FLAIL MOWERS WITH HOPPER

Transcription

1 SaMASZ Sp. z o.o. Poland, Bialystok, ul. Trawiasta 15 Established 1984 NIP PL tel. (+48) (85) fax (+48) (85) samasz@samasz.pl OPERATOR'S MANUAL FLAIL MOWERS WITH HOPPER EMU 160 1,60 m EMU 160 S 1,60 m EMU 160 UP 1,60 m IBIS 150 IBIS 150 UP 1,50 m 1,50 m Serial no: Translation of original instructions IN380EN EDITION 4

2 DO NOT OPERATE WITH MOWER WITHUN AUTHORIZED PERSONNEL PRESENT WITHIN LESS THAN 50 M DO NOT TURN MOWER S DRIVE UNTIL MACHINE IS IN OPERATING POSITION Keep this manual for future reference. Well-proven design with thousands of machines in regular use in many countries and quality materials ensure high durability and reliability of SaMASZ tedders. 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.

3 CONTENT Page 1. IDENTIFYING MACHINES INTRODUCTION DESIGNATION Technical data Design and working principle Optional equipment Standard equipment and spare parts Flail knives applicable in mowers SAFETY ADVICE AND WARNING Safety rules and regulations Qualifications of operator Conditions of mounting mower on tractor Transport Relocating mower onto another vehicle for transport Operating parts PTO shaft Hydraulic assembly Residual risk Bans Residual risk assessment Safety decals and their meaning OPERATION Mounting mower to tractor Preparing mower for transport Preparing mower for transport on public roads Mounting PTO shaft Preparing mower for operation Adjusting the IBIS mower for scarifying of lawns Operation Basic information on mowing Operating mower Dismounting machine from tractor MOUNTING AND ADJUSTMENTS Adjusting mowing height Operating service Belt gear s V-belts tension control Flail knife condition control Daily maintenance After-season maintenance Restarting the machine after longer idle periods LUBRICATING Intersecting axis gear Bearing housing of flail shaft Risk present when lubricating DEFECTS AND THEIR REPAIR REPAIR AND WITHDRAWAL FROM USE Repair Disassembly and withdrawal from use WARRANTY CARD WARRANTY TERMS Warranty claim procedure Warranty repairs record APPENDIX CALCULATING AXIS LOAD

4 1. IDENTIFYING MACHINES Data plate is permanently mounted to the mower's main frame in place shown below on Fig. 1. Fig. 1. Data plate placement Data plate includes: - name of the manufacturer, - mower serial number, - mower symbol, - date of manufacture, - version number, - weight, - quality management sign, - CE marking, means that mower is conforming with Directive 2006/42/EC and harmonized standards, - 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. 2. INTRODUCTION This operator's manual should be considered the mower's basic equipment. If the mower is handed over to other user, it should be in good condition, and have operator's manual and its basic equipment attached. Prior to operating the mower its user must familiarize himself with this manual as well as common work safety rules. The mower is manufactured in accordance with safety standards requirements. Respecting recommendations herein shall ensure full operation safety. If you have any questions concerning commission and operation of the mower, please contact the manufacturer. This operator s manual is an indispensable part of any machine and is intended to familiarize future user with principles of proper operation and use of the machine as well as the risks involved. GENERAL PRECAUTION When operating the mower warnings and safety rules marked with this sign herein should be respected. Operating the mower without previous familiarizing with its contents as well as by unauthorized personnel, particularly by children, is strictly forbidden

5 3. DESIGNATION Self-collecting flail mower with hopper is used for maintaining and curing of greenery, mowing road shoulders, squares, small shrubs on uncultivated areas, weeds with moderate congestion and agricultural works. Depending on flail type the mower shreds branches (with diameter up to approx. 4 cm). Self-collecting flail mower with container IBIS is intended for works related to maintenance and curing of municipal greenery, i. e. for mowing parks, squares, pitches, lawns, golf courses, etc. Depending on flail type the mower shreds branches (with diameter up to approx. 2 cm).owing to the application of special knives type XII mower IBIS can be used for scarifying in order to remove old, too thick turf and enable new grass to grow Technical data Use of the mower for purposes other than mentioned herein is forbidden. Any other use than the above mentioned shall be considered as improper and may lead to revoking the warranty. The mower should be operated, maintained and repaired only by personnel who are learned with its detailed specifications and safety rules and procedures. Willful modifications to the mower may lead to revoking of the warranty. Technical data for flail mowers with hopper are provided in Tab. 1. Tab. 1. Technical data Mower type: EMU 160 EMU 160 S EMU 160 UP IBIS 150 IBIS 150 UP Working width [m] 1,6 1,5 Knife (flail) count [pcs.] Tractor's PTO rears [rpm] 540 Cooperating tractor power [HP] Length [mm] Width [mm] Height [mm] Weight [kg] Tractor lifter category II I Maximum hopper capacity [m 3 ] 1,5 1,2 1,4 1,0 Grass discharge height [m]

6 3.2. Design and working principle Design and working principle of flail mower with self-collecting hopper are provided on Fig. 2, Fig. 3, Fig. 4, Fig. 5. (1) comprises linkage body (9), which is designed to mount the mower to 3-point linkage (7) at tractor s rear (Fig. 12). Mowed grass is emptied from the hopper with cylinders (3) started by tractor's hydraulics. Drive onto flail shaft (12) is transmitted through PTO (8) onto intersecting axis gear, which is mounted on mower's linkage body (9). Then the drive is transmitted through belt gear onto flail shaft (12), with mounted flail knives (13) (Fig. 7). Mounting manner of flail (cutting) knives is performed to provide protection of operating elements against overload and damage. When operating, if resistance of an obstacle exceeds knife s centrifugal force, it is then deflected and obstacle is passed by. Mowing height is adjusted by modifying setting of ground following bar (11) (Fig. 6) (p. 6.1) Fig. 2. Overview of flail mower EMU 160, EMU 160 S Markings: 1 hopper 2 hopper flap 3 cylinder 4 belt gear 5 slides 6 front guard 7 3-point linkage hitch 8 PTO mounting 9 linkage body 10 remote arm 11 ground following bar 12 flail shaft 13 flail knife 14 outlet option 15 jet 16 basket cover 17 support wheel 18 tiller Fig. 3. Overview of flail mower EMU 160 UP

7 Fig. 4. Overview of flail mower IBIS 150 Fig. 5. Overview of flail mower IBIS 150 UP Markings: 1 hopper 2 hopper flap 3 cylinder 4 belt gear slides 6 front guard 7 3-point linkage hitch 8 PTO mounting 9 linkage body 10 remote arm 11 ground following bar 12 flail shaft flail knife 14 outlet option 15 jet Fig. 6. Ground following bar Fig. 7. Flail shaft 16 basket cover 17 support wheel 18 tiller Optional equipment Front support wheels (for: EMU 160, EMU 160 S, EMU 160 UP, IBIS 150, IBIS 150 UP) Front support wheels are used for ground following, the same as ground following bar. Wheel height can be adjusted within 6 cm range by spacers. As an option, each machine has a pair of front support wheels (2 pcs.) assigned. In IBIS mowers support wheels are equipped with locking mechanism disabling their 360 rotation, and when driving the machine in reverse this might cause wheel locking. Rear support wheels (for: EMU 160 UP) If mower EMU 160 UP is aggregated with tractor weighing less than 3 tons then the machine should be equipped additionally with rear support wheels

8 For mowing rear support wheels should be lifted up as high as possible. When transported or on headlands the wheels are lowered, so the machine is lifted up to 20 cm height which causes the tractor to be unloaded and become more stable. Rear support wheels enable increasing height up to 2.2 m on which hopper with mowed grass is emptied. If mower is equipped with rear support wheels tractor can be mounted to machine with use of lower 3-point linkage arms (or with tiller as an option) - when mowing the mower is supported on ground following bar and when transported then on rear support wheels. Rear support wheels are self-torsion and it is possible to lock them when driving forward (to be used when the mower is mounted on the tractor by means of a drawbar). Tiller (for: EMU 160 UP) Tiller is mounted only when EMU 160 UP mower is equipped with rear support wheels. It improves servicing and maneuvering of the mower. Servicing and controlling the mower equipped with tiller and support wheels is quite the same as in single-axis trailer. Tiller features hydraulic control of height, so the machine can be lifted up for transport. In the event of mounting the tiller, the machine is then equipped with longer PTO shaft. Outlet (for: IBIS 150, IBIS 150UP) The outlet is mounted on the top of container (collecting basket) as an option. It is designed to direct the output air to the behind of the container back (to reduce dusting) Standard equipment and spare parts Mowers are sold with the following standard equipment: warranty card, operator's manual with catalogue of spare parts and declaration of conformity, flail knives 2 pcs., PTO shaft, spray paint (150 ml). Optional equipment (on extra charge): optional flail knife set, optional set of bearings for ground following bar and flail shaft, optional sealing kit for bearings for ground following bar and flail shaft, front support wheels (2 pcs.), rear support wheels (set), tiller. Tab. 2. Recommended PTO shaft by Bondioli & Pavesi Mower EMU 160 EMU 160 S EMU 160 UP EMU 160 UP + tiller IBIS 150 IBIS 150 UP Power Length Momentm Shaft terminations Symbol HP mm Nm Tractor Mower 1 3/8 z= G4N061CE007096MA 1 3/8 z=6 right overrunning clutch 1 3/8 z= G4N091CE007096MA 1 3/8 z=6 right overrunning clutch G4N086CE007007HA 1 3/8 z=6 1 3/8 z=6 Full cover Remarks - 6 -

9 Fig. 8. PTO shaft lubrication. Mounting direction PTO shaft lubrication frequency must be respected as provided in corresponding manual. Lubricate the marked points 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 only on the SaMASZ permission Flail knives applicable in mowers In order to provide proper operation of mower flails need to be repalced once they are worn. Corresponding symbol of flail knife can be found in mower's catalogue of parts. The table below shows knives that can be mounted in mowers EMU and IBIS. Tab. 3. Flail knives Flail knives EMU IBIS KNIFE TYPE I Application: grass, shrub, stalks, remnants after trimming, stubbles Standard KNIFE TYPE VII Application: grass, plants stalks Standard - 7 -

10 Flail knives EMU IBIS KNIFE TYPE IX Application: grass, plants stalks, smaller bushes, branches Option LEFT RIGHT KNIFE TYPE XI Application: grass, plants stalks Option KNIFE TYPE XII Application: Scarifying lawns Option 4. SAFETY ADVICE AND WARNING 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. Operating with damaged or worn fasteners is not permitted. Start mowing only when the tractor's PTO shaft reaches its nominal rpm (see Tab. 1 Technical data). Do not exceed nominal speed on PTO by more than 5% see Tab. 1 Technical data Tractor 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 as well as when shredding trunks and operating near roads (danger of throwing out of hard elements). Any maintenance and adjustment work is allowed only with the drive disconnected and the flail bar in complete standstill. Flail knives should be inspected periodically for proper mounting (screw connection clearance and worn holes in mounting holders). Damaged or worn mounting bolts must be replaced with new ones. When driving on public roads always respect the local traffic regulations concerning warning lights, while the mower shall be equipped with required devices. When transported the mower shall have remote warning light device and warning triangle mounted

11 Any service and repair related works must be conducted with the tractor drive off, flail shaft on the ground and all rotating parts in complete standstill. When the mower is lifted for repair on the 3-point linkage, it should be protected against accidental falling by a mechanical support or by chain. The bolts and other fasteners should be inspected on regular basis. Operating with damaged or worn fasteners is not admissible. When operating the mower, 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 agriculture Dz. U. no. 12/98 item 51. When operating the mower, the tractor should always be equipped with operator's cabin. The mower shall never be started when it is lifted. The mower shall never be started, with people or animals near the machine. The safety guard shall never be lifted unless the rotating drums are in complete standstill. Tractor's engine must be stopped. Always comply with safety decals describing hazards, and warning signs placed on the machine. Prior to starting the tractor make sure that each drive is disconnected while the hydraulics control levers are in neutral position. Do not let the tractor's engine operate without any supervision. Before leaving the tractor, turn the engine off and take the ignition key out. It is forbidden to drive the mower backwards when operating. Never get onto the mower. It is forbidden to lift the mower on the tractor 3-point linkage with the drive on and flail shaft rotating. For operating and transport drive permissible slope shall be 8. Never stand between the tractor and the mower, unless tractor-mower aggregate is protected against shifting with the tractor's parking brake. Any inspection of mower's technical condition or adjustment may be performed when the mower is lowered onto the ground or protected from falling with supports or chains. If any maintenance or adjustment works under the lifted mower are necessary, it must be secured against falling with a support. Please be extremely careful when opening and closing the hopper. Do not enter the hopper upon opening hopper flap without providing any additional protection firstly. If any part of the mower needs to be replaced, use only genuine spare parts according to spare part list. Pay particular attention to PTO shaft guards and mower and tractor spline shaft guards. Never operate with damaged guards. Hydraulic hoses should be inspected on regular basis and if any damage is found or they expire, replace these with new ones. Expiry period for hydraulic hose should be no longer than 5 years. Never use scotch tape to repair damaged hydraulic hoses. When connecting hydraulic hoses to tractor hydraulic connectors make sure, that either tractor or mower hydraulics are pressure free. Be extremely careful when mounting and dismounting the machine to and from the tractor. Bearing this in mind there is high risk of being crushed or cut within area of mounting tractor to machine. When servicing hydraulic unit, always wear protective gloves and eyewear. Hydraulic oil leaking under pressure (16 MPa) may permeate through the skin and cause its infection thereafter. If such is experienced, immediately visit a doctor

12 The mower should be stored under roof and in manner that effectively prevents animals and people from being injured. The operator is not allowed to leave the tractor while driving. Prior to approaching operation with the machine, make sure that all safety guards are not damaged and fitted in place. 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 Qualifications of operator To provide safe machine operation each person being the machine operator must meet the following requirements: Operator should hold driving lecense, have ability to drive vehicles safety and know road traffic rules. Operator must be in proper physical conditio 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 Conditions of mounting mower on tractor Prior to the mounting operation, check whether the tractor s and the mower s hitch categories are compatible and make sure that tractor s hitch load is adequate for the machine aggregated. Prior to mounting the machine, examine technical condition of the mower's hitch assembly and tractor's 3-point linkage. Use only genuine pins and cotters to mount the mower on a tractor Transport Any modifications in the mower's position are possible only if no unauthorized personnel is around (children in particular). When transported the mower shall have remote warning light device and warning triangle mounted for a slow driving vehicle. When transported the mower should always be set in transport position. See item 5.3. Prior to setting the mower to transport position make sure, that the tractor PTO is disconnected and all the rotating parts are in complete standstill. Always adjust your driving speed to the current road conditions and according to local traffic rules. Do not exceed permissible speed of 25 km/h. No person and no objects must remain on the mower when driving or transporting. When taking turns pay particular attention and consider the machine's weight and dimensions Relocating mower onto another vehicle for transport Both the carrier and the driver shall be responsible for the mower transport safety. Any equipment and parts must be secured properly for transport

13 In order to have the mower relocated safely onto another vehicle, please follow these rules: seize the mower by any lifting device only in places indicated on the machine with the hook sign (Fig. 9). Mower should be relocated with use of spanset with manner of routing belts through eyes in the linkage, to lift the mower, use only lifting devices with hoisting capacity bigger than the mower weight provided on data plate. It also applies to 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, Transport holders a) b) Transport holders c) d) Fig. 9. Transport holders in mower: a) EMU 160, EMU 160 S, b) EMU 160 UP c) IBIS 150 UP d) IBIS 150 when relocating the mower onto another vehicle, there should be no unauthorized personnel permitted to remain within the danger area, the mower should be protected from shifting on the vehicle's trailer

14 Tab. 4. Location of centre of gravity Dimension [mm] Fig. 10. Location of centre of gravity Model EMU 160 EMU 160 S EMU 160 UP IBIS 150 IBIS 150 UP A B C Securing both the danger area and activity performed shall lie under the responsibility of the person in charge of the mower transportation Operating parts Prior to operating the mower inspect condition of flail knives. Worn or damaged flail knives should be replaced immediately with new ones featuring the same weight PTO shaft Before operating learn provisions found in bar manufacturer's manual placed on the bar. Use only the mower's manufacturer recommended PTO shafts. 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 Caution! Hydraulic assembly is under pressure! Hydraulic oil under pressure may permeate troigh 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 dismounting the machine from the tractor, set the equipment aside, deflate the pressure from hydraulics. 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

15 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 gydraulic hoses is 5 years from their production date Residual risk Despite the fact, that SaMASZ Białystok company the manufacturer of the mower takes the responsibility for the mower design and manufacturing, in order to eliminate hazard, certain elements of risk when operating the mower are unavoidable. Major source of risk follows performance of these operations: operation of mower by minors as well as not being learned with content of the operator's manual, operation of mower by persons under influence of alcohol or other abusive substances, not keeping caution while transporting and relocating the mower during operation, transport of persons remaining on the machine, presence of persons and animals within the mower operation range, performing operations related to servicing and adjustment with engine on. 1. Danger of catching This kind of risk occurs when the mower position is changed, when operating near rotating parts, operating without safety guards. When operating, maintenance and regulation works are conducted always wear protective gloves, footwear and clothing with no loose parts, belts, etc. Always comply with safety decals placed on the mower. 2. Danger of injury, abrasion and damage of skin Present when replacing working parts with sharp edges, cleaning the machine and removal of any clogging and jams. During any maintenance work always use safety gloves. 3. Danger of ejection of liquid under pressure out of hydraulics When connecting hydraulic hoses to tractor hydraulic connectors and disconnecting these make sure, that either tractor or mower hydraulics are pressure free. When servicing hydraulic unit, always wear protective gloves and eyewear. Inspect hydraulic hoses regularly. Residual risk results from incorrect behavior of the mower's operator

16 4.9. Bans Bear in mind the following bans when operating the mower: do not unblock the mower, make any adjustments or repairs when the mower is operating, never change the sequence of operation and maintenance works specified in the operator's manual, never operate the mower when its working condition is poor or has safety guards damaged, never get your limbs close to mower's rotating parts, do not enter the hopper upon opening hopper flap without providing any additional protection, do not use the machine with opened hopper, as it may cause hard objects to be thrown out, during the mower 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 works, focus your attention solely on the tasks to do, never operate the mower being under influence of alcohol, drugs, or strong medicines, wear clothing that is not too loose, nor too tight. Too loose clothing elements may be pulled in by the mower's rotating parts, the mower cannot be operated by children nor handicapped people. When describing residual risk, the mower shall be considered a machine, which until the moment of production launching had been designed and manufactured in accordance with top technology until the day of the mower manufacture. There is possibility of residual risk if not complying with specified instructions and bans Residual risk assessment Keep the following recommendations: learn operator s manual thoroughly, do not allow any person to remain on the machine when operating and driving, do not allow any person to remain within the mower's operating range, perform any works related to machine's adjustment, maintenance and lubrication with engine off, perform machine repair works if skilled in such respect, operate the machine, if learned the operator s manual, protect the machine against access of children and any unauthorized personnel and in result residual risk when operating the mower may be limited to necessary minimum. When the risk of being exposed to noise cannot be avoided or eliminated by any group protective means or organization of work, employer (operator) 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 its proper use, if the noise level in work place reaches or exceeds 85 db

17 4.10. 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-1 Be extremely careful when PTO shaft is rotating. N-3 Prior to operation commencement read the operator's manual carefully N-4 Prior to approaching any maintenance or repair works, the machine shall be turned off N-5 Warning: belt gear, keep particular attention N-7 Operating the mower is forbidden with presence of any unauthorized personnel within the danger area of 50 m N-9 Warning: rotor N-11 N-29 N-40 Transport holders for mower relocating N-49 Never stand near the tractor 3- point linkage when controlling the lift N-52 Wear protective gloves N

18 N-106 Caution: flail knives! Keep away from operating mower N-110 Danger of crushing body in mower's hopper operating area N-117 Avoid fluid escaping under pressure. Consult technical manual for service procedures N-118 Warning: full hopper N-119 Closing hopper flap N-201 Admissible transport speed N-167 No person is allowed to remain on the machine while driving N-168 Do not touch the machine before the rotating parts have not come to a complete standstill N-217 Wheel locking For: EMU 160 UP N-29 N-11 N-11 N-40 N-217 N-118 N-01; N-03; N-04 N-07; N-09; N-49 N-52; N-105 N-110; N-117 N-167; N-168 N-05 N-11 N-55 N-55 N-11 N-119 Fig. 11. Warning decals placed

19 5. OPERATION 5.1. Mounting mower to tractor When mounting and dismounting the mower, there should be no persons in between the machine and the tractor. Any accidental manoeuvring with the set may cause to crushing of unauthorized personnel. The machine should be mounted on a level ground. Mower IBIS 150 and IBIS 150 UP can be mounted to tractors equipped with category I lifter. Mower cooperates with tractors featuring lifters Cat. II. The mower should be mounted to tractor with use of 3point linkage as provided on (Fig. 12) unless EMU 160 UP mower is equipped with tiller (option). The mower should be adjusted, so that sliding skid is parallel to the ground. Upon mounting the mower adjust the machine position on even ground with use of connector (S) and hangers (W) of tractor's lower links (Fig. 12). Hangers (W) of the tractor lower links should be placed on pins (A) (Fig. 12) of the mower 3 point linkage frame. Pay attention to proper connection of hydraulic hoses. In case of EMU 160 UP mower equipment featuring tiller and rear support wheels the tractor has to be equipped with 3 pairs of hydraulic connectors. As the mower is attached to the tractor, examine the longitudinal balance and steering of the tractor-mower aggregate. To do this, calculate to formulas given in the appendix or weigh the set, and then drive on the scales only with front axis of the tractor (the mower must be in transport position, so lifted upwards). If pressure on the front axis is at least 20% of the whole pressure for the aggregate, it means the aggregate is stable. If not, the tractor front axis should be balanced accordingly. S W A Fig. 12. Connecting mower to tractor

20 5.2. Preparing mower for transport In order to prepare flail mower with hopper mounted to tractor for road transport the following should be performed: lift mower up with use of rear 3-point linkage; to meet safety precautions concerning transport on the public roads the mower should be equipped with warning triangle, attached at the mower's rear; when maneuvering, pay special attention to area around tractor-mower aggregate Preparing mower for transport on public roads Due to safety of road traffic and law regulations the mower is equipped with side lamp, stop light and driving direction. Before transporting inspect connection of lighting system wiring and its function Mounting PTO shaft PTO shaft should be mounted with overrunning coupling from the mower side. The guard should be protected against rotating by securing the shaft set chains to immovable parts of the tractor and the mower. If need be, shorten the PTO haft according to its operator s manual given by the shaft s manufacturer (Fig. 13). Fig. 13. Instruction of PTO shaft shortening Use machines with PTO shafts designed to drive them. Prior to the work commencement, safety guards should be inspected whether they (in the tractor, the mower and the PTO shaft) are placed correctly and are not damaged. Damaged or missing parts must be replaced with genuine ones. Make sure that the PTO shaft is mounted properly. Approaching the rotating parts is strictly forbidden, as it may lead to serious injuries or even cause death. For any service and repair works related to the shaft and the mower, the tractor engine and its drive must be turned and ignition key taken out, either. Prior to the operation commencement, read the operator's manuals of both the machine and the PTO shaft

21 When changing the tractor, with which the machine operates, control the length of PTO shaft again, as otherwise the machine can be damaged Preparing mower for 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. Prior to work commencement please learn the above items. Upon completing certain actions provided therein the mower shall be considered as operation-ready. Then: lower the flail shaft freely until ground following bar touches the ground, slowly engage PTO drive (see Tab. 1 - PTO rears) until PTO shaft reaches its nominal rotation speed, engage proper tractor gear and start mowing Adjusting the IBIS mower for scarifying of lawns To prepare the IBIS mower for scarifying of lawns do the following: place the mower's basket and secure it against falling, unscrew bolts from flap (6) (Fig. 15), replace knives for type XII - Tab. 3, unscrew counter-knife, place bolts (A) into holes (B) located below the previously screwed bolts and re-install counter-knife (Fig. 14)

22 A B Fig. 14. Counter-knife position adjustment in mower IBIS WARNING! If counter-knife position is not raised collision with scarifying knives will follow! 5.6. Operation Basic information on mowing In order to ensure the mower defect-free operation, it is recommended to engage a pilot in front of the mower to mark any obstacle. When traversing a road, pedestrian crossing or any other obstacle, the mower must be lifted up. Apparently the user must follow the common sense when operating the machine. Therefore, in case of intensive operation, bear in mind any expenses on necessary service checkups see WARRANTY TERMS. Upon driving onto single shrub with section up to approx. 2 cm, stop the tractor for a while, until the mower shreds the shrub at the ground, and then slowly drive forward, so there occurs no flail shaft locking. In order to provide proper mower operation empty the hopper. If hopper is full of forage it is indicated by fill gauge set in STOP position on decal N-118. In order to empty the hopper of mowed grass use corresponding handle of hydraulic distributor located in tractor in accordance with connection of machine's hydraulic hoses to tractor's connectors. EMU 160 UP, IBIS 150 UP mowers are equipped with adjustable hydraulic choke located in linkage body (EMU 160 UP) and at the end of hydraulic hose (IBIS 150 UP) thanks to which hopper lifting and rotating rate can be adjusted according to operator's needs or cooperating tractor's parameters. Adjustment of rear support wheels (EMU 160 UP) is performed with use of hydraulics, operated from tractor upon connecting hydraulic hoses to tractor's connectors first. Adjustment of tiller (EMU 160 UP) is performed with use of hydraulics, operated from tractor upon connecting hydraulic hoses to tractor's connectors first. If machine is equipped with front support wheels it is then recommended to set handle of distributor for tiller cylinder in floating position. For dense and high shrubs, trunks, etc. use heavy duty grinders

23 Operating mower The mower has access plate (6) (Fig. 15). It is used to open or close a channel for mowed forage. When the flap is opened the material is transported to the hopper and when closed it is mulched and left on the ground. In EMU mowers in order to close the plate (mulching) unlock the lock (1) and using handle (2) rotate the plate and secure the lock (3). Access plate (6) enables access to flail shaft without lifting the mower to facilitate knife replacement or examination of knife and flail shaft connection. In order to open access plate first unlock the lock (4) from both sides of the mower and then lift the window with use of holder (5) (Fig. 15). In IBIS 150 mower the access plate is mounted with screws (7). By rotating and removing the plate (6) it is possible to gain full access to flail shaft without having to lift the mower. In the IBIS 150 UP mower the access plate is an integral part of the nozzle assembly. Lifting the hopper for discharging of the forage enables easy access for replacement of flail knives without having to remove the access plate. 1 2 a) Markings: 1, 3, 4 stiffer 2 handle 5 clamp 6 flap 7 bolts b) 6 7 Fig. 15. Overview of flap and revision window for hopper of mower a) EMU160, b) IBIS

24 In order to safely operate flail mower through revision window or other maintenance works requiring opening or lifting the hopper cylinder rod (in case of EMU 160 UP for two cylinders) should have protective support on (1) When performed unscrew wing nuts (2) which hold the support, take the support away and safety pins out (3). Next put support on onto cylinder retracted to maximum and protect it from falling with use of safety pins (3). Screw wing nuts (2) on protective support mounting bolts (Fig. 16) a) b) c) Fig. 16. View of protective support: a) EMU 160, EMU 160 S, b) EMU 160 UP c) IBIS protective support, 2 mounting nut, 3 safety pin 5.7. Dismounting machine from tractor When dismounting, make sure there is no person in between the machine and the tractor. To dismount the machine from the tractor: Set the machine onto an even, stable ground, Turn the tractor's ignition off and take the key out, Secure the machine against moving by placing wedges at wheels, Fold out the support leg and protect with safety pin, Dismount the telescopic articulated shaft, Detach the machine from the tractor

25 6. MOUNTING AND ADJUSTMENTS 6.1. Adjusting mowing height Smooth wowing height adjustment within 3 8 cm (EMU), 1,5 6,5 cm (IBIS) range is performed with use of ground following bar (Fig. 18). To adjust mowing height unscrew bolt (3) (wrench 21) and using nuts (1) (wrench 19) lift or lower ground following bar. The bar should be set from both sides on the same height basing on a scale (2) (Fig. 17) Markings: 1 - nut 2 - scale 3 - bolt Fig. 17. Maximum mowing height a) b) Fig. 18. Setting mowing height: a) minimum, b) maximum Adjustment of front support wheels (if provided) encompasses adequate relocation of 1 cm or 2 cm thick spacers so that the mower is supported at the rear on ground following bar and at the front on support wheels while sliding skids are parallel to the ground Operating service Belt gear s V-belts tension control Examine tension of V-belts of belt gear periodically. To adjust belt tension use tensioner with mounted tensioning spring with bolt (Fig. 19). Adjusting belt tension is performed by screwing nut onto bolt. To check if belts are tensioned properly, press belts with finger by applying force ~10 kg, so that correct deflection of ~0.5 cm is achieved (Fig. 20)

26 Compression spring Bolt Nut V-belt Maximum belt deflection Angle bar Tensioner Fig. 19. View of belt gear Fig. 20. Belt deflection value Flail knife condition control All knives must be of the same type and weight. If need be replace knife with new one. To keep the shaft well balanced, always replace a pair of knives, that is two knives mounted on counter-sides of the shaft in dimensions nearest to each other (Fig. 21). Knives should be ordered at the mower manufacturer SaMASZ company. Rotating direction Operating direction Fig. 21. Knife mounting manner Worn or damaged flail knives mounting screws must be replaced for new ones. It is not permitted to use screws of strength class lower than Daily maintenance Upon daily completion of operation the following should be performed: remove grass and mud from the mower; examine of visible external parts and assemblies as well as their connections, screw all loose connections and replace worn or damaged parts, lubricate the PTO shaft tubes with STP grease, if necessary, lubricate the other parts and assemblies in accordance with the lubrication instructions (item 7), use ŁT 43 grease for bearings of both sides of flail shaft see Fig. 22, control radial clearances in bearings of flail shaft and ground following bar. If these are found, replace bearings with new ones After-season maintenance At the end of the season the mower should be cleaned, washed and dried. Carefully lubricate unpainted surfaces and 3-point linkage pins. Moreover: remove any traces of rust and paint the area affected, check oil level in 3-point linkage gearbox (Fig. 22)

27 It is recommended to store the aggregate on paved ground, preferably in roofed places, inaccessible to unauthorized personnel. Machine should be stored in a dry place, and if exposed to precipitations, apply lubrication regularly Restarting the machine after longer idle periods Make sure that all nuts and screws are tightened with correct torque. Make sure that all guards are installed in place. As the storing period is over lubricate the whole machine. Tab. 5. Torque values for bolts 7. LUBRICATING 7.1. Intersecting axis gear Prior to daily work commencement check the oil level and, if needed, refill after removing the vent (A) in upper section of the gearbox (to fill oil first take off a cap (C) (Fig. 22). The oil level can be checked by opening check plug (B) on the side of the gear. If oil level is too low, refill oil until it is visible in the check opening (B). Oil level in gear: approx. 1 liter (Tab. 6). Oil level is inspected as the machine is set horizontally on the ground. Tab. 6. Oil level in belt gear Mower type Oil volume [l] Oil type Replacement frequency All types 1 (according to ISO 3448 oil with viscosity class; VG ) Once every 3 seasons (for intensive operation)

28 A B C 7.2. Bearing housing of flail shaft Fig. 22. Belt gear oil control and replacement points Lubricate the shaft bearings once a week with ŁT 43 grease. Lubrication points for mowers with shafts with external and internal bearings are provided on Fig. 23. Lubrication points 7.3. Risk present when lubricating Fig. 23. Lubrication points of flail shaft bearings To avoid being splashed with pressurized liquid wear protective eyewear with side guards. When lubricating protect skin against contact with the substance. Therefore use adequate long-sleeved protective clothing and protective shoes. Use protective gloves, too. In case of a contact with skin, immediately wash the infected area with plenty of soap water. Do not allow the product to contaminate water outlets, water courses and soils. In case of an in intentional release to the environment plug the leak, limit the spillage, and then collect the oil with non-flammable absorbent material (e.g. sand). The product is flammable. In case of fire, use adequate fire-extinguishing means (e.g. foam, water mist, extinguishing powders). Do not use water jets. Disposal of the used product must be made according to local regulations. Improper disposal of the used oil poses danger to the environment

29 8. DEFECTS AND THEIR REPAIR Defect type Reason Recommendations Mower is not mowing Hopper is not lifted up Cylinder is not tight Excessive vibrations Transmission belts sliding Too low PTO rears despite high engine rears Locked flail shaft Damaged key or collet on pulley Damaged belt gear Damaged or missing flail knives Cylinder failure. Broken hydraulic hoses Contaminated oil in the tractor s hydraulics Deflected PTO shaft Damaged flail shaft or missing knife Damaged bearings on the shaft Adjust belts tension with use of spring according to corresponding manual Worn V-belts replace them with new ones, possibly spread some belt paste Check the PTO efficiency in service station Remove any odd element from flail shaft Replace damaged parts Replace or recover the gear Replace flail knives Replace with new ones Replace oil in tractor's hydraulic assembly (recommended oil purity class acc. to NAS 1638 a minimum is 9-10). Order brand new cylinder repair kit and replace worn sealings Check the condition of PTO shaft and replace if needed Examine condition of knife and replace if needed Replace damaged bearings on the shaft 9. REPAIR AND WITHDRAWAL FROM USE 9.1. Repair Prior to commencing repair works the mower should be disconnected from the tractor. For works under lifted collecting hopper make sure to secure it against falling. Prior to any repair works, potentially related to admitting it for use, clean the mower thoroughly and remove any grass, dirt or mud. Once the machine is repaired perform the following: Make sure that all elements are installed properly, Install the removed guards, Check that all screws and nuts are tightened, Once all the guards are installed, perform a warm-up start to make sure the repaired machine operates properly

30 9.2. Disassembly and withdrawal from use If the mower cannot be repaired anymore, it should be withdrawn from use. In such case, oil should be drained from intersecting axis gearbox and taken away 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 unhitching the machine pay particular attention to additional threat such as crush or cut. Special protective equipment must be used: gloves, protective clothing, glasses etc. Pay attention not to allow the machine lose its stability and therefore protect it with supports. 10. WARRANTY CARD FLAIL MOWER WITH HOPPER Serial number Date of manufacture Warrantor stamp QC signature Date of purchase Dealer stamp Dealer signature The product quality has been checked and meets the required standards and regulations and is permitted for use. Warranty card without the required information or with corrected or illegible information is invalid

31 11. WARRANTY TERMS Warranty claim procedure The manufacturer guarantees its products against faults in materials or production. It only concerns operation in good conditions, so when there is no obstacles such as: a) stones b) sewage, pipeline, gas chambers and any other municipal obstacles c) edges perpendicular to operating direction d) transverse ditches e) concrete poles, etc. As a matter of fact, such conditions occur rarely, so this instruction should be followed in accordance with item 5.6 herein. Operation. For the abovementioned inconveniencies occur most often, the operator should be familiarized with item Basic information on mowing. 2. Faults or damages to the mower found within a 12-month warranty period (from the date of purchase) shall be removed free of charge at the purchaser. 3. Faults or damages should be submitted personally, by letter or by telephone. Repairs shall be carried out within 14 days. Any repair which is subject to warranty should be carried out by an authorized SaMASZ dealer. 4. Warranty claims regarding replacement of the product or repayment are considered within 14 days by the manufacturer. 5. The following cases are not covered by the warranty: a) use of the mower for any purpose other than described in the operator's manual; b) fortuitous events or other occurrence, for which the manufacturer does not bear any responsibility; c) normal wearing of parts such as: sliding skids, ground following bar, gears and their internal parts, flail shaft, cutting knives, flail knives, V-belts, knife mounting bolts, flail shaft and ground following bar bearings, sliding bushings, etc. These repairs may be carried out only at the user or purchaser cost. 6. The costs of technical assessment are borne by the Purchaser - if the manufacturer determines that the product being subject to claim is defect free and what is confirmed by a further expertise. 7. The manufacturer has the right to cancel the warranty in the following cases: a) interference to the interior of the mower, modifications to its mechanical design or unintentional damages, b) vast damage caused by accidents, running into obstacles, chambers or other occurrence, for which the warrantor does not bear any responsibility, c) lack of required records in the warranty card or filling in the warranty card independently, d) use of the mower for any purpose other than described in the operator's manual. 8. Manufacturer can break the service agreement with immediate effect when the user does not pay receivables under the agreement in a timely manner and the delay in payment is longer than 30 days from maturity date. Breaking the service agreement by the Contractor for causes lying on the the user side makes simultaneous termination of the warranty given for the particular machine. 9. Manufacturer does not bear any compensation responsibility for the loss caused by the machine breakdown during its operation.

32 When purchasing the machine, request your dealer to carefully fill in the warranty card providing date and location of the purchase along with the dealer stamp and signature. Otherwise the warranty is invalid and any warranty claim rejected. If the warranty expires, repairs can be carried out for charge by the entitled repair shops suggested by the dealer. The dealer is obliged to inform the purchaser on these. Manufacturer have right to introduce construction modifications. The SaMASZ company is working on development of all of its machine types and models. Therefore, there is always a possibility in change of form, equipment and technology of the delivered machines. No claims can arise from data, drawings and descriptions included herein as well as the spare part list. The SaMASZ is not responsible for printing errors Warranty repairs record Repairs scope and spare parts replaced: Date, stamp and signature of repair shop. Date, stamp and signature of repair shop. Date, stamp and signature of repair shop

33 APPENDIX CALCULATING AXIS LOAD ATTENTION! When mounting the machine on a tractor using front and/or rear 3-point linkage, a maximum value of permissible load cannot be exceeded tractor's front axis load must be 20% of the tractor's overall weight. Before using the tractor-machine assembly, check whether these conditions are met, while calculating and weighing the assembly. 1. Defining the total weight, axis load, tyre load capacity and minimum load. M P T P T T M T A B C D For calculations the following data is necessary: T [kg] Tractor's overall weight T P [kg] Front axis load on unloaded tractor T T [kg] Rear axis load on unloaded tractor M P [kg] Total weight of machine mounted on front 3-point linkage or weight of front ballast M T [kg] Total weight of machine mounted on rear 3-point linkage or weight of rear ballast 2 3 A [m] Distance between centre of gravity of machine mounted on front 3-point linkage / front ballast and tractor's front axis centre B [m] Distance between tractor's axes C [m] Distance between tractor's rear axis centre and centres of ball joints on tractor's lower links D [m] Distance between centres of ball joints on tractor's lower links and centre of gravity of machine mounted on rear 3-point linkage / rear ballast Refer to tractor's operation manual Refer to technical data for machine in operation manual or price list Dimensions / measurement