Chopper SE3155-3185-3200-3230 Operator s manual Translation of original operator s manual Edition 09.2015 Date of print 12.2015 Language EN From machine number MACHOxx105426 Model Document number A137249940
Machine identification In order for your dealer to assist you as efficiently as possible, you will need to provide some information about your machine. Please enter the details here. Designation SE3155-3185-3200-3230 Operating width Weight Machine number m ( ft) kg ( lbs) MACHOxx Accessories Address of supplier Address of manufacturer California Proposition 65 Engine exhaust, some of its constituents, certain machine components and fluids, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Copyright by Kverneland Group Ravenna, Italy. Reproduction, transfer to other media, translation or the use of extracts or parts of this manual without the explicit permission of Kverneland, is not permitted. All rights reserved. The contents of this operator s manual are subject to change without notice. The right to technical revision is reserved.
Table of contents Table of contents Preface... 4 Target group for this operator s manual 4 Symbols used 5 Safety... 7 For your safety 8 Definitions 15 Who is allowed to operate the machine? 15 General safety information 15 Coupling 18 Distance of center of gravity 19 Road transport 22 Operating the implement 23 Uncoupling 25 Care and maintenance 25 Further regulations 26 Description of the implement... 27 Range of application 27 Field of use of the implement 27 Characteristics of the implement 27 Names of components 28 Specifications 30 Supply and assembly... 31 Checking the standard of the supply 31 Hitching the implement... 32 Hitching to the tractor 32 Preparation for work... 37 Adjusting the working height 37 Lifting and transportation... 39 Lifting 39 Driving on the road... 40 Transport position 40 Use... 41 Working 41 Cleaning and care... 44 Cleaning 44 Detaching and storing... 45 Detaching the implement 45 Storage of the implement 45 Maintenance... 47 For your safety 47 Maintenance intervals and adjustments 49 Lubricants 51 Hydraulics 55 Comparative classification of viscosity 56 Troubleshooting... 61 Troubleshooting 61 Disposal of the implement... 63 EC Declaration of Conformity... 64 In accordance with EU Directive 2006/42/EC 64 Index... 65 3
Preface Preface Target group for this operator s manual Simplified illustrations for better understanding Illustrations of the machine in the operator s manual are shown without protective equipment or with the protective equipment open for better understanding. Be sure to observe the safety information and follow the handling instructions in the operator s manual. Otherwise, serious or fatal injury may be caused as a result. This operator s manual is intended for trained agriculturists and persons who are otherwise qualified for agricultural activities and have received instruction in working with this machine. It should be considered as an integral component of the implement, and should accompany it until the end of its service life. For your safety You must familiarize yourself with the contents of this operator s manual before assembly or initial operation of the machine. In this way, you will achieve optimum work results and operational safety. The operator s manual forms an integral part of the machine and must always be kept at hand. This will ensure that you: avoid accidents. comply with warranty conditions. have a fully functional machine in good working order at all times. Demonstration and training Your dealer will provide instruction on operation and care of the machine. Information for the employer All personnel are to be regularly, but at least once a year, instructed on the use of the machine, in accordance with the regulations of the national organisation for Health and Safety at Work. Untrained or unauthorized persons are not permitted to use the machine. You are responsible for ensuring that the machine is operated and maintained safely. Make sure that you and all other persons that operate, maintain or work in close proximity with the machine are familiar with the operating and maintenance regulations, as well as the corresponding safety instructions in this operator s manual. 4
Preface Symbols used In this operator s manual, the following symbols and terms have been used: A bullet point accompanies each item in a list. A triangle indicates operating functions which must be performed. An arrow indicates a cross-reference to other sections of this manual. [+] A plus sign indicates additional equipment which is not included in the standard version. We have also used pictograms to help you find instructions more quickly: This symbol indicates information, suggestions and instructions for use. This symbol denotes useful suggestions for the assembly and adjustment of the implement. This symbol denotes examples designed to aid understanding. Disengage the pto, lower all implements to the ground, place all controls in neutral or park position, set the parking brake, switch off the tractor, remove the ignition key and secure the tractor against rolling away. 5
Preface 6
\ Safety Safety \ SAFETY FIRST This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit. \ DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. \ CAUTION Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE the symbol indicates critical technical and operating informations concerning safety of person or the machine. 7
Safety For your safety \ Know your equipment and it's limitations. Read this entire manual before attempting start and operate the units. This chapter contains general safety instructions. Each chapter of the operator s manual contains additional specific safety information which is not described here. Observe the safety information: In the interest of your own safety. in the interest of the safety of others. to ensure the safety of the machine. Numerous risks can result from handling agricultural machinery in the wrong way. Therefore, always work with particular care and never under time pressure. Information for the employer Inform all persons who work with the machine about this safety information at regular intervals and in accordance with statutory regulations. 8
\ DANGER, WARNING and CAUTION labels Safety Safety-related labels attached to the machine indicate potential hazards. The labels must not be removed. Illegible or missing labels should be replaced. You can obtain new labels as spare parts from your dealer. DANGER, WARNING and CAUTION labels on the machine 9
Safety \ Meaning of DANGER, WARNING and CAUTION labels Outer tube. Inner tube. 10
\ Safety 11
Safety \ 12
\ Signalling equipment USA Safety On the machine there are signalling equipment, signs and stickers that serve to ensure safety in road traffic. The signalling equipment must be in good working order at all times. The signs and stickers must not be removed. Illegible or missing labels should be replaced. You can obtain new labels as spare parts from your dealer. 13
Safety \ Signs Additional markings are required for road transport in some U.S. states and some Canadian provinces: Marking for slow-moving vehicle SMV This SMV emblem shall be used on all slow moving machines when operated or traveling on public roads. On slow moving machines with design specifications of a maximum speed of 40 km/h (25 mph) or less, the SMV emblem shall be used. On slow moving machines with design specifications of speed greater than 40 km/h (25 mph) but not exceeding 65 km/h (40 mph): a SMV emblem shall be used and a Speed Identification Symbol (SIS) shall be used. 14
\ Definitions Safety For all direction indications, we consider the implement in the direction of movement: upwards forwards right left downwards backwards Who is allowed to operate the machine? Only qualified persons may operate the machine Only qualified persons who have read and understand the operator s manual, and have been informed of the dangers associated with handling the machine are permitted to operate, service or repair the machine. The necessary knowledge can be gained in the course of agricultural vocational training, professional training or intensive instruction. General safety information The general safety information and warning signs apply to every phase of the life cycle of the machine and to every application. Switch off the tractor and secure it Before you dismount: Disengage the PTO Lower all implements to the ground Place all controls in their neutral or park position Set the parking brake Switch off the tractor. Remove the ignition key. Secure the tractor against rolling away. An unsecured tractor can run you over or trap you. Otherwise, serious or fatal injury may be caused as a result. Operate for the first time only after proper training The machine may only be put into operation after proper training has been provided by an authorized dealer. Operation without proper training can lead to damage to the machine due to incorrect operation, or may cause accidents. Safety is your responsibility Follow the safety instructions. Ensure that all operators read and understand the manual and comply with the safety instructions. Prevent serious or fatal accidents by following the safety instructions. 15
Safety \ Instructions in the event of malfunctions In the event of a malfunction: shut down as set forth above, stop and secure the machine immediately. Rectify the malfunction immediately yourself if qualified to do so, or seek the assistance of an authorized dealer. Operating a faulty machine can cause accidents or damage. No persons in the working area Ensure that no persons are present in the slewing and working area of the machine. Persons could be caught by the machine within this area. This could result in fatal injury. Proper working condition Ensure that the tractor and the machine are always in proper working condition. Make sure that the tractor brakes work in synchronization with the machine. Also follow the instructions in your tractor's operator s manual. Switch off the tractor PTO shaft drive Switch off the PTO shaft drive on the tractor when changing from work to transport position. Wait for moving parts to come to a stop. If this requirement is ignored, the consequence may be damage to the machine and even life-threatening injuries. No reversing while the drive is running Never drive in reverse with the PTO shaft drive switched on and in the work position if people could enter the working area of the machine. Switch off the PTO shaft drive. Rotating, unprotected parts can damage the machine and cause life-threatening injuries. Specified workwear Do not wear loose fitting or other inappropriate clothing. Loose fitting items of clothing may become caught in rotating parts. Wear workwear and protective clothing, appropriate for the operating environment and conditions. Serious or fatal injury may be caused if these guidelines are not followed. No riding on the machine Persons or objects must never be transported on the machine. Carrying passengers, especially children, on the machine is life threatening and prohibited. Serious or fatal injury may be caused as a result. Safety for children Never assume that children will remain where you last saw them.be alert and shut your machine down if children enter into the work area. Never allow children to play on or operate the machine. 16
\ Safety Never work on the machine while it is running No operations may be performed on the machine while it is running. Objects or persons can be caught, drawn in or crushed. Serious or fatal injury may be caused as a result. PTO shaft Use only the PTO shafts specified by the manufacturer and read the attached operator s manual carefully. Adjust the length of the PTO shaft as required. Incorrect PTO shaft lengths can cause damage to the machine and personal injury. Check and fasten the PTO shaft guard in position The rotating PTO shaft is protected by the PTO shaft guard. Ensure that the guard is not damaged. Fasten the PTO shaft guard in position by connecting the chains on the machine and the tractor. Unguarded PTO shafts can cause life-threatening injuries. Make sure the machine is standing level Before changing from the transport to the work position (and vice versa), make sure the machine is standing level. Otherwise, damage to the machine and serious or fatal injury may be caused as a result. Do not make any modifications to the machine No modifications of any kind may be made to the machine. Unauthorized modifications can adversely affect the correct operation and safety of the machine and shorten its service life. Unauthorized modifications to the machine, including any or all safety guards or mechanisms, render the manufacturer's guarantee null and void and free the manufacturer from all liability. PTO shaft speed 540 rpm The specified maximum PTO shaft speed of 540 rpm must not be exceeded. A higher PTO shaft speed will damage the machine. Unrestricted field of vision to the rear After it has been coupled, ensure that you have an unrestricted view of the machine, in both its work and transport positions. Otherwise, dangerous situations may not be detected in time, resulting in accidents or damage. 17
Safety Coupling \ Increased risk of injury While hitching the implement to the tractor, there is an increased risk of injury. Therefore ensure that: the link-up is carried out on a flat, even and stable surface secure the tractor so that it cannot move (handbrake on, wheels chocked) the tractor and implement belong to the same category of machinery during the hitching, you do not stand between the tractor and the implement you activate the 3-point hydraulic lift slowly and with great care Failure to observe these precautions could lead to serious injury or death. Only make the electrical connections after assembly is complete While the any electrical equipment is being fitted, the power source must not be connected to the tractor. This could cause short circuits and damage to the electronic parts. Only connect the hydraulic components when they are not pressurized Only connect the hydraulic hoses to the tractor's hydraulic system if neither hydraulic system (tractor and implement) is pressurized. A pressurized hydraulic system can cause the implement to move unexpectedly. High pressure inside the hydraulic system The interior of the hydraulic system is highly pressurized. Check for any leaks or external damage to the cables, hoses and screw attachments on a regular basis. When checking for leaks, only use a suitable product. Do not check for leaks by feeling with hands or any other body parts. Repair any damage immediately. Oil leaks can cause serious injury and burns. In the case of injury, seek medical attention immediately. Replace hydraulic hoses every six years or earlier Hydraulic hoses age without showing externally visible signs. Replace hydraulic hoses every six years, or earlier if aging or degradation is visible. Defective hydraulic lines can cause serious or fatal injuries. Colored markings on hydraulic hoses In order to prevent malfunctions, mark the hydraulic connection sleeves and coupling pins between the tractor and implement with different colors. Incorrect connection of the hydraulic hoses can cause the implement to make unpredictable movements. Drive shafts Before connecting or disconnecting a transmission shaft, disengage the PTO, switch off the engine and remove the ignition key. Observe the operator s manual of the PTO shaft manufacturer Observe the operator s manual of the PTO shaft manufacturer. It will provide you with instructions on how to handle the PTO shaft correctly. If these instructions are ignored, damage may be caused to the PTO shaft and machine. 18
\ Distance of center of gravity Safety Observe recommendations for the gross weight, the axle loads, the tire load capacity and the minimum counterweights Front or rear attachment of implements must not cause the permitted gross weight, axle loads or tire load capacity of the tractor to be exceeded. In order to maintain a safe turning capacity, the front axle must carry at least 20% of the unladen weight of the tractor. Using a few simple calculations, it is possible to determine: gross weight axle loads tire load capacity and minimum counterweights (B) load on front axle (A) unladen weight (C) load on rear axle For these calculations, the following data is required: (A) unladen weight (B) load on front axle (C) load on rear axle consider also, for example: weight of water in the tires, of attachments and similar. (E) gross weight with front attachment (D) gross weight with rear attachment (D) gross weight of the implement with rear attachment. With towed implements, take the support load into consideration (E) gross weight of implement with front attachment (F) distance from center of gravity of implement to the center of front axle (forward mounting) (F) distance: from center of gravity of the implement to the center of the front axle (forward mounting) (G) distance: from the center of the lower attachment bearings to the center of gravity of the implement (rear mounting) (G) distance from center of lower attachment bearings to center of gravity of implement (rear mounting). With towed implements G=0 Data obtained from measurements: (H) tractor wheelbase (I) Distance from center of rear axle to center of lower attachment bearings (H) wheelbase (I) distance: from the center of the rear axle to the center of the lower attachment bearings 19
Safety \ Calculation Counterweight with front weights The values taken from measurements can now be used to calculate formulas. Calculation of counterweight with front weights for implements with rear attachment. Front counterweight in kg (lbs) = D I+ G B H 0, 2 A ------------------------------------------------------------------------------------------ + H F + H Counterweight with rear weights Calculation of counterweight with rear weights for implements with front attachment. Rear counterweight in kg (lbs) = E F, C H 0 45 A ------------------------------------------------------------------------------------ + H H + I+ G Front axle load Calculation of the effective load on the front axle Front axle load in kg (lbs) = E F H B H D I -------------------------------------------------------------------------------------- + + + G H gross weight Calculation of the effective gross weight + + Gross weight = E A D Rear axle load Tire load capacity Calculation of effective load on rear axle Rear axle load in kg (lbs) = effective gross weight - effective load on front axle Data relating to front and rear tire load capacity can be found in the documentation supplied by the tire manufacturer. Where there are two wheels present, the front tire load capacity is found by multiplying the permitted load capacity of one front tire by two. Where there are two wheels present, the rear tire load capacity is found by multiplying the permitted load capacity of one rear tire by two. Assessment Ensure that the following conditions are met: the effective rear axle load values must be less than the permitted values specified in the tractor operator s manual. the tire load capacity must be greater than the rear axle load values specified in the operator s manual. the effective gross weight must be less than the permitted gross weight specified in the tractor operator s manual. If these conditions are not met, the implement must not be attached to the tractor. If there is a weighing machine of sufficient dimensions available, the gross weight and the rear axle load can be measured by weighing. 20
\ Example Safety Calculation of counterweight with front weights for implements with rear attachment. D = 2100 kg (4629.7 lbs) I = 1180 mm (46.457 in) G = 650 mm(25.59 in) B = 2520 kg (5555.6 lbs) H = 2720 mm(107.086 in) A = 6300 kg (13889 lbs) F = 1367 mm(53.82 in) kg= 2100x(1180+650)-(2520x2720)+(0.2x6300x2720) =102 1367+2720 lbs= 4629.7x(46.457+25.59)-(5555.6x107.086)+(0.2x13889x107.086) =224.3 53.82+107.086 21
Safety Road transport \ Ensure that the vehicle configuration meets the requirements of the highway code If it is necessary to travel on public roads with the implement, it must comply with current traffic regulations. For example: installation of lighting, signalling and protection devices, compliance with width/weight transport limits, and permitted axle load, tire load capacity and gross weight limits, the maximum permissible road transport speed must be complied with, but not exceed 40 km/h (25 mph), the steering capacity of the tractor must not be limited, the steering axle must be loaded with sufficient weight, the machine should only be towed by agricultural or forestry tractors, implement is centered for transport. The driver and owner of the vehicle are responsible for any failure to comply with traffic regulations. Close the ball valves If the hydraulic hoses or hydraulic cylinders are equipped with ball valves, these must be closed when driving on the road, in order to avoid accidental activation of the tractor distributors which could cause the implement to move. This could result in damage to the implement or accidents. Immobilizing moving parts During carriage and transit, always use the transportation safety devices on all the moving parts, accessories and equipment which require their use. If the implement is equipped with quick-release couplings, check the rope All remote controls (ropes, electric cables, hoses, etc.) must be positioned so that they cannot accidentally activate the corresponding devices. In particular, the ropes must hang freely and must not under any circumstances provoke the automatic activation of the quickrelease coupling. Otherwise, the implement could release itself from the 3-point hitch. Be aware of effects on driving and braking Driving with the implement will affect driving and braking characteristics. Be especially careful on corners, and keep in mind the increased width and/or overall mass of the implement. Inappropriate conduct on the road can cause accidents. Proceed at a suitable speed Always adapt driving speed to the conditions of the road surface. Driving on unfavourable road surfaces or driving too fast can lead to the development of powerful forces which overload the tractor and the implement. Driving at an inappropriate speed can cause accidents or damage to the implement. Accident with serious or fatal injures may be causes as a result. Check hitch pins Hitch pins must be in perfect condition. Hitch pins must show no signs of wear and be properly secured. Otherwise, hitched machines may detach themselves of their own accord. Accidents with serious or fatal injuries may be caused as a result. 22
\ Operating the implement Safety The implement may only be put into operation after training The implement may be used for the first time only after the user has read and understood the operator s manual and completed training under the guidance of the retailer, representative or manufacturer. Using the implement without appropriate training could cause damage to the implement, due to misuse, or accidents. Ensure technical conditions are perfect Only begin using the implement if it is in perfect technical condition. Before use, check all the most important components and replace any that are faulty. Faulty components can cause damage to property and persons. Do not remove any protective equipment Protective equipment and guards must not be removed or changed. Before use, check all protective equipment. If not equipped with protective gear, parts of the implement can cause serious injury or death. Height of the implement and overhead power lines Keep a safe distance from live overhead power lines during any operation involving the implement. This carries a risk of electric shocks. In the case of contact between the implement and a live overhead power line: do not leave the tractor cabin do not touch any metal parts of the tractor do not create a connection with the ground warn persons not to approach the tractor or implement await the arrival of qualified rescue personnel; the overhead power line will need to be switched off. Never climb on the implement when beneath live overhead power lines. The current could be transmitted even without direct contact. Check the danger zone The danger zone around the implement is 70 m (230 ft). Check the danger zone around the implement before driving off and continually during operation. Make sure that you have an adequate view. Only start up and operate the implement if there are no people, animals or objects in the danger zone. In unfavourable circumstances, objects may be thrown from the implement at high speed. Failure to respect these conditions when using the implement could lead to serious injury or death. Tighten screws and bolts Tighten screws and bolts regularly, and if necessary check they are in the correct position. With use screws can become loose, though not obviously so. Check also that the hydraulic fittings are correctly tightened. Failure to do so could result in damage to the implement or accidents. In case of malfunction In the case of malfunction, stop work immediately and halt the implement. Resolve the problem immediately or contact an authorized workshop. Continued use could lead to damage to the implement or cause accidents. 23
Safety \ Cornering and turning manoeuvres Centrifugal forces are in operation during cornering. The machine's center of gravity at the rear of the tractor is displaced. Be aware of the turning radius and the moment of inertia. A driving style which is not adapted to conditions can cause accidents. Accidents with serious or fatal injuries may be caused as a result. The rotor continues turning after the PTO has been switched off After the PTO shaft drive on the tractor has been switched off, the machine continues to run due to the moment of inertia. Maintain a sufficient safety distance until all moving parts have come to a complete standstill. Otherwise, damage to the machine and serious or fatal injury may be caused as a result. 24
\ Uncoupling Safety Increased risk of injury Disassembling the implement from the tractor carries an increased risk of injury. Therefore ensure that: all moving parts are complete standstill, the detachment is carried out on a flat, even and stable surface, the tractor is secured so that it cannot move, the foot of the implement is lowered and adjusted to ensure correct support on the ground, during disassembly, you do not stand between the tractor and the implement, you activate the 3-point hydraulic lift slowly and with great care, shut off the engine and remove the ignition key before disconnect the PTO driveline and hose connections, only disengage the hydraulic hoses if the hydraulic system (of the tractor and implement) is not pressurized, place the PTO shaft in the holder provided, disconnect all electrical connection if present. Failure to observe these precautions could lead to serious injury or death. Care and maintenance Observe care and maintenance intervals Respect the recommended intervals for checks and inspection as specified in the operator s manual. Failure to observe these intervals could lead to damage to the implement, inferior performance or accidents. Only use genuine spare parts Many components have special characteristics which are essential to the stability and function of the implement. Only the accessories and spare parts provided by the manufacturer are checked and approved. Other products could impact negatively on the function and safety of the implement. Use of non-genuine spare parts renders the warranty and manufacturer's liability void. In addition, any modification of the implement and its accessories will render the warranty void. Before commencing any maintenance work: switch off the PTO shaft drive Warning: moving rotor After switching off the PTO shaft drive, the rotor on the implement will continue to rotate for a few seconds due to inertial force. Wait until all parts have stopped moving completely. Otherwise, damage to the machine and serious or fatal injury may be caused as a result. switch off the hydraulic system pressure, whenever possible, uncouple the tractor. place all controls in neutral or park, set tractor parking brake. secure the tractor using wheel chocks so that it cannot move, switch off the tractor and remove the ignition key. ensure that the implement is safely positioned on a flat, even and stable surface, lower and adjust the foot to ensure correct support on the ground and if necessary use additional fastenings, 25
Safety \ do not climb on any part of the implement; use a suitable ladder, Safety during care and maintenance work can only be guaranteed when all of these precautions are taken. Interrupting the power supply Before handling the electrical system, disconnect the power supply. Live systems can cause damage to property and persons. Replacing hydraulic hoses It is recommended that hydraulic hoses be replaced every six years. Even if they are not visibly damaged, hydraulic hoses wear out over time. Damaged hydraulic hoses can cause serious injury or death. Take care when cleaning with high pressure water jet washers The implement can be cleaned with water or steam. When cleaning in proximity to certain components, for example bearings, electrical parts, distributors, plastic parts, hydraulic hoses and other areas of the implement where penetration could damage equipment, use only low pressure. Pressure that is too high could damage these parts. No aggressive washing additives Do not use any aggressive washing additives for cleaning. Uncoated metal surfaces can be damaged. Welding operations It is forbidden to carry out any welding on the implement. Tightening screw connections Once maintenance work is complete, re-tighten all screw connections that were previously unscrewed. Failure to tighten screw connections can lead to gradual loosening of the screws and subsequent detachment of parts from the implement. This could lead to serious injury or damage to property. See page 50 for proper torque values. Further regulations Personal protective equipment (PPE) Warranty Observe the regulations In addition to these warnings, you must also observe: accident prevention measures, universally-recognised rules regarding technical safety, occupational health and the highway code, the warnings contained in this operator s manual, the prescribed instructions for use, maintenance and repair. It is compulsory to use personal protective equipment (helmet, gloves, boots, goggles, ear protectors, etc.) as appropriate to the work being carried out with and on the implement. The warranty and manufacturer's liability will no longer be valid if the instructions provided in the chapter on Safety are not observed, if maintenance is inadequate or faulty, if the machine is used for purposes other than those for which it was intended and if it is overstressed, or if impermissible modifications are made to the machine. 26
Description of the implement Description of the implement Range of application This product is classified as replaceable equipment in accordance with EC directive 2006/42/EC and agricultural implement in accordance with ASABE S390. This chapter contains general information on the implement and information on: field of use characteristics names of components technical information Field of use of the implement The implement must be used as intended, depending on the tools it is equipped with, for agricultural activities or in similar sectors. Blades Universal blade Hammer Blade for stony ground Purpose For cutting grass, small shrubs or vines For shredding cuttings in orchards Similar to the universal blade but can be used on stony ground Due to variable working conditions, the operator must pay particular attention the performance limits of the implement. At the first sign of overloading, the implement must be stopped immediately. Prescribed use The implement must only be used for the activities laid out in this operator s manual. Different or other use is not recommended. Examples of non-prescribed use: transporting persons or objects breaking up of products different to those mentioned, or similar»field of use of the implement«transmission of power to other objects Non-prescribed use of the implement will render the warranty void. The manufacturer and the retailer do not accept any responsibility for damage caused by non-prescribed use. Risks are born exclusively by the operator. Characteristics of the implement lateral movement The chopper models covered in this manual are fitted with a threepoint hitch equipped with a system which enables the implement to be moved laterally, to adjust it to working requirements using a manual device (standard version) or a hydraulic jack (Optional). Solid structure Thanks to the use of materials which undergo a special hardening process along with an optimized structure, the implement is a reliable and robust working tool. Safety In order to allow you to work in the safest conditions possible, we have constructed the implement in accordance with EU and industry standards. The implement carries a CE mark. 27
Description of the implement Names of components frame drive shaft drive shaft support lateral movement system roller lateral transmission and cover skid front safety guards rotor attachment for lower arms unit with PTO cover support foot blades attachment for upper arm three-point hitch skid rear deflector Types of blade Universal blade The universal blade is suited to most types of work, and allows for the mulching of grass, shrubs or vines. Hammer The hammer is used to shred shrubs or thick vines, as well as debris resulting from pruning of fruit trees. 28
Description of the implement Blade for stony ground A clevis fastener enables the blade for stony ground to float above the ground, making it ideal for stony terrain. It is used in a similar way to the universal blade. Accessories In cases where optional extras are requested after the purchase of the machine, these must be fitted by the retailer. Counterblade counterblade optional The counterblade improves the quality of work, breaking down the material in a more uniform manner. The second counterblade is an optional extra. counterblade as standard Grippers The kit is useful for finely shredding any pruning and shoot residues. grippper 29
Description of the implement Specifications depth height width Height In working position Width Minimum Depth Minimum Working width Gross weight Standard machine with universal blades and without drive shaft, approx. 155 185 200 230 1750 mm (68,89 in) 1545 mm (60,82 in) 475 kg (1047,19 lbs) 1214 mm (47,79 in) 2050 mm (80,70 in) 2200 mm (86,61 in) 950 mm (37,40 in) 1845 mm (72,63 in) 540 kg (1190,49 lbs) 1995 mm (78,54 in) 572 kg (1261,04 lbs) Distance from the implement's center of gravity to the center of lower attachment bearings Rear mounting only 484 mm (19,05 in) Speed of rotor rotation (rpm) PTO 540 rpm 2243 Absorbed power Minimum 27 kw (36,19HP) 32 kw (42,89HP) 35 kw (46,91HP) 2500 mm (98,42 in) 2295 mm (90,35 in) 620 kg (1366,86 lbs) 40 kw (53,61HP) Maximum permitted 60 kw (80,42HP) Cutting height Adjustable 40-80-120 mm (1,57-3,14-4,72 in) Number of blades Universal blade 40 48 52 60 Hammer 20 24 26 30 Noise level db(a) At place of work < 70 30
Supply and assembly Supply and assembly Checking the standard of the supply Delivery is in the fully assembled state The machine is delivered fully assembled. If any parts of the machine have not been fitted, please contact your dealer. Do not assemble the machine yourself Trained personnel are required to assemble the machine. Do not perform assembly work yourself. The following points are required to be met for the machine to be in proper condition: Observance of the sequence of work steps. Compliance with tolerances and torques. Knowledge of work safety during assembly. Incorrect assembly can result in damage to the machine or accidents. Missing parts, or parts that have been damaged during transportation must be reported immediately to the retailer, the importer or the manufacturer. Pay particular attention to the presence and completeness of the safety guards. Operator s manual The operator s manual belongs with the machine and must always be kept on board. A document box for the operator s manual and spare parts list is delivered with the machine. 31
Hitching the implement Hitching the implement Increased risk of injury It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Crushing, cutting and shearing hazards During the following operations, there is a risk of crushing, cutting and shearing injuries: act with caution and care, and take all the necessary steps to avoid dangerous situations. In particular the implement and its parts must be immobilized and supported with appropriate supports The following hitching procedure assumes the machine is parked on a firm level surface using the locking foot. to adjust the foot, refer to page 39 The implement can only be hitched to the rear of the tractor. Respect the direction of travel Respect the direction of travel of the machine: when working, the roller should always follow the blades. Hitching to the tractor Observe the safety information Disregard for safety information can lead to serious or fatal injury. See chapter Safety, page 18. Increased risk of injury When the machine is being coupled to the tractor, there is an increased risk of injury. Therefore: Never stand between the tractor and machine. Secure the tractor against rolling away. Failure to observe these instructions can result in serious or fatal injury. 32
Hitching the implement Manual lateral movement When the machine is equipped with a three-point linkage with manual side adjustment device, it must be adjusted before hitching the machine to the tractor. In this case, proceed as follows: unhook the security clip which is inserted in one of the holes of the telescopic adjustment of the three-point linkage, move the three-point linkage sideways to the desired position, insert the security clip in the hole corresponding to the new setting and ensure that the safety lock is correctly positioned. security clip telescopic adjustment Hitching washer foot lower arms locking pins and lynch pins bearing upper arm The following description refers to connecting the implement to a tractor equipped with quick-release hooks for attachment to the top link of the implement. If this is not the case or if in doubt, please contact your retailer. Line up the tractor with the implement, balanced on the ground in a stable manner, mount the tractor's lower attachment bearings on the lower locking pins of the implement and secure with lynch pins, interposing the washers, fit the bearing of the tractor's top link tie rod onto the locking pin of the upper attachment of the implement, insert the washer and secure with the lynch pin, fasten the lower hoist arms, adjusted to the same height, to the implement's corresponding lower attachments, The attachment is easier if the lateral stabilizers of the tractor's lift arms can move freely. On completion of the hitching operation, the stabilizers should be adjusted so as to limit oscillation (during machine transport, all oscillation must be completely eliminated). fit the end of the tractor's top link tie rod into the implement's upper attachment, activate the tractor's hoist to reach the working height, record the length of the tie rod, taking into consideration that the implement's PTO must be horizontal when the implement is at work, for adjustment of the top link tie rod, see page 38. lift the support foot as far from the ground as possible and secure this in place with the locking pin and lynch pin. 33
Hitching the implement Drive shaft Switch off the tractor and secure it Before you dismount: Disengage the PTO Lower all implements to the ground Place all controls in their neutral or park position Set the parking brake Switch off the tractor. Remove the ignition key. Secure the tractor against rolling away. An unsecured tractor can run you over or trap you. Otherwise, serious or fatal injury may be caused as a result. Attachment to the implement drive shaft set screw implement attachment The right drive shaft is usually already attached to the implement. When replacing the drive shaft, or following maintenance work, the drive shaft must be reattached to the implement. Carefully clean and lubricate the drive shaft coupling and the attachment to the implement Loosen and remove the set screw Push the drive shaft onto the implement attachment Insert the set screw. Gently move the drive shaft backwards and forwards to correctly insert the set screw in the attachment groove. Tighten the set screw, applying approximately: 54-60 Nm for M10 screws 93-101 Nm for M12 screws 146-155 Nm for M14 screws In some cases, the drive shaft can be attached to the implement using a coupling collar or a pushbutton coupler. In this instance, the assembly process is similar to that indicated in the following paragraph. Attachment to the tractor Before connecting the drive shaft to the tractor PTO, check that the speed and direction of rotation comply with the usage instructions for the implement. Attach the drive shaft to the PTO of a tractor operating at 540 rpm. Carefully clean and lubricate the drive shaft coupling and the PTO shaft Push the pushbutton or slide the drive shaft collar Slide the coupling onto the PTO until the axis of the pushbutton or the bearings on the collar are lined up with the groove of the shaft Release the pushbutton or the collar as the coupling moves slightly Ensure that the pushbutton or the bearings of the collar are correctly inserted into the grooves in the shaft and that the drive shaft is correctly connected 34
Hitching the implement pushbutton splined coupling. Once the two ends of the drive shaft are connected, check that the two half guards rotate freely and independently, then attach the support chains for the protection tubes. The protection-tube chain of the drive shaft on the side of the implement can be attached to the eyebolt above the gearbox. splined coupling During work, check at regular intervals that the two joints are connected correctly. eyebolt chain collar If the tractor is replaced, it may also be necessary to replace or upgrade the drive shaft. The drive shaft will be adapted by the retailer according to the type of tractor. In such cases, it is necessary to check that the drive shaft is of the right dimensions and that its length is correct in respect of the tractor specifications. The length of the two half-shafts must be such that during operation: The drive shaft tubes overlap by at least 1/3 of their length. They do not separate under any working conditions. The ends of the half-shafts do not reach the limit stop under any working conditions. Also: The difference in length between the protective tubes and the halfshaft tubes must be maintained, ensuring that they always provide maximum coverage of the sliding elements. If it is necessary to shorten the drive shaft, do not attempt to do this yourself; contact the retailer or a qualified technical support center. Hydraulic connection Hydraulic oil Hydraulic oil is dangerous, avoid all contact. In addition, pressurized oil easily penetrates skin and clothes, causing serious injury. Before commencing any work on the hydraulic system, switch off the tractor's engine and depressurize the system. Make sure the connection is correct Ensure that the hydraulic system is connected correctly, Otherwise, damage to the machine and personal injury may be caused as a result. If the chopper is equipped with the hydraulic lateral movement system: Shut off the engine, set the parking brake, remove the ignition key and secure the tractor against rolling away. 35
Hitching the implement Release any pressure from the tractor's hydraulic system Connect the quick-release couplings of the chopper's hydraulic hoses to the corresponding attachments on the tractor's hydraulic distributor. Check that the type of hydraulic connection between the implement and the tractor's hydraulic service couplers is such that the top link does not move when the remote control valve is not operated. 36
Preparation for work Preparation for work Increased risk of injury It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Crushing, cutting and shearing hazards During the following operations, there is a risk of crushing, cutting and shearing injuries: act with caution and care, and take all the necessary steps to avoid dangerous situations. In particular, ensure the machine and components are properly supported and in a stable position! Adjusting the working height Correct adjustment of the implement's working height provides the maximum return and the best results. In order to work correctly, the machine must be parallel to the ground and the rotor must operate at the right distance from the soil. In addition, the chopper PTO must be as horizontal as possible while the machine is functioning. The working depth can be adjusted by altering the position of the skids, which are fixed to the roller. 0 Carry out any adjustments on a flat, firm and even surface. Adjust the roller to the desired position. Adjust the height of the lift arms so that the implement frame is parallel to the ground. Check the distance between the blades and the soil: generally, a distance of around 6 cm (2.4 in) is the correct adjustment. However, this distance should be increased when working with rocky or irregular soils. 0 Distance from the ground of the blades The blades must be at least 3 cm (1.2 in) from the ground when in operation. 37
Preparation for work Adjustment of the roller nut on end of skids Raise and secure the implement loosen the nuts that lock the end of skids, unscrew and remove the nuts and the screws that fix the skids on the roller side, vary the position of the roller by moving the supports until it is possible to insert the screws previously removed into the new holes on the implement frame, reposition the corresponding nuts, tighten all the nuts. The roller must be adjusted in the same way on both sides. screws and nuts of roller alternative holes Adjustment of the top link rod correct adjustment The upper attachment of the implement have a slot which allows the implement to absorb any differences in the evenness of the ground, so it continues to support the roller correctly. After setting the working height, it is necessary to adjust the tie rod of the top link so that the implement can function properly. The tie rod is correctly adjusted if the fixing pin is in line with the inner end of the slot. Refer to the figure. Grippers (Optional) gripper pin On the models described in this user manual, a rear gripper housing is available as optional. The grippers, which hold the cut material, allow pruning and shoot residues to be more finely shredded. Each gripper is equipped with a series of holes and a pin which is inserted into one of these; each gripper can be positioned higher or lower depending on which hole the pin is inserted into. Adjustments can be made according to the material that needs to be chopped and the desired result. The grippers must all be adjusted to the same height gripper housing 38
Lifting and transportation Lifting and transportation Adjustment of the supporting foot safety pin To ensure correct support, the machine is fitted with one adjustable foot (see figure). Support the machine Take all necessary precautions to prevent accidents caused by accidental falling of the machine during positioning and adjustment of the supporting foot. Ensure the machine is properly supported and in a stable position! To perform this operation, remove the safety pin and locking pin, move the foot to the desired position then reposition the locking pin and corresponding safety pin. locking pin Lifting lifting points Suspended load Take all necessary precautions to prevent accidents caused by accidental falling of the machine during the lifting. Ensure the machine is properly supported and in a stable position! While lifting and moving the implement, it is compulsory to ensure that safe distances are maintained. Only use the points indicated to attach the lifting device; see figure. The three-point hitch on the machine must be positioned so that the machine is properly balanced when it is lifted. The three-point hitch must be locked; In particular, in cases where the implement is equipped with mechanical movement, check that the locking device is positioned and secured correctly. Attach the implement to the points indicated with the appropriate fixing devices, lift the implement using a suitable lifting device, ensure that the support foot has been correctly positioned, place the implement on a suitable surface. If it is necessary to transport the implement on a truck: secure the implement so that it cannot move, all moving parts of the implement must be firmly secured. 39
Driving on the road Driving on the road The implement can be transported hitched to the tractor. Before driving on the road It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Check the width of the implement Implement must be in transport position. All moving parts of the implement must be firmly secured. Brake lights, reversing lights and direction indicators During transportation, the brake lights, the reversing lights and the direction indicators, as well as the tractor licence plate, must be clearly visible. If not clearly visible, the lights and licence plate must be attached to the implement. Removing dirt Remove any crop remains, stones and clumps of earth. When driving on the road, these foreign objects can become detached from the implement and cause accidents. wrapper bracket Marking for slow-moving vehicle SMV Additional markings are required for road transport or traveling on public roads in some U.S. states and some Canadian provinces. In general the SMV emblem is placed behind the tractor. Move the SMV emblem position from the tractor to the wrapper bracket of the machine in case of this obstructs the visibility of the Tractor SMV triangle. Transport position three point hitch locked Implement transported hitched to the tractor: centered frame. Before proceeding to transport, ensure that the the three-point hitch is centered positioned on the frame of machine. Only this will reduce the overall width. Support foot raised. Ensure that the support foot is as far from the ground as possible. = centered frame = support foot raised The three-point hitch must be locked. In particular: in cases where the implement is equipped with mechanical movement, check that the locking device is positioned and secured correctly, in cases where the implement is equipped with hydraulic movement, check that the type of hydraulic connection between the implement and the tractor's hydraulic service couplers is such that the top link does not move when the remote control valve is not operated. 40
Use Use Increased risk of injury It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Check the danger zone The danger zone around the implement is 70 m (230 ft). Before starting up, opening and beginning operation as well as during operation, check the danger zone around the implement. Ensure good visibility. In unfavourable circumstances, objects may be thrown from the implement at high speed. Only start up and operate the implement if there are no people, animals or objects in the danger zone. Failure to respect these conditions when using the implement could lead to serious injury or death. Before raising the implement, disengage the PTO Do not lift the implement too high with the transmission in operation: the drive shaft could be forced to an excessive angle and break causing serious injury to the operator and damage to the implement itself. The maximum angle permitted for the drive shaft is 25. When lifting, always ensure that the PTO is disengaged when this value is approached or when there is a risk of exceeding it. Only work forwards The implement must be in the working position only when the vehicle is travelling forwards. When manoeuvring or reversing, disengage the PTO and lift it up. Keeping the implement in the working position could cause it to be seriously damaged. Ensure that the tractor and implement are aligned and stable Pay particular attention when using on uneven and/or sloping terrain, or when close to ditches or banks. Adapt speed, driving and use of the incline adjustment and lateral movement functions depending on the conditions of the terrain. Always check the stability of the tractor and implement. Failure to ensure stable conditions when using the implement could cause serious accidents or death. Set the tractor's lift arms to the float position Set the tractor's lift arms to the float position; the arms must not be locked while working, as this will create a poor cut and cause premature wear on the blades. Working Working with the chopper is a particularly hazardous activity, and for this reason requires very close attention from the operator. This manual provides only general warnings and advice. All situations must be evaluated by the operator. Ensure that there is no debris (wood, metal, plastic, glass, etc.) in the working zone which could be thrown from the implement or damage it. 41
Use Starting up Working speed Lift the machine slightly so that it can be started up without coming into contact with the material to be cut Engage the PTO and slowly increase the rotation speed Lower the implement until it reaches the working position and gradually increase the PTO speed, until working speed is reached (540 PTO rpm). The working speed should be regulated according to several criteria: the type and conditions of the material to be cut the desired fineness of the worked material The greater the working speed, the lower the quality of the cut material Obstruction When working with vegetation that is too dense, too damp or at excessive working speeds, the implement can become clogged. In such cases, the tractor engine speed will fall and the results will not be optimal. At the first signs of clogging: reduce the working speed of the tractor lift the chopper slightly If the clogging persists, please refer to the «Maintenance» section. Hydraulic lateral movement Only if the implement is equipped with the hydraulic lateral movement, it is possible to vary the movement during operation, to adjust it to working requirements. Simply operate the corresponding function on the tractor hydraulic distributor. When the machine is equipped with a three-point linkage with manual side adjustment device, it must be adjusted before hitching the machine to the tractor. For the manual side adjustment, see on page 33. Lateral movement during the chopping: do not perform this operation when the implement is in contact with the ground. This could lead to stress being exerted which could cause damage. Do not raise the implement more than strictly necessary to avoid the contact from the ground. Lift the implement Actuate the tractor's distributor to achieve the desired movement. Lower the implement again. 42
Use Finishing work To stop the implement, reduce the tractor's engine speed and disengage the PTO. Warning: moving rotor After disengaging the PTO, the rotor on the implement will continue to rotate for a few seconds due to inertial force. Wait until all parts have stopped moving completely. Abnormal noise and vibrations If abnormal noise or vibrations are noted during use, stop the implement immediately and, whilst observing safety precautions, remove the cause of the problem or if necessary contact your retailer. Safety guards Safety guards correctly installed Check carefully that all the safety guards are present and correctly installed on the machine. Periodically check the condition of the safety guards and replace them immediately if they are damaged In particular: the PTO cover the drive shaft guards the front safety guards the rear deflector. description of the implement on page28 The deflector may be removed for maintenance and cleaning operations without infringing the safety regulations, but when the machine is operating it must be assembled and locked with the correct fasteners. Working position Correct positions of work It is forbidden to operate the machine with the tractor straddling a ditch. 43
Cleaning and care Cleaning and care Cleaning Clean the implement by washing with gentle detergents. Ensure that components that could be damaged by penetration are adequately protected. Take care when using pressurized water jets If using a pressurized water jet for cleaning, do not hold it too close to the implement and avoid directing it directly onto any parts that could be damaged or affected by penetration; in particular, pay attention to vent plugs, bearings, washers, seals, hydraulic hoses, housing, etc. When cleaning the jack shaft, be careful not to scratch it When you have finished washing the implement, it is recommended that you dry it carefully. Cleaning is an ideal occasion to check the condition of the implement: check for any defects and take steps to eliminate them. Residue can accumulate on the upper left-hand side of the machine, (see following figure): check this periodically, and if necessary, remove any build-up. 44
Detaching and storing Detaching and storing Safety first! It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Detaching the implement Storage of the implement Rest the implement with its frame in the horizontal position on a solid, flat and even surface, in order to: Lower and adjust the foot to ensure correct support on the ground Disconnect the drive shaft from the tractor Remove the hydraulic hoses from the tractor Disconnect the implement's three-point hitch from the tractor Disconnect any electric cables. Safety first! It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Keep children away from the machine Forbid children from playing on or around the machine. Select a parking area to which no unauthorized persons have direct access. Metal edges and machine work tools can cause serious injury. Support the machine Ensure the machine is properly supported and in a stable position! Make sure the machine is with its frame in the horizontal position and with the adjust foot to ensure correct support on the ground. The machine could tip over. Damage to the machine and serious or fatal injury may be caused as a result. The implement must be parked on a solid, flat and even surface, in a dry, sheltered area, and in such a way that it does not pose a risk to people or animals. Before storing in a garage, it is advisable to: clean the implement check the conditions of the implement check that nuts, bolts and hydraulic connections are tightened replace any worn or damaged components apply grease where indicated check the oil levels of the unit and the transmission carry out all the necessary maintenance work 45
Detaching and storing Preserve the piston rods of the hydraulic cylinders For winterizing or storing, preserve the piston rods of the hydraulic cylinders with grease. Otherwise the pistons rods may corrode. Damage to the machine may be caused as a result. Using the implement after storage When preparing to use the implement after storage, it is necessary to carry out a series of checks, such as: the condition of the implement and safety equipment the oil level in the multiplier unit the presence of grease, where necessary the condition of the blades the absence of lubricant leaks 46
Maintenance Maintenance For your safety Special safety warnings Safety first! It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Preliminary conditions for maintenance work Only carry out maintenance work if you have the necessary technical skills and have the appropriate tools. A lack of technical knowledge and misuse of tools can cause accidents. Use only genuine spare parts In the interests of safety, only use genuine spare parts. The dimensions, resilience and quality of the material must be respected. If non-genuine spare parts are used, the warranty is void. Secure the implement so that it cannot be activated involuntarily Normal and special maintenance activities and checks to ensure the equipment is functioning correctly should be carried out when the implement is connected to the tractor only when: PTO is disengaged engine is switched off ignition key is removed the tractor handbrake is applied and wheels chocked implement and its parts are immobilized with appropriate supports Involuntary operation can cause serious accidents. 47
Maintenance Safety when handling oils and lubricants The additives present in oils and lubricants can have toxic effects on your health. Please pay attention to the following safety advice: Avoid contact with the skin Avoid contact with skin: risk of damage to skin. Protect your skin When using oils or lubricants, protect your skin with suitable creams or gloves. Oils can cause damage to health. in the event of skin injury caused by oils or lubricants seek medical advice immediately Do not use oils for cleaning purposes Never use oils and lubricants to clean your hands. Shavings and other materials present in these substances can cause injury. Change clothes soiled with oil Change clothes soiled with oil as soon as possible. Oils can cause damage to health. Collect waste oil and dispose of it as prescribed by law. 48
Maintenance General principles The operations described in this chapter are essential to the correct functioning of the implement. Respect maintenance intervals All of the indications refer to moderate use of the implement. For more intensive use, more frequent maintenance intervals are necessary (e.g. contractors) Extreme working conditions can also mean that more frequent maintenance intervals are necessary, for example, when large amounts of dust are present. Maintenance intervals and adjustments after the first few hours of use once a day after 30 hours of use after 100 hours of use after 250 hours of use once a season when necessary when worn lubricate / oil / grease check replacement cleaning General details Re-tighten all screws Visual inspection Hydraulics Hydraulic hoses, every 6 years Drive belts Tools Lubrication Hydraulic hoses, in general Tightening hydraulic connections Check tension Replacing Fixing devices on the rotor Conditions, wear Rotor bearings Roller bearings Drive shaft (1) Multiplier unit oil (1) Refer to maintenance advice laid out in the documentation provided with the drive shaft. 49
Maintenance Screw attachments Re-tightening of screws Tightening torques in general All screws must be tightened after the first few hours of use depending on frequency of use at least once a season Use the correct screw and bolt tightening torque Securely tighten screws, nuts and bolts to the specified torques. Damage to the machine and serious or fatal injury may be caused as a result. Tighten all screw attachments according to the indications laid out in the table. If other tightening torques are required, these will be indicated in the Maintenance chapter. The minimum quality of screws is "8.8". Quality of screws Screw dimensions "8.8" "10.9" "12.9" Tightening torque in Nm M6 9.9 Nm (7.3 ft.lbs) 14 Nm (10.3 ft.lbs) 17 Nm (12.5 ft.lbs M8 24 Nm (17.7 ft.lbs) 34 Nm (25 ft.lbs) 41 Nm (30.3 ft.lbs) M10 48 Nm (35.4 ft.lbs) 68 Nm (50.2 ft.lbs) 81 Nm (59.8 ft.lbs) M12 85 Nm (62.7 ft.lbs) 120 Nm (88.6 ft.lbs) 145 Nm (104 ft.lbs) M14 135 Nm (99.6 ft.lbs) 190 Nm (140 ft.lbs) 230 Nm (166 ft.lbs) M16 210 Nm (155 ft.lbs) 290 Nm (214 ft.lbs) 350 Nm (258 ft.lbs) M20 410 Nm (302 ft.lbs) 580 Nm (428 ft.lbs) 690 Nm (509 ft.lbs) 50
Maintenance Lubricants \ CAUTION Use only prescribed lubricants Is prohibited mixing different type of lubricants. Impermissible lubricant mixture can damage the components of machine. Observe the correct fill quantities Observe the correct lubricant fill quantities. Check them regularly. A lubricant level which is too low or too high may result in damage to the machine. Greasing operations Grease specifications The following figure shows the position of the grease fittings on each component. There may be additional grease fittings on the implement to those shown in this operator s manual; usually greasing points are positioned near the joints, moving parts and bearings. For this reason, please check the entire implement for greasing points. NLGI 2 DIN 51825 K2K-20 Greasing the bearings The bearings should be lubricated on a regular basis: as per the maintenance table, after being subjected to high stress levels, at least once a season. Bearings that do not need maintenance work should not be lubricated. Working with the pneumatic grease gun: Lubricate by pressing 1-2 times on the pneumatic grease gun. If resistance is felt from the pneumatic grease gun on the second pump, stop the operation. Excessive quantities of grease lead to the oil seals moving from their positions, allowing dirt and dust to penetrate inside the bearings, which leads to premature wear. 51
Maintenance Description of points to be greased = area to lubricate cap with grease fitting underneath The rotor bearing grease fitting, from the side of the lateral transmission, is accessible by removing the cap which is found on the cover of the housing. Greasing the drive shaft Refer to maintenance advice laid out in the documentation provided with the drive shaft. 52
Maintenance Gearbox oil when necessary Risk of burns Surfaces and oil in the gearbox could be hot. Therefore please wait until these cool down before starting work. Check the seals on the plugs after each operation. Gearbox Checking Place the implement on a flat surface, so that it is horizontal, wait for a few minutes after it has completely stopped, control cap filler cap drain cap unscrew the control cap, check the oil level: the oil should come up to the lower edge of the threaded hole, re-tighten the control cap. Top up Remove the filler cap and the control cap, with a funnel, fill the transmission with oil as specified, until the oil reaches the lower edge of the inspection plug, replace the control and filler caps. Do not exceed the prescribed levels. Do not mix oils of different types and specifications: this could cause malfunctions and breakage of components. Replacing Position a container underneath the drain cap to collect the waste oil, Alternatively, you can use an oil siphon pump and siphon the oil directly from the oil filler hole remove the filler cap, remove the drain cap so that all of the oil flows out, replace the drain cap, using a funnel, refill with oil as specified, Replace the filler cap, Check the level. Quantity of oil in the unit Model 155-185-200-230 Oil type Mineral EP ISO VG 460 DIN 51517 Part 3 -CLP Quantity in litres 1,2 53
Maintenance Transmission Checking filler cap Position the machine horizontally and wait for a few minutes after it has completely stopped, unscrew the cap to check the level: the oil should reach the lower rim of the hole, screw the cap back on. control cap If necessary, top up with oil of the type recommended in the tables using a funnel: unscrew the filler cap, top up the oil and replace the cap. Do not exceed the prescribed levels. Do not mix oils of different types and specifications: this could cause malfunctions and breakage of components. Quantity of transmission oil Model Oil type Quantity in litres 155-185 Mineral 0,8 EP ISO VG 460 200-230 DIN 51517 Part 3 -CLP 1 54
Maintenance Hydraulics Hydraulic connections Check periodically that the hydraulic connections are correctly tightened Hydraulic system at zero pressure Work must only be performed on the hydraulic system if the tractor and machine hydraulic system is at zero pressure. A pressurized hydraulic system can trigger unforeseen movements on the machine and can cause serious machine damage and personal injury. Serious or fatal injury may be caused as a result. Exercise caution when welding Do not perform any welding work in the vicinity of the hydraulic hoses. Hydraulic oil can catch fire very easily. Clean hydraulic system Close or disconnect the quick couplings with great care. Remove any dirt or air which has entered the hydraulic system. The hydraulic system may otherwise be seriously damaged. Material damage or personal injury may be caused as a result. Collect escaping oil Escaping oil must be collected and disposed of in accordance with national regulations. Otherwise, damage may be caused to the environment. Hydraulic hoses Replace hydraulic hoses every six years or earlier Hydraulic hoses age without showing externally visible signs. Replace hydraulic hoses every six years, or earlier if aging or degradation is visible. Defective hydraulic lines can cause serious or fatal injuries. Hydraulic hoses age without showing externally visible signs. We therefore recommend replacing the hydraulic hoses every six years. Lower the machine to the work position. Depressurize the system. Switch off the tractor. Remove the ignition key. Disconnect the hydraulic hoses. Replace hydraulic hoses. Hydraulic oil specifications Kubota UDT or equivalent. 55
Maintenance Comparative classification of viscosity ISO VG AGMA lubricant SAE gear viscosity SAE viscosity Normal oil base nomenclature 56
Maintenance Tools when necessary Blades and fixing parts (fixing nuts, screws, clevis fasteners) should be replaced if: they are damaged, they are very worn, the hole on the blade is worn. It is important that the rotor functions evenly. Therefore ensure that: always replace blades with new ones of the same type always replace blades that are positioned diametrically opposite each other at the same time if all the blades need to be replaced (in the case of wear, for example), contact an authorised retailer. The rotor will need to be balanced after the blades have been replaced Safety first It is strongly recommend that you observe the safety warnings given in the previous pages of this manual. Secure the implement so that it cannot be activated involuntarily Normal and special maintenance activities and checks to ensure the equipment is functioning correctly should be carried out when the implement is connected to the tractor only when: PTO is disengaged engine is switched off ignition key is removed the tractor handbrake is applied and wheels chocked implement and its parts are immobilized and secured with appropriate supports Involuntary operation can cause serious accidents. blade In particular, if the implement is only held up by the lower arms and no other fixation is applied, working underneath the implement risks fatal injury. The lower arms can collapse unexpectedly due to the weight of the implement, causing serious injury or death. screw nut Raise and secure the implement Unscrew the nut and pull out the screw Remove the old blade Insert the new blade. If washers are present, reinsert, taking care to position them correctly. Insert a new screw and lock with a new nut 57
Maintenance Trapezoidal drive belts Checking the tension Trapezoidal drive belts should be tensioned using an adjustable tensioning system. Check the tension of the drive belts after the first 10 hours of use and subsequently every 30 hours, or when necessary. Insufficient or excessive tension greatly reduces the life of the belts. Remove the housing that covers the lateral transmission by unscrewing and removing the fixing screws Drive belt tension can be controlled in several ways. From this point, two possible methods are outlined, using: A) a tool provided by the drive belt manufacturer B) a frequency meter Please refer to the following figures. indicator arm specific device graduated scale pushbutton A) This method requires knowledge of the smallest pulley diameter and of the drive belt characteristics. Ensure that the drive belts are completely still. Position the device in the center of one of the drive belts. Make sure that the indicator arm is pointed downwards in the body of the device With one finger, slowly and firmly press down on the pushbutton When a "click" is heard, stop the pressure and remove the device Read the graduated scale on the body of the device, at the exact point at which the upper surface of the indicator arm crosses the scale Check the tension against the tensioning table provided with the device In general, tensions values are around: 600 N for initial installation 460 N after testing/running in Important: during this procedure, do not touch the indicator arm, or the readings may be inaccurate frequency meter B) Ensure that the drive belts are completely still. Hold the frequency meter near the drive belt, and if possible, lean against a fixed object, in order to avoid false readings due to hand movement Touch the drive belt to make it vibrate Read the drive belt frequency on the display The frequency of the drive belt is approximately: 86 Hz for initial installation 72 Hz after testing/running in For both methods, carry out tests on all drive belts if possible and calculate the mean value. If necessary, adjust the tension of the drive belts. refer to paragraph Adjusting the tension 58
Maintenance Replace the housing, taking care to position it correctly, and tighten the fixing screws. Adjusting the tension when necessary trapezoidal drive belts stretcher roller To adjust the tension of the drive belts, proceed as follows, referring to the figure: remove the housing that covers the lateral transmission, unscrewing and removing the fixing screws Loosen the lock nut which locks the push rod adjustment Alter the adjuster nut on the push rod so that the previously indicated tensioning values are reached. Refer to paragraph Checking the tension Secure the lock nut Replace the housing, taking care to position it correctly, and tighten the fixing screws. push rod adjuster nut lock nut Replacing the drive belts when necessary cracks on the belt If cracks form or the trapezoidal drive belts are damaged or worn, they must be replaced. The drive belts must always be replaced as a set, not individually; this is to ensure that the belts are all tensioned equally. To replace the drive belts, proceed as follows, referring to the previous figure: Remove the housing that covers the lateral transmission by unscrewing and removing the fixing screws Loosen the lock nut which locks the push rod adjustment Loosen the pressure of the stretcher roller by unscrewing the adjuster nut on the push rod Remove the trapezoidal drive belts. Position the new trapezoidal drive belts. Close the stretcher roller again and adjust the drive belt tension using the adjuster nut on the push rod. refer to paragraph Adjusting the tension Secure the lock nut Replace the housing, taking care to position it correctly, and tighten the fixing screws. 59