW KWT 550 / KW KWT 550 / KW KWT 550 / Lama KWT 550 / Lama KWT 550 / Lama KWT 550 / Lama KWT 550 / Lama 120 P KWT 550 / Lama 101 P KWT 550 / Lama 121 HD KWT 650 / KW KWT 650 / KW KWT 650 / KW KWT 650 / KW KWT 650 / KW KWT 650 / KW KWT 650 / Lama KWT 650 / Lama KWT 650 / Lama KWT 650 / Lama KWT 650 / Lama 120 P KWT 650 / Lama 101 P KWT 650 / Lama 121 HD KWT 651 / KW KWT 651 / KW KWT 651 / KW KWT 651 / KW KWT 651 / KW KWT 651 / KW KWT 651 / Lama KWT 651 / Lama KWT 651 / Lama KWT 651 / Lama KWT 651 / Lama 101 P KOLIBER 400 / LAMA KOLIBER 400 / LAMA KOLIBER 450 / LAMA KOLIBER 450 / LAMA CAMEL 900 / LAMA

9 G 45 Fig. 4. Scheme of operating reach of extension arm with flail head with marking type: KWT 550/650, KWT 651 and CAMEL

10 Fig. 5. Scheme of operating reach of extension arm with flail head with marking type: KOLIBER

11 Fig. 6. Operating reach of extension arm KWT 651 E and KWT 651 EP with flail head 3.2. Design and working principle Extension arm comprises basic assemblies shown in Fig. 7 Fig Lifting and lowering cylinder 2- Lifting and lowering cylinder 3- Long boom 4- Head cylinder 5- Mounting eye 6-7- Rotor 8- Support leg 9- Hydraulics with oil tank 10- Multiplier 11- Linkage 12- Telescopic arm 13- Telescope s cylinder 14- Gauge plate cylinder 15- Control panel 16- Joystick 17- Closed housing - 9 -

12 Fig. 7. Overview of Koliber extension arm Fig. 8. Overview of CAMEL extension arm

13 Fig. 9. Overview of KWT 550 extension arm Fig. 10. Overview of KWT 650 extension arm

14 Fig. 11. Overview of KWT 651 extension arm Extension arm is equipped with independent hydraulics with oil cooler and oil tank (9). Rotor s drive and arm control is possible owing to own hydraulic pumps assembly driven by multiplier (10), transmitter s shaft without coupling and tractor s PTO. Controlling extension of telescopic arm is done directly from the tractor's hydraulics (KWT 650, Camel 900 with mechanical control) by means of telescope actuator (13), and arms are moved with hydraulic actuators (1 and 2). Controlling operation of extension arms is performed from tractor s cabin with use of control panel (15), equipped with a cylinder control handle and a joystick (1, 2, 4 and 14). With use of corresponding handles, the operator can set position of machine s movable assemblies. Tractor drives along road s edge while flail head mows grass. Use of cylinder (14) controlled rotor (7) enables arm to be set in transport position. Working arms are protected against overloads by gauge plate cylinder (14) equipped with sweep valve (item 6.4.7). While head s cylinder (4) acts as head s rotation (6). Extension of telescopic arm causes shifting of centre of gravity of the set (tractor, machine) what may cause alternation of its stability. It is recommended to extend the arm just above the ground

15 a) b) c) d) Fig. 12. Machine's control panel with option: a) mechanical (KWT 550/560, CAMEL 900, KOLIBER 400/450), b) electrical (KOLIBER 400E/450E), c) electrical (KWT 550 E, KWT 650 E, KWT 651 E, KOLIBER 400EP/450EP), d) electrical proportional (KWT 550 EP, KWT 650 EP, KWT 651 EP, CAMEL 900 EP),

16 Fig. 13. Hydraulics with oil tank and KWT mower radiator Fig. 14. Multipliers with hydraulic pumps Fig. 15. Machine suspension: 18 - Protective and tensioning strands, 19 - Mounting points on tractor's 3-point linkage All flail heads (KW, Lama) adjusted to operate with extension arms have similar construction. Construction scheme of flail head is provided on Fig

17 Operating assembly of extension arm is a flail head (6), which comprises flail bar (20) with flail knives (21) for different purposes (item 6.4), screwed with mounting bolts (knife type depends of kind of surface mowed (grass, bushes, hay, cornstalks). Flail shaft (20) of flail head is driven by hydraulic engine (23). Ground following bar (22) features mowing height adjustment function (item 6.3). It is protected with metal sheet guards from each side. Cutterbar can be rotated in relation to linkage axis by approx Flail bar 21. Flail knives 22. Ground following bar Fig. 16. Overview of flail head 23. Hydraulic pumps' engine 24. Engine guard 25. Housing Lama 121/141 head comprises flail shaft (20) with flail knives (21) of different application (Section 6.4) mounted with mounting screws (knife type depending on type of material cut: grass, shrubs, straw, corn stalks). Flail shaft (20) of mowing head is driven by hydraulic motor (23) through belt gear (24) with v-belt. Ground following roller (22) has mowing height adjustment function Fig. 17. Overview of flail head Lama Flail bar 21. Flail knives 22. Ground following bar 23. Hydraulic pumps' engine 24. Belt gear 25. Housing

18 Lama 120P mowing head with ejection comprises flail shaft (20) with flail knives (21) mounted with mounting screws. Alike KW and Lama heads, the flail shaft (20) of mowing head is driven by hydraulic motor (23). Ground following shaft (22) has mowing height adjustment function (Section 6.3). Ejector (19) comprises a fixed and a movable part, and the latter is controlled with hydraulic motor driven directly from the tractor's hydraulics Fig. 18. Overview of mowing head with ejection 19. Ejector 20. Flail bar 21. Flail knives 22. Ground following bar 23. Hydraulic pumps' engine KW 141 mowing head consists of flail shaft (20) with flail knives (21) dedicated for various purposes (flail type depends on the type of cut material: grass, bushes, straw, corn stalks). Maschine is equipped with adjustable counter-knife (25). Flail shaft is powered by hydro-motor (23) and power is transferred through speed-belt gear (24). Slide bar is a part of the machine and the plate mount (27) can be easily adjusted. Ground shaft (22) has a cutting height adjustment function Fig. 19. Overview of flail head KW Flail bar 21. Flail knives 22. Ground following bar 23. Hydraulic pumps' engine 24. Belt gear 25. Counter-knife 26. Slide bar 27. Plate mount

19 Mounting flail heads Lama 121 and Lama 141 Lama 121/141 heads are attached to an extension arm with a standard single or 4 optional types of fittings available, which enable different manners of mounting the head (Fig. 20). Fittings are of the following types: 1. The basic is a rigid fitting, simple and light, attached to an extension arm with 6 screws M14 (SaMASZ-standard). 2. Swivel fitting, mounted with 6 screws M14 (SaMASZ-standard) to an extension arm, enables the head to be swiveled every 15 in 4 positions. 3. Swivel push-in fitting, enabling quick coupling/releasing of the head to/from the arm and allowing the head to be swiveled every 15 in 4 positions. 4. Mounting for ground-following linkage, connected to extension arm with 6 bolts M Mowing head ground-following linkage. Extension for mechanical ground following with 260mm travel. Mounted on extension arm with 6 bolts M14 (SaMASZ standard) Fig. 20. Types of head mountings: Lama 121/ Fixed mounting, 2 Rotary mounting, 3 Hydraulic turntable, 4 Mounting ground following linkage, 5 Mowing head groundfollowing linkage

20 3.3. Characteristics of hydraulics of arm (Subject: KWT 550/650/651, Camel 900, Koliber 400/450) Geared pumps power two independent circuits: machine's drive circuit with capacity of 50 l/min and hydraulic cylinders' drive circuit with capacity of 11 l/min. In machine's drive circuits wires have 16 mm diameter, while in cylinders' control circuit 10 mm. Control of oil circulation is possible owing to hydraulic distributors (3, 6). Oil tank (4) of adequate capacity. In arm-type mower's hydraulic engine's drive circuit there is suction oil filter (5) with capacity of 70 l/min. On gauge plate cylinder (8) there is sweep valve (7) mounted to protect the machine's arms from getting overloaded (Fig. 21) applies only to KWT 550, KWT 650 and Camel 900. Koliber 400 and Koliber 450 instead of gauge plate cylinder (8) both have overload breaker. Hydraulic cylinders (8-11) with throttle choke valves (12) control the arm Fig type mower's hydraulic drive diagram 1. Hydraulic pumps 2. Hydraulic pumps' engine 3. Four-section distributor 4. Oil tank 5. Suction filter 6. Single-section distributor 7. Sweep valve 8. Gauge plate cylinder 9. External arm cylinder 10. Internal arm cylinder 11. Cutterbar cylinder 12. Throttle check valve 13. Cooler

21 (Subject: KWT 650 E/EP, Camel 900 and Camel 900 EP) Geared pumps power two independent circuits: machine's drive circuit with capacity of 50 l/min and hydraulic cylinders' drive circuit with capacity of 11 l/min (22 l/min. - EP). In machine's drive circuits wires have 16 mm diameter, while in cylinders' control circuit 10 mm. Control of oil circulation is possible owing to hydraulic distributors (3, 6). Oil tank (4) of adequate capacity. In arm-type mower's hydraulic engine's drive circuit there is suction oil filter (5) with capacity of 70 l/min. On gauge plate cylinder (8) there is sweep valve (7) mounted to protect the mower's arms from overloading (Fig. 22) Hydraulic cylinders (9-12) with throttle choke valves (13) control the arm Fig. 22. Diagram of proportional hydraulic drive of the arm 1. Hydraulic pumps 2. Hydraulic pump engine 3. 5-section divider 4. Oil tank 5. Suction filter 6. Single-section distributor 7. Sweep valve 8. Gauge plate cylinder 9. Hydraulic cylinder of cutting unit 10. Hydraulic cylinder of arm extension 11. External arm cylinder 12. Internal arm cylinder 13. Throttle check valve 14. Cooler

22 3.4. Standard equipment and spare parts Machine are sold with the following standard equipment: warranty card, operator's manual with spare part list, control panel, extra cutting knives 2 pcs, PTO shaft, warning plate with combined lights and reflectors, warning triangle, plate C-10 Drive at the left of the sign, spray paint (150 ml). Tab. 5. Recommended PTO shaft for mounting the machine to a tractor type Power Length Moment Symbol Clutch Manufacturer Remarks HP mm Nm KWT CAMEL KOLIBER G3N066CE007007MA Bondioli & Pavesi Shaft end without clutch Connect from tractor s side 50h Shaft end without clutch Connect from mower s side 50h 50h Fig. 23. PTO shaft lubrication. Mounting directions PTO shaft lubrication frequency must be respected. Points shown on Fig. 23 shall be lubricated every 50 hours. PTO shaft shall also be lubricated prior to and after period of longer idleness. PTO shafts of other brands with equivalent technical parameters may be used on the SaMASZ permission Flails applied in mowing heads In order to ensure proper operation of mowing head, if excessively worn flails should be replaced. Relevant reference for flail could be found in mower parts catalogue. The table below shows knives that can be mounted in SaMASZ mowers. Flail knives LAMA KW KNIFE TYPE I Application: grass, shrub, stalks, remnants after trimming, stubbles Standard

23 Flail knives LAMA KW KNIFE TYPE III Application: grass, shoots, stalks, shrubs, remnants after trimming, hay Option KNIFE TYPE IV Application: grass, shoots, stalks, shrubs, remnants after trimming, hay Option KNIFE TYPE V Application: Grass, stubbles, branches, shrubs R=105 Standard in LAMA 121 HD mowing head Standard in KW 111, KW 126, KW 141 mowing head 100 KNIFE TYPE VI Application: grass, shrub, stalks, remnants after trimming, stubbles Option in KW 111, KW 126, KW 141 mowing head KNIFE TYPE VII Application: grass, plant stalks Standard KNIFE TYPE VIII Application: grass, plant stalks, bushes, shoots, smaller branches Option KNIFE TYPE IX Application: grass, plants stalks, smaller bushes, branches Option

24 4. SAFETY ADVICE 4.1. Safety rules and regulations Front axis of the tractor should be well weighted to keep the balance. If need be, use front wheel weights. Any operation with the hydraulic lift lever should be conducted from the operator's seat; DO NOT move the lever from outside of the tractor. In case of tractors equipped with EHR, controlling with hydraulic lift is conducted with a button located outside the tractor's cabin. When operating, please be extremely careful. Use PTO shaft with CE marking. Operating without safety guards is not permitted. Neither operation with damaged or raised guard is permitted (danger of stones, etc. being thrown out). Start mowing only when the tractor PTO reaches its nominal 540 rpm value. DO NOT exceed 600 PTO rpm. No unauthorized personnel is allowed to remain within the danger area of at least 50 m. Keep particular caution when operating near roads and in stony areas. Any maintenance and adjustment work is allowed only with the drive disconnected. Flail knife mounting should be checked regularly. Damaged or worn knives must be replaced in pairs. When driving on public roads always respect the local traffic regulations concerning warning lights. Any service and repair operations must be conducted with the tractor drive disconnected, cutterbar on the ground and all rotating parts in the complete standstill. Keep the children away from the mower both in operation and standstill. When the machine is lifted for repair on the 3-point linkage, it should be secured against falling by a mechanical support or by chain. When operating the machine, the tractor should always be equipped with the cabin. The machine shall never be started when it is lifted. The machine shall never be started, with people or animals near the machine. The safety guard shall never be lifted before the rotating drums are in complete standstill. Tractor engine must be stopped. Always comply with safety decals describing hazards, and warning signs placed on the machine. Before the tractor is started make sure that every drive is disconnected while the hydraulics control levers are in neutral position. The tractor engine shall never be left running without supervision. Before leaving the tractor, the engine shall be disconnected and the key put off from the tractor ignition switch. Driving the machine backwards when operating is forbidden. In any case never get onto the machine. When operating and transport drive permissible slope shall be 8. Never stand between the tractor and the machine, before tractor-mower set is secured against moving by means of the tractor parking brake. Any maintenance checkups and regulations may be conducted only when the machine is disassembled and on the ground,

25 If any part of the machine needs to be replaced, use only genuine spare parts according to spare part list. Pay particular attention to PTO shaft guards and machine and tractor spline shaft guards. Never operate with damaged guards. The machine should be stored under roof and in manner preventing animals and people to be injured. Attachment and detachment of mower from tractor should be performed on even and paved surface while keeping particular attention. Prior to moving make sure whether directly nearby the machine there are no unauthorized personnel, give acoustic signal. Unauthorized personnel should be present in safe distance from the machine, that is at least 50 m along the machine's working line. The most particular attention should be paid when operating in stony area, at trunk shredding as well as operating on road shoulders (danger of throwing hard objects out). During operation the machine's knives should not touch the ground. During each break-time the drive should be disconnected and the cutterbar lowered onto the ground. It is recommended to avoid lifting the head by means of extension arms with drive operating and flail shaft rotating. The bolts and other fasteners should be checked regularly. Operating with damaged or worn fasteners is not permitted. Do not operate the machine after dusk. Do not leave the machine on slopes without any protection. During operation do not lift, take out, put on guards or other protection. When operating the machine, please comply with the Resolution of the Minister of Agriculture and Food Economy of on work safety when operating tractors, machines, technical instruments and devices used in farming Dz. U. nr 12/98 poz. 51. The operator is not allowed to leave the tractor while driving. In the event of any break in the equipment operation, turn off the drive. In case of a fatal failure, stop the machine's drive, turn the tractor's engine off and take out the ignition key. Then call for technical service, and if an accident (in this case: road accident) occurs, respect first aid rules and contact responsible authorities Conditions of mounting machine on tractor Before attachment, be sure that the tractor and machine hitches are compatible and that the tractor's hitch load capacity is adequate for the machine which is to be mounted or attached. Before mounting the machine, examine the technical condition of the machine's hitch assembly and tractor's 3-point linkage. Use only genuine cotter pins to mount the machine on a tractor Transport Any change in the machine's position are only possible when no unauthorized personnel is around (children in particular). When transported the machine should always be set in transport position. (see chapter 5.2). Prior to putting the machine to transport position make sure, that the tractor PTO is disconnected and all the rotating parts in complete standstill. Always adjust your driving speed to the current road conditions and according to local traffic rules. Permissible speed of 25 km/h cannot be exceeded. Allow no person and object to remain on the machine when driving or transporting. When taking turns pay particular attention and consider the machine's weight and dimensions

26 Putting the machine onto another vehicle for transport Both the carrier and the driver shall be responsible for the machine transport safety. Any equipment and parts must be properly secured for transport. To put the machine onto another vehicle safely, please follow these rules: it is recommended to transport extension arms using a forklift truck (Fig. 24), the machine should be seized by any lifting device only in places indicated on the machine by the catch sign (Fig. 24), for lifting the machine, lifting devices with hoisting capacity bigger than the machine weight shown in data plate should only be used. It also concerns ropes and chains used for lifting, transport belts, belt suspensions, ropes cannot be damaged. Whenever damages to these parts are spotted replace these with new ones, when mounting slings, chains, handles etc. always pay attention to setting the machine's center of gravity properly, to catch machines, pick ropes of adequate length, so that the angle between them is no greater than 120, and the angle between the strand and the vertical is no greater than 60 collapsible elements should be locked in transport position, when putting the machine onto another vehicle, no unauthorized personnel shall be permitted to remain within the danger area, the machine on the vehicle trailer should be protected from shifting. Fig. 24. Manner of loading extension arms Securing both the danger area and activity performed shall lie under the responsibility of the person in charge of the machine transporting

27 Tab. 6. Location of centre of gravity for flail heads Dimension [mm] Fig. 25. Location of centre of gravity for flail heads Type KW 110 KW 111 KW 125 KW 126 KW 140 KW 141 A B C Type Dimension LAMA LAMA LAMA LAMA LAMA LAMA LAMA [mm] 101 P P HD A B C Working parts Prior to operating the machine check flail knives condition. Worn or damaged knives should be replaced immediately with new ones PTO shaft Before operating learn provisions found in bar manufacturer's manual placed on the bar. PTO shafts recommended by the machine's manufacturer shall only be used. In order to operate safely use only fully technically fit, undamaged PTO shafts. Damaged PTO shaft shall be repaired or replaced with new one Hydraulic assembly Elastic hydraulic hoses should be checked regularly and if any damage occurs or they expire, replace with new ones. Replaced hoses must conform with the manufacturer's technical requirements. Prior to performing service works at hydraulics the tractor's engine should be stopped and ignition key taken out. It is not acceptable to adjust sweep valves on factory set distributors. Do not drain oil onto the ground, to the sewage system, into rivers or lakes. Only tight tanks should be used for temporal storing of used oils. Used oils contain substances harmful for the natural environment and should be delivered to a proper used oil treatment plant

28 Thermostat turns ventilator for cooling oils for temperature over 65ºC on, if oil is heated up to approx. 90º interrupt work and find cause of high temperature. Scotch tape shall never be used to repair damaged hydraulic hoses. When connecting hydraulic hoses to tractor hydraulic connectors make sure, that either tractor or machine hydraulics are pressure free. When operating hydraulic unit, always wear protective gloves and eyewear. Leaking hydraulic oil under pressure (16 MPa) may permeate through the skin and cause an infection. If experienced, immediately visit a doctor. Caution! Hydraulic assembly is under pressure! Hydraulic oil under pressure may permeate through skin and cause serious injury, therefore skin and eyes should be protected in particular. In case of injuries caused by a liquid under pressure, call a doctor immediately. Hydraulic hoses can be connected to tractor's hydraulics, provided that both the tractor s and the mower's hydraulic assemblies are not under pressure. To remove the pressure from the hoses just simply restart the tractor's hydraulic valves several times, once the tractor is off. When controlling for hydraulic assembly's malfunction and looking for oil leaks, it is forbidden to touch any potential leaks until the entire assembly is under pressure. Note! It is recommended to use hydraulic oil featuring oil purity class 9-10 in accordance with NAS When using hydraulic hoses: Avoid stretching the hoses when operating. Do not allow hydraulic hoses to get deflected. Do not expose hydraulic hoses to contact with any sharp edges. If damaged or worn, replace the hoses with new ones. Useful life for hydraulic hoses is 5 years from their production date Residual risk Despite the fact, that SaMASZ Białystok company the manufacturer of the machine takes the responsibility for the machine design and manufacturing, in order to eliminate hazard, certain risk when operating the machine is unavoidable. Major source of risk follows performance of these operations: operation of machine by minors as well as not being familiarized with operator's manual, operation of machine by persons under influence of alcohol or other abusive substances, not keeping caution while transportation and shifting of machine during operation, presence of persons and animals within the machine operation range, performing operations related to servicing and adjustment with engine on. 1. Danger of catching This kind of risk occurs when the machine position is changed, when operating near rotating parts, operating without safety guards. When operating, maintenance and regulation works are conducted protective gloves, footwear and clothing with no loose parts, belts, etc. shall always be worn. Always comply with safety decals placed on the machine. 2. Danger of wound This kind of risk occurs when working parts with sharp edges are replaced. At any repair and maintenance work safety gloves shall always be worn. 3. Danger of liquid ejection out of hydraulics When connecting hydraulic hoses to and from the tractor hydraulic connectors make sure, that either tractor or mower hydraulics are pressure free. When operating hydraulic unit, always wear protective gloves and eyewear. Check the hydraulics hoses regularly. Residual risk results from incorrect behavior of the machine operator

29 4. Bans The following bans should be borne in mind when operating the machine: do clean impurities, make any adjustments or repairs when the machine is in operating mode, never change the sequence of operation and maintenance works specified in the operator's manual, never operate the machine when it is not in working condition or has safety guards damaged, never get your limbs close to rotating parts of the machine, during the machine repair and maintenance works always comply with the descriptions included in the operator's manual, while conducting them with the tractor drive disconnected, prior to approaching any activities, focus your attention on the tasks to do, never operate the machine being under the influence of alcohol, drugs, or strong medicines, your wear should not be too loose, nor too tight. Too loose clothing elements may be pulled in by the machine rotating parts, the machine cannot be operated by children nor handicapped people When describing residual risk, the arm shall be considered a machine, which until the moment of production launching had been designed and manufactured in accordance to top actual technology level until the day of the machine manufacture. There is possibility of residual risk if not complying with specified instructions and bans Residual risk assessment When keeping such recommendations as: thorough familiarizing with operator s manual, no persons remaining within the machine operation range, adjustment, maintenance and lubrication of the machine with engine off, performing repairs of the machine only by skilled persons, operation of the machine by persons, which are familiarized with operator s manual, in the event of the machine protection against children and unauthorized personnel residual risk when operating the mower may be limited to necessary minimum. When the risk of exposing to noise cannot be avoided or eliminated by any group protective means or organization of work, employer (farmer) must: 1) provide the operator with individual means of noise protection, if the noise level in work place exceeds 80 db. 2) provide the operator with individual means of noise protection and supervise the correctness of its use, if the noise level in work place reaches or exceeds 85 db Operator's qualifications To provide safe machine operation each person being the machine operator must meet the following requirements: Operator should hold driving license, have ability to drive vehicles safely and know road traffic rules. Operator must be in proper physical condition to be able to operate the machine. Operator must not be under the influence of alcohol, drugs and medicines, which all have influence on vehicle driving and machine operation. Operator should be familiarized with this manual and follow its provisions. Operator should be familiar with working principles of both the tractor and the machine, and be able to recognize and avoid hazards resulting from operation of the aggregate

30 4.9. OHP recommendations during operation - remarks for operator If You wish to operate on full reach make sure, whether the tractor's static allows this. Driver Your safety depends of Your imagination and following the rules. The SaMASZ company has not conducted any tests on static. Therefore the user should pay special attention and be careful and potentially following his own efforts determine a slope parameter which allows for proper set operation. Operation at slope greater than 8 o may lead the set to fall and therefore put health and life of the operator in danger. When the set comprising the tractor and the machine is tilted too much immediately lower the machine onto the ground and stop the tractor. Further drive is possible only after reducing the arm length or alteration of follow path. The above recommendations are general. The manufacturer does not bear any responsibility for the operator's safety during operation. Any service and repair operations should be conducted with the tractor drive disconnected, ignition key out and all rotating parts in the complete standstill Safety decals and their meaning a) all warning decals (labels) should be clean and legible, b) lost or damaged decals (labels) must be replaced, c) new decals (labels) may be ordered at the manufacturer. N-01 N-02 N-3 N-4 Caution: flail knives! Do not get near operating machine Be extremely careful when PTO shaft is rotating Prior to the machine operation read the operator's manual carefully Prior to approaching any maintenance or repair works, the machine shall be disconnected

31 N-06 N-07 N-09 N-11 Caution: pulling-in parts Keep away from the machine for a safe distance Caution: rotor Lubrication points N-23 N-28 N-29 N-40 Pay attention to powerlines On special order Transport holder for moving the machine N-49 N-50 N-52 N-55 Never get near the tractor 3-point linkage when controlling the lift Do not get near the machine s swinging area Wear protective gloves N-106 N-117 N-134 N-167 Avoid fluid escaping under pressure Caution: pulling-in parts Do not remain on the machine while driving N-169 N-170 N-171 P-2 Concerns models: KWT and CAMEL Concerns models: KWT E/EP, CAMEL EP, KOLIBER E/EP Concerns models: KWT E/EP, CAMEL EP, KOLIBER EP

32 Any assembly used for the machine repair should hold all warning decals provided by the manufacturer. N-134 N-11 N-40 P-2 N-171 N-03 N-04 N-117 N-167 N-01 ; N-02 N-03 ; N-04 N-06 ; N-07 N-09 ; N-52 N-106 N-11 N-169 N-170 N-01 ; N-07 N-28 N-40 N-11 N-23 ; N-49 N-29 N-52 Fig. 26. Placement of warning signs on extension arm with mowing head

33 5. OPERATION During storing of the machines in company SaMASZ the cylinders are protected by special grease in order to secure them against weather which may cause their premature wear. Before starting the operation excess grease should be removed from the cylinders Attaching the arm to the tractor Extension arm should be mounted on tractor with use of rear 3-point linkage, as provided on Fig. 27. Upon complete mounting of arm adjust machine s alignment on even ground with use of upper link (40) so that the machine is set horizontally in relation to the ground. Tensioning strands (41) must be tensioned and set on the same level. Their use ensures a stable position of the tractormachine set. The strands are not intended to protect the machine against falling. When using extension arm, hydraulic actuator should be locked. Strands (41) should be attached to the tractor depending on the design of hitches on the tractor. Do not adjust the tractor's lower strands (lifting/lowering) once the set is stabilised using the tensioning strands. Otherwise both the machine and the tractor could be damaged! Preparing machine for transport Fig. 27. Machine lifted onto rear tractor's 3-point linkage Control panel should be installed in tractor s cabin. Tractor operating on public road should be equipped with yellow flashing light and warning triangle (Fig. 28). For transport set the arm KWT 651 with working head as farthest behind the tractor as possible (Fig. 28)

34 max. 4 m max. 4 m a) b) Fig. 28. in transport position. Placing warning plate and lights on the machine The arm is connected to tractors on rear 3-point linkage. Machine driving on public road must be in transport position (Fig. 28) and hold proper marking. Transport position is when flail head is set nearest possible to tractor s axis (width is minimal). Inner extension arm (cylinder 2) is protected against hydraulics failure with special rupture valve (Fig. 29) (42) and additionally with oil flow regulator (Fig. 29) (43). For transport time cylinder rod should additionally be protected with channel lock. Moreover the tractor must be equipped with warning triangle, as well as yellow flashing light mounted on the cabin's roof (at street side). Warning plate with white and red stripes equipped with a light on right side should also be mounted Fig. 29. Actuator hydraulic lock and choke valve in extension arms KWT 550/650, CAMEL 900, Koliber 400/450 For transportation of outrigger close valve (Z) (Fig. 30) applies to: KWT 550 E, KWT 650 E

35 Z Fig. 30. Safety valve for transportation of outriggers KWT 550E/650E/651E For transport purposes protect outrigger from getting rotated by means of a pin (Fig. 31). Fig. 31. Protecting outrigger from getting rotated Do not drive machine on public roads, if its transport height is more than 4 m (transport height should be lowered with tractor s links when transported). Telescope in telescopic cylinders should be protected against any incidental extension

36 5.3. Mounting PTO shaft The guard should be protected from rotating by securing the shaft small chains to immovable parts of the tractor and the mower. Use machines with PTO shafts designed to drive them. Prior to the work commencement, safety guards should be checked whether they (in the tractor, the machine and the PTO shaft) are placed correctly and not damaged. Damaged or missing parts must be replaced with genuine ones. Make sure whether the PTO shaft is properly mounted. Approaching the rotating parts is strictly forbidden, as it may lead to serious injuries or even death. For any service and repair works of the shaft and the machine, the tractor engine and its drive must be disconnected Prior to the operation commencement, read the operator's manuals of both the machine and the PTO shaft. If need be, shorten the PTO shaft according to its operator's manual given by the shaft s manufacturer (Fig. 32).. Fig. 32. Instruction of PTO shaft shortening 5.4. Switching the machine from transport to working position Moving the machine to and from working position from the transport position should only take place on an even and stable ground. Before moving make sure whether there are no unauthorized persons exposed to any hazardous moving parts. Each time before operating, the following shall be examined condition of cutterbar guards, condition of cutting knives and holders (all knives must be of the same type, have the same weight, if need be, knife should be replaced with new one in pairs with the same SaMASZ manufacture weight), condition of bolt connections and pins, condition of hydraulic hoses, oil level in the tank,

37 tightness in hydraulics, rotation ease of flail rotor, warning signs for needs of driving on public road (warning triangle at the tractor's rear, warning plates painted in skew white and red stripes and yellow flashing light), open oil shut-off valve, engage front PTO drive, inserting multiplier with pumps into the drive, set the machine in working position respectively for each location mowed, set the cutterbar freely until adapting bar touches the ground, start the cutterbar until flail shaft reaches its nominal rotary speed, when starting use horn to warn anyone around, engage proper tractor gear and start mowing, in case of telescopic extension arm dismount telescope s locking Operation During operation with arm extended over 4 m from tractor's axis it is forbidden to lift head higher than 0.5 m above the ground. Fig. 33.Mowing of shoulder slopes and land drainage ditches with KWT Fig. 34. Mowing of shoulder slopes KOLIBER 400 Fig. 35. Mowing of shoulder counterslopes and land drainage ditches with KWT

38 Fig. 36. Mowing behind protection barriers with KWT Fig. 37. Mowing behind protection barriers with CAMEL 900 Fig. 38. Working position for KWT 651 When maneuvering the operating head pay attention so as not to hit it against a tractor or the extension arm (Fig. 39). Fig. 39. Risk of head collision with tractor or extension arm

39 Operating control panel Tilting with the machine's arms is performed with use of hydraulic cylinders controlled from control panel located in the tractor's cabin. On the panel there is the machine diagram placed with numbering of each cylinder (Fig. 41) and corresponding control levers. Fig. 40. Cords set-up Minimum bending radius of cords is 20 cm. The cords set with lower radius will break. I. Control panel with mechanical controlling Controlling the machine is performed with use of lever in control panel Fig. 41, marked with corresponding pictograms: a) Lever A adjusting the cutterbar vertically/horizontally with "floating" position cylinder 4 ; b) Lever B adjusting the machine in working/transport position (rotation of arms) cylinder 14 ; c) Joystick C controls the arms cylinder 1 and 2 ; d) Lever D starting/stopping hydraulic engine 23 driving the cutterbar; Lever D features function of sudden rear direction change locking. Lock in position as on Fig. 42a allows right rears to be switched on only. Lock in position as on Fig. 42b is used for turning opposite rears on. Non-shaded pointers Shaded pointers (lever down) turning right rears on, (lever up) position for turning opposite rears on in order to clean the shaft from wound up material

40 A B D C floating left 1 right Lever A Lever B Joystick C Lever D Fig. 41. Control pictograms a) b) Fig. 42. Lock of direction change a) right rears (work), b) left rears Sudden changing direction of rears may lead to damaging hydraulics. Left rears can be turned on as soon as hydraulic engine's rears are completely stopped

41 II. Control panel with electrical controlling Controlling KOLIBER E extension arms and operating head is possible thanks to lever (I) as well as (J) control panel Fig. 43, marked with corresponding labels: E power on/off; F hydraulic engine (22) on/off; - position 0 - turning hydraulic engine off; - position I - turning hydraulic engine on; - position II once switch is in position II hydraulic engine is being turned on and opposite rears are possible to be turned on earlier than during operation by means of switch G ; G hydraulic engine turn on/off rears opposite to operation, used for cleaning the shaft from wound up material. Opposite engine rears can be turned on only upon pushing F to position II ; H - floating function for operating head on/off: ON turning floating function for operating head on, OFF turning floating function for operating head on (controlling operating head by means of cylinder (4) with lever I), I controlling extension arms external cylinder (1) and internal cylinder (2) of the lifting device, J controlling operating head. E F G H I J Fig. 43. Control panel with electrical option (applies to: Koliber 400E/450E)

42 III. Panel with electrical control (semi-proportional) Proportional controlling set for extension arms KWT 550 E, KWT 650, KWT 651E, Koliber 400EP, Koliber 450EP and Camel 900 EP comprises the following elements as provided on Fig. 44: A. Control joystick, B. Control panel, C. Joystick control panel connection pin, D. Executive module control panel connection pin, E. Feeding pin for socket 12 V, F. Executive module. CAUTION! Once PTO shaft is turned off remember to switch control off! A B F E D C Fig. 44. Proportional control system parts Control panel and its functions: Fig. 45. Control panel

43 1. Power switch. Once the feeding is switched off, all diodes one by one light up and go out, and diode (3) starts to blink. 2. Control switch off. To turn control off, hold button (2) for around 2 seconds. Turning control on is signaled by a diode (3), which turns to steady light. 3. Diode signals turning both power and control on. 4. Safety breakaway device. 5. Button for switching to mowing head's right-hand gears and diode signaling turning the head on. To turn the head on, press and hold button (3) for around 2 seconds. In order to turn the head off push button (5) or (6) until the diode goes out. 6. Button for switching to mowing head s left-hand gears and diode signaling turning the head on. Left-hand gears are turned on, whenever wire or flexible, thick branches get wound up onto the flail shaft. Turning left-hand gears on: a) If right-hand turns are engaged, turn them off, release the button and wait for 3 seconds (in this period the buttons are inactive) and then push button (6). In order to turn left-hand gears off hold button (6) or (5) again until the diode above the button goes out. NOTE: Once the head rears are off buttons (5) and (6) become inactive for 3 seconds. 7. Button for turning arm s floating function and diode for signaling the floating function. To turn arm s floating function press button (7). To turn the function off just hold the button (7) again. 8. Diode for signaling turning the mowing head s floating function on. Turning the head s floating function on/off is performed by means of button (3) found on joystick (Fig. 46). 9. Diode signaling if the first arm s unloading function is on. Turning the unloading function on/off is performed by means of joystick s button (4). 10. Diode for signaling, if admissible oil temperature is exceeded. Caution! If oil temperature is exceeded, turn the working head off. If oil temperature does not get lower within 10 minutes, control would be turned off. Control will be turned on again when oil temperature gets lower. Diode for signaling low oil level. 11. Diode for signalling low oil level. Joystick and its functions Fig. 46. Control joystick overview and description of its functions - KWT 550E/650E/651E, Camel 900 E, Koliber EP 1 Button 1 and pictogram 1 to symbolize the button. 2 Button 2 and pictogram 2 to symbolize the button. 3 Button for turning on the head's floating function. Pushing the button turns on the head s floating function, which is signaled with lighting up of diode (8) on control panel (Fig. 45). Pushing button 3 on joystick again turns off the head's floating function. The floating function gets turned off also when the head s rotation is being controlled. 4 Button for turning on the head's unloading function. Pushing the button turns on the first arm s

44 unloading function, which is signaled by lighting up of diode (9) (Fig. 45). Pushing button 4 on joystick again turns off the head's unloading function. Description of decal on manner of controlling arm Joystick s forward motion lowers the first arm. Joystick s motion to the right lifts the second extension arm up. Joystick s motion to the left lowers the second extension arm. Joystick s backwards motion lifts the first arm up. Joystick s button 1 pushed with joystick s forward motion extends telescopic arm (for Camel 900 E and KWT 650 E only). This function enables also moving the second arm forward (applies to KWT 651 E). Joystick s motion to the left with joystick s button 1 pushed rotates head to the left (head s floating function is the turned off). Pushing joystick s button 1 with joystick s backwards motion shortens telescopic arm (for Camel 900 E and KWT 650 E). This function enables also moving the second arm backwards (applies to KWT 651 E). Pushing joystick s button 1 with joystick s motion to the right rotates head to the right ((head s floating function is the turned off). Pushing joystick s button 2 and joystick s forward motion sets extension arm in working position. Pushing joystick s button 2 and joystick s backwards motion sets extension arm in transport position. IV. Control panel with proportional control Proportional control of extension arm is possible using the same control panel as for electrical control (Fig. 45) and joystick (Fig. 47). Controlling is presented in Fig. 48. Fig. 47. Proportional control joystick

45 3 Fig. 48. Proportional control description 6 7 Proportional control description: 1) Moving joystick in directions as marked in Fig. 48 as (1), enables control of the main extension arm. 2) Moving joystick in directions (2), enables control of the other extension arm. 3) Unloading function switch on button. Pushing the button will turn on the first extension arm s unloading function, which is signalled by lighting up of diode (9) (Fig. 45). Pushing the button again (3) (Fig. 48) switches the unloading function off. 4) Head rotation control lever. Moving the slide up/down changes position of the mowing head. 5) turntable control lever. Moving the slide up unfolds extension arm to its working position. Moving the slide down folds the machine to its transport position. 6) Function button (P). Pushing this button and moving the joystick right/left extends/retracts the arm respectively. 7) Button for turning head's floating function on. This function is signalled by lighting up of diode (8) on control panel (Fig. 44). Pushing button (7) on joystick again turns off the head's floating function. The function is turned off as soon as the head s rotation is being controlled

46 Basic information on mowing Basing on long-term experience, in order to ensure the machine damage-free operation, it is recommended to engage a pilot in front of the mower to mark any obstacle. When traversing the road, pedestrian crossing or any other obstacle, the machine must be lifted with use of cylinder 4. Actually, the user must follow the common sense when operating the machine. Therefore, in case of intensive operation, bear in mind expenses on necessary service checkups see Warranty terms. Basing on experience, upon driving onto single shrub with section up to approx. 2 cm, the tractor should be stopped for a while, until the machine shreds the shrub at the ground, and then slowly with intervals drive forward, so there occurs no cutterbar locking. 6. MOUNTING AND ADJUSTMENTS 6.1. Mounting and dismounting flail head Place machine on even ground and disconnect tractor's engine. Mounting flail head on extension arm is performed with use of multi-purpose linkage with mounting catch (5) (Fig. 49). Prepare flail head (6), which first should be dismounted. Lift extension arm and drive tractor away. Drive the tractor and position extension arm so it is possible to attach a head. Turn the tractor's engine off and take ignition key out. Screw bolts in mounting catch (5) and connect quick fasteners (44). For Lama 120 P head, connect 2 cables for rotation control of the moving part of ejector directly to push-in fittings of tractor's hydraulics Fig. 49. Mounting flail head with use of multi-purpose linkage In order to dismount flail head take analogical steps, that is place machine on even ground and disconnect tractor s engine. Then unscrew bolts in mounting catch (5) and disconnect quick fasteners (44) (Fig. 49). The arm is equipped with set of twist-on push-in fittings designed for quick mounting and dismounting of the cutterbar or working adapters

47 6.2. Mounting flail heads Coupling Lama 121/ 141 mowing heads is significantly facilitated owing to application of mountings. Mountings such as: basic mounting (Fig. 20, item 1), rotary mounting (item 2), hydraulic turntable (item 3) are normally bolted to extension arm with 6 bolts. Hydraulic turntable can be attached to mowing heads. For Lama 121 and 141 heads it is possible to manually shift the head to the side in relation to the arm. In order to perform this, first: untighten 6 screws M14 (1) (Fig. 50), move the head as desired, tighten screws M14 (1). 1 Fig. 50. Lateral shift in relation to arm Rotary mountings (item 2, Fig. 20), hydraulic turntable (item 3, Fig. 20) can be rotated vertically. In case of the first type, the rotation is performed manually, and the hydraulic turntable rotation is powered by the tractor's hydraulics. In order to turn head in rotary mounting (item 2, Fig. 20) perform the following: lift the head over an even ground and set it horizontally, remove safety cotter (1) (Fig. 51), remove locking pin (2), rotate the head as desired, secure the head with the pin and the cotter. 1 2 Fig. 51. Rotary mounting

48 Hydraulic turntable is controlled with a special hydraulic motor (Fig. 52), which is powered directly from the tractor's hydraulics. For this purpose: connect two hydraulic push-in fittings to the tractor's hydraulics, moving an appropriate control lever for distributor in the tractor, rotate the mowing head and set it in the desired position, if the head rotation is performed too fast, throttle the oil flow with throttle valves (3) located just behind hydraulic push-in fittings. 3 Fig. 52. Hydraulic turntable For heads Lama 120/140 and Lama 121/141 head suspension can be fitted. If fitting for Lama 121/141 is used, it is necessary to use suspension mounting. Head suspension facilitates the operator's work as he doesn't need to constantly control the extension arm because of the suspension which enables the mowing head to follow ground vertically within 260 mm, and also enables driving speed increase while mowing. The suspension has 2 springs providing the head relief which enables the head to tackle ground unevenness more smoothly. Head relief is adjustable according to the ground configuration and the operator's preferences. For transport, suspension is fitted with locking pin which locks the mechanism against uncontrolled motions. Fig. 53. Linkage with mounting for Lama 121 head

49 6.3. Adjusting flail head mowing height In order to set the desired mowing height, the following should be performed: preset mowing height is approx. 3 cm (Fig. 54). Mowing height modification for 5; 7.5 cm respectively can be obtained by loosening adapting shaft mounting bolts, what is shown on Fig. 55 and Fig. 56). Fig. 54. Setting I, mowing height: ~3 cm Fig. 55. Setting II, mowing height: ~5 cm Fig. 56. Setting III, mowing height: ~7.5 cm 6.4. Replacing knives in mowing adapter If damaged or worn knives are found, they should be replaced. In case of replacing cutting knives, they should have the same weight. Admissible difference in weight should not exceed 5 g. If a single knife requires replacement, the opposite one should be replaced also so as to prevent their improper balance. If rotor of cutterbar is equipped with standard knives, make sure whether these are mounted in right direction. Operation direction Fig. 57. Knife mounting manner CAUTION! Flail knives must be replaced in pairs. Prior to entering hands or any other tools to casing of the cutterbar follow the below advice: wait until the rotor is stopped, lower the machine s cutterbar onto the ground, disconnect the tractor's engine, take ignition key off, lock valves at oil tank, wear protective gloves and clothing as required by safety precautions

50 6.5. Operating hydraulics Condition of hoses and hydraulic fittings should be examined periodically and in case of finding damages replaced with new ones. Irrespective of the above hydraulic hoses should be replaced with new ones every 5 years taking their storing period into consideration. In winter idle period it is recommended to store the machine in dry, well vented room, paying attention the hydraulic hoses are not deflected. Oil used in hydraulic circuits is toxic. Prior to performing any servicing, oil replacement, the operator should wear protective clothing. Strictly follow the binding provisions on hazardous waste. Used oils should be drained to special containers and then taken to a nearby oil treatment plant Oil tank with equipment Tightness of tank's (9) welded joints should be examined as well as hoses connections. These activities should be performed at least once a month (Fig. 58) Fig. 58. Oil tank Potential leaks shall be welded after the oil is drained. Drain plug (45) is located underneath the tank (9). Damaged paintwork should be repainted and oil loss supplemented with HYDRAULIC PREMIUM 32 oil group oil with similar properties. The tank holds approx. 150 l of oil Koliber 400/450, 220 l of oil Camel 900 and KWT 550/650/651. Refilling oil should be performed through upper air vent filter (46). In order to perform this "can" should be dismounted from the tank, and only special sieve shall remain inside, which collects impurities contained in oil. Oil level is indicated by indicator plug, which should be unscrewed when oil is filled into the tank. Upon obtaining proper oil level all plugs and filter should be tightened. Above the indicator plug there are hydraulic hoses nozzles tank fills (48). The oil must conform with purity class: in conformity with ISO 4406, 9 in conformity with standard NAS If the oil does not conform with the provided purity class then replace it. If the oil purity is doubtful then it should undergo a purity test in corresponding testing authority Oil shut-off valve Tightness of joint connections at valve (49) should be controlled at least once a day. Leaks should be removed by tightening nuts and /or band clips (50) (Fig. 59). Open position lifting set along feeding hydraulic hoses (ON). Close position lifting set perpendicular to feeding hydraulic hoses (OFF)

51 OFF 49 ON Multiplier with pump set Fig. 59. Shut-off valve placed on tank Tightness of connections and oil level in multiplier (10) should be examined as well as tightness of connection of hoses to pumps (51). This activity should be performed at least once a week (Fig. 60) Fig. 60. Mounted multiplier with pump set Leaks in casing of multiplier should be removed by tightening casing bolts and sealing with silicone. If oil level is low, take out air vent (53) and refill oil up to about 1L (half the inspection window (52). Then air vent should be tightened anew. Drippings at connecting hoses to pumps should be removed by tightening bolts, possibly sealing should be replaced Suction filter CCA 302 CD1 Suction filter is equipped with two inserts CS 100 (54), contamination of which is determined with use of indicator located in upper part of casing MPS 300 (55) (Fig. 61). At commission these inserts (54) should be replaced after 100 h, next replacement after 500 h of operation, if indicators do not show any contamination. If indicators show contamination, these inserts should be replaced regardless of the operation time. Contamination level should be controlled daily. No indicators control and no replacement of inserts may lead to damaging hydraulics parts, what is not covered by warranty. During control of indicators attention should be paid to condition of hoses and potential leaks. If such occur, seats and clip bands should be tightened. Applied inserts and indicators must be purchased at manufacturer's or at recommended stores. Use of non-genuine sub-assemblies may lead to damage, which is not covered by warranty

52 If filter indicator shows full contamination the filter will be disabled causing the system to work without a filter what may lead to pumps and hydraulic drive failure Control distributors 54 Fig. 61. Suction filter in hydraulics In arm two distributors are applied: 1) single-section (57) designed for starting hydraulic engine driving the cutterbar, 2) four-section (58) or five-section designed for operating hydraulic cylinders controlling the machine. Sweep valves of distributors are factory set (Fig. 62). Adjusting them is forbidden, as it may lead to damaging hydraulics, what is not covered by warranty Fig. 62. Hydraulics control assembly II Control assembly I: Single-section distributor (57) is responsible for starting the cutterbar. The drive is started from the tractor's cabin using the control system. Sweep valve of distributor is set on 200 bar. On tank fill there is oil cooler (59) (Fig. 63). Cooler radiator is started when oil temperature exceeds 65 o C

53 59 Fig. 63. Hydraulics control assembly Control assembly II (Fig. 62): Four-section (58) or five-section distributor is responsible for tilt of the machine's arms, extension rotation to proper mowing/transport position as well as settings of the cutterbar (control is specified in chapter Control panel operation). Sweep valve of distributor is set on 200 bar Initial regulations Four hydraulic cylinders (1, 2, 4, 13) are equipped with throttle valves (60) (Fig. 64 and Fig. 65), designed for regulation of oil flow. Their task is to adjust settings for any machine's operator. Reducing oil flow improves operation of cylinders (eliminates jerks), but at the same time slows down their operation. Setting is performed by turning the valve rotary handle: Turning right reduces capacity, improves operation, slows down the cylinder's operation. Turning left improves capacity, causes jerks, accelerates the cylinder's operation Fig. 64. Adjustment of cylinders Fig. 65. Cylinder protection Safety valves Cylinder (2) is connected to twin locking valve (61) (Fig. 65). Its main task is to keep the cylinder's position, in case of hydraulics failure. This valve is factory set and is not covered by warranty. Rotation cylinder (14) is connected to sweep valve (62) (Fig. 66), which protects working arms from overloading. Increasing pressure in cylinder shall cause oil flow and arm deflection. Valve adjustment is performed with bolt (63) located on the valve. Do not make any self adjustments of the valve. Keep in mind that hydraulic hoses (64) of cylinder (14) must be suitable to hold high pressure (min 300 bar). It should be borne in mind, that too big a deflection of the boom, changes the mower's position to improper. Then the tractor should be stopped immediately and lever (B) switched in up position

54 (extension arm turned left) (Fig. 41). Improper mower's position causes impairment of mowing quality Hydraulic engine Fig. 66. Sweep valve (62) for underrun protection Hydraulic engine drive's (23) hydraulic hoses connection should be controlled at least once a month. In case of leaking tighten the hoses (Fig. 67). Hydraulic motor (23) connected to flail shaft by means of a coupling. Hydraulic engine can operate in one direction only (to the left from engine bar side). Do not connect the engine in the other direction it shall lead to its damage! Operation without guard around the hydraulic engine is forbidden it may lead to damaging the engine! 6.6. Operating service Daily maintenance 23 Fig. 67. Hydraulic engine driving shaft with cutterbar's knives Upon daily completion of operation the following should be performed: remove grass and mud from the machine, etc., (pay particular attention to cutterbar, flail shaft, adapting shaft and engine guard), examine condition and number of flail knives. If need be, replace following the manual (in pairs), perform check-up of vivid external parts and assemblies as well as their connections: tighten loosened connections and replace worn or damaged parts, lubricate all pins and cylinder joints, visually examine technical condition of hydraulics: oil filter contamination indicator, fitting elements for leaks. If these are major, check oil level in the tank and remove defects following provisions give in the manual (tighten fitting elements, replace copper washers, tighten band clips, examine technical condition of connections between the machine and the tractor

55 After-season maintenance At the end of the season the machine should be cleaned, washed and dried. Carefully grease unpainted surfaces and 3-point linkage pins. After that the following work should be carried out: examine the paintwork condition. If need be, clean and paint any damaged points, examine technical condition of hydraulics taking actions as in case of daily servicing. Moreover condition of hydraulic hoses should be examined thoroughly. If need be, replace with new ones meeting technical requirements of the manufacturer, examine technical condition of moving parts of the machine. If clearance is found on pins, these should be replaced along with slide bushings and well protected, examine condition of bearings in fail and adapting shaft (whether there is no run out). If necessary, replace bearings and gaskets (it is recommended that these activities are performed by the SaMASZ company specialized personnel). cooperating elements (pins, joints, cylinder rods, etc.) should be protected for corrosion by covering them with thin film of solid grease Dismounting machine from tractor When detaching, make sure there is no person in between the machine and the tractor. When dismounting machine from tractor perform the following: turn off unloading function and do not turn it on again, open pressure reduction valve for 10 seconds and then close it (Fig. 68), lower flail head onto paved and even ground, put forth and protect support legs, dismount linkage frame (undo bolts and remove pins), take linkage pins out, lower the machine by means of 3-point linkage, unscrew control panel with handles and links (Bowden s links and hydraulic hoses feeding pump should not be deflected), manner of mounting PTO shaft is provided on Fig. 69, then drive tractor away. Fig. 68. Pressure reduction valve in unloading system

56 Storing Fig. 69. WPT linkage after machine is detached from tractor Detached machine should be stored in standstill position, so it is supported onto supporting legs and the cutterbar (Fig. 70). It is recommended to store the set on paved ground, preferably in roofed places, inaccessible to unauthorized personnel or animals. After storing for winter period prior to the machine operation, its technical condition should be examined and special attention should be paid to the hydraulics and the drive. Paintwork should be complemented, hydraulic hoses checked and lubricated. Fig. 70. Correct machine storage position: a) KWT, Camel, b) KOLIBER When performing repair and maintenance works the machine should be lowered onto the ground or supported (cutterbar) onto supports ensuring its full stability, with the tractor's engine disconnected and ignition key off. Storing the machine otherwise as given, may result in machine instability and thus its damage

57 7. LUBRICATING For lubrication of the machine use only mineral solid greases such as ŁTU-53. Do not use any plant or animal based grease. Prior to applying the grease clean out grease fittings as well as lubrication points prior to grease application. The following should be lubricated: rolling bearings of cutterbar rotor, joint pins. After 2 h of operation: make sure whether nuts, pipe fittings and clips are well tightened. Every 4 h of operation: apply grease into permanent grease fittings. Every 8 h of operation: lubricate all eyes of hydraulic cylinders, examine pressure oil filter sucking (if the indicator is in red apply a new insert), examine proper operation of Bowden lines (if any line cuts occur, lubricate). After 100 h of operation: check oil level in multiplier (if the level is too low refill with SAE 90 type oil or similar). After 600 h of operation: replace oil in multiplier (SAE 90). Tab. 7. Torque values for bolts

58 8. DEFECTS AND THEIR REPAIRS In case of a malfunction, immediately stop the machine, turn off the motor and wait until the mowing head is fully stopped. Before disconnecting any of the hydraulic hoses, check whether there is no pressure in the hydraulics and remember to cut-off the oil feed from the tan to the machine's hydraulics. Hot or pressurized oil leak may cause serious bodily injuries. For the sake of the operator's safety, the machine must be stopped on even ground. All hydraulic cylinders and moving elements must be completely locked. Defect Reason Recommendations Machine is not mowing Machine 's arms are locked Cutterbar is not working No possibility of controlling hydraulic cylinders Ventilator does not turn on Excessive vibrations. Loud machine operation Too low rears in machine Distributor out of order Pump, engine out of order Pump does not deliver oil Distributor out of order Worn bearings Hydraulic engine out of order Distributor out of order Damaged clutch Damaged control system Temperature sensor out of order Burnt fuse No 12V voltage No lubrication Damaged or no knives Opposite knives have different weight Damaged bearings Bent flail shaft Manual control of electrical and electrical-proportional distributor Check the PTO efficiency in service station Check pump operation with use of flow meter and pressure gauge. If oil feed and pressure are right, check distributor Replace distributor Replace pump, engine Check pump operation (a.o.) Replace distributor Replace bearings Replace hydraulic engine Replace distributor Replace clutch Replace at the manufacturer's service point Replace sensor. Replace fuse Check voltage and plug Lubricate shaft bearings Replace knives with new ones as in manual Make sure, that difference in knives' weight does not exceed 5g Replace Replace In case of electrical and electrical-proportional control failure it is possible to adjust the hydraulic distributor manually. This allows for mechanical machine folding and emergency service drive. Please learn the below description of procedure for two types of distributors:

59 a) Electrical E control Fig. 71. Hydraulic distributor E description of distributor functions: 1- turntable, 2- arm extension, 3-2nd extension arm, 4- main extension arm, 5- cutting part, 6- start distributor To overload hydraulic distributor with electrical control: push the button (6) and turn it left, next adjust hydraulic actuators by pushing buttons (1), (2), (3) on coils under hydraulic hoses, to change sections (4) and (5) firstly apply 12V voltage on the coils and then adjust in the same manner as in the case of other. b) EP control electrical-proportional Fig. 72. Hydraulic distributor EP description of distributor functions Camel 900 EP, KWT 650 EP, KWT 651 EP: 1- turntable, 2- arm extension, 3-2nd extension arm, 4- main extension arm, 5- cutting part KWT 550 EP: 2- turntable, 3-2nd extension arm, 4- main extension arm, 5- cutting part To adjust hydraulic distributor with electrical-proportional control: adjust hydraulic actuators by pushing buttons (1), (2), (3) on coils, to change sections (4) and (5) firstly apply 12V voltage on the coils and then adjust in the same manner as in the case of other. CAUTION! Follow the above procedure only in an emergency, and therefore do not apply it for normal extension arm operation

60 9. REPAIR AND WITHDRAWAL FROM USE Prior to any repair works, potentially related to admitting it for use, the machine should be cleaned thoroughly and any grass, dirt or mud removed. Carefully check nuts and bolts for adequate torque and the pins for wear. If it is found, that after replacement of some worn parts the machine is able to operate, then damaged parts are to be replaced with new ones. Fitting elements (bolts, nuts, shaft pins, etc.) should also be replaced. If the machine cannot be repaired anymore (its repair is impossible), it should be withdrawn from use. In such case, oil should be drained (to special tight containers) from intersecting axis gearbox and taken to used oil and grease treatment plant. Thoroughly clean remains with cleaning agent, take plastic elements off. These should be used further on or delivered to a proper waste treatment company. Remaining metal parts should be sold to breaker's yard. When dismounting the set and particularly during disconnection of assemblies and parts, keep all safety precautions. Dismounting works should be performed in protective gloves. Withdrawal of dismounted parts should conform with natural environment protection requirements

61 Cooler Marking of main symbols S z - Power switch S s - Hydraulic engine switch S p - FLOATING function switch J 1, J 2 - Joystick S 1 -S 8 - Tilt microswitches L 1 -L 8 - Coils of tilt valves L s - Hydraulic engine valve coil L p - Coil of FLOATING function switch valve X 1 -X 3 - Contactors Numbering of wires in 12x1,5 2mm2 cable tilt microswitches S 1 -S tilt microswitches S 5 -S FLOATING function 10 - hydraulic engine 11 - cooler 12 - power negative side - 12V Feeding Engine Floating Schematic diagram KWT 10. ELECTRIC DIAGRAMS Operator's manual

62 Connection diagram KWT cooler CONTROL PANEL 12-WIRE CABLE socket plug 16-PIN JOINT 12-WIRE CABLE WORKING PART

63 Control panel assembly diagram (internal view) OFF ON OFF ON OFF ON FEEDING