Frontier DM1160 User manual

OPERATOR'S MANUAL
DISK MOWER
DM1160
9N004AUS F
- English (USA) - 12-2012

Dear Owner 1
DM1160
$DEAR OWNER
In buying a Frontier machine you have chosen wisely. Into it have gone years of thought, research and
improvement. You will find, as have thousands of owners all over the world, that you have the best that
engineering skill and actual field testing can produce. You have purchased a dependable machine, but only
through proper care and operation can you expect to receive the performance and long service built into it.
This manual contains all the necessary information for you to receive full efficiency from your machine. The
performance you get from this machine is largely dependent on how well you read and understand this manual
and apply this knowledge. Please DO NOT ASSUME YOU KNOW HOW TO OPERATE AND MAINTAIN YOUR
MACHINE before reading this manual carefully. KEEP THIS MANUAL AVAILABLE FOR REFERENCE. Pass
it on to the next owner if you re-sell the machine.
Your John Deere dealer can offer a complete line of original manufacturer service parts. These parts are
manufactured and carefully inspected in the same factory that builds the machine to assure high quality and
accurate fitting of any necessary replacements.
About improvements
We are continually striving to improve our products. We therefore reserve the right to make improvements or
changes when it becomes practical to do so, without incurring any obligations to make changes or additions to
the equipment sold previously.
Wearing parts
Wearing parts fitted on our machines have been tested in very different situations to optimize their service life.
Nevertheless, the service life depends highly on the conditions of use (products to handle, soil, weather
conditions, etc...).
Designated use of the machine
The DM1160 mower must only be used for the purpose for which it was manufactured: mowing on the ground
of hay fields, grass silage fields and improved pastures for the purpose of harvesting fodder for feeding
livestock.

2Contents
DM1160
$CONTENTS
Dear Owner.....................................................................................................................1
Contents .........................................................................................................................2
Identification of the machine ........................................................................................4
Front view..........................................................................................................................................4
Rear view...........................................................................................................................................4
Model identification plate.................................................................................................................5
Optional equipment..........................................................................................................................5
Safety..............................................................................................................................6
Description of symbols used in this document.............................................................................6
Safety instructions............................................................................................................................7
Location and description of safety decals on the machine........................................................16
Machine specifications................................................................................................21
Description and glossary...............................................................................................................21
Technical specifications.................................................................................................................22
Sound levels....................................................................................................................................22
Putting into service......................................................................................................23
Description of control elements....................................................................................................23
Coupling and uncoupling...............................................................................................................23
Instructions for transport............................................................................................34
Putting the machine into transport position ................................................................................34
Conformity with the road regulations...........................................................................................36

Contents 3
DM1160
Instructions for work....................................................................................................37
Putting the machine into work position .......................................................................................37
Adjustments in working position..................................................................................................39
Machine use....................................................................................................................................42
Optional equipment......................................................................................................43
Reinforced PTO shaft.....................................................................................................................43
"HD" disks.......................................................................................................................................43
Raised skid shoes ..........................................................................................................................48
2 swath shields...............................................................................................................................48
Inner swath shield ..........................................................................................................................49
Maintenance and storage ............................................................................................50
Frequency chart..............................................................................................................................50
Lubrication......................................................................................................................................51
Maintenance....................................................................................................................................54
Storage ............................................................................................................................................61
Troubleshooting guide.................................................................................................62

4Identification of the machine
DM1160
$IDENTIFICATION OF THE MACHINE
1. Front view
2. Rear view

Identification of the machine 5
DM1160
3. Model identification plate
Please write below the type and serial number of the
machine. This information is to be given to your John
Deere dealer for all parts order or warranty claim.
Type: DM1160
Serial no.:
4. Optional equipment
Check the boxes corresponding to the equipment fitted
on your machine:
TYPE
MASSE kg
KUHNS.A.
67700SAVERNE- FRANCE
N°
MADEINFRANCE
DEERE & COMPANY, MOLINE, ILLINOIS USA
MADE IN FRANCE
Kit no. KN1086060: PTO shaft with free wheel.
Kit no. KN1036040: "HD" disks.
Kit no. KN1016400: Raised skid shoes.
Kit no. KN1036010: 2 swath shields.
Kit no. KN1036000: Inner swath shield.

6Safety
DM1160
$SAFETY
1. Description of symbols used in this
document
This symbol indicates a potentially hazardous situation
that if not avoided, could result in serious bodily injury.
This symbol is used to identify special instructions or
procedures which, if not followed strictly, could result in
machinery damage.
This symbol is used to communicate technical
information of particular interest.

Safety 7
DM1160
2. Safety instructions
Read and follow the safety instructions
Before using the machine, carefully read all the safety
instructions in this manual and the warnings placed on
the machine.
Before starting work, the operator must be familiar with
all machine controls, handling devices and their
functions. It is too late to learn once work has been
started!
Never let anyone operate the machine who is not trained
to do so.
Should you have any difficulties in understanding certain
parts in this manual, please contact your John Deere
dealer.
Precautions to be taken before carrying out
any operations on the machine
Before leaving the tractor or before adjusting,
maintaining or repairing the machine, disengage the
PTO drive, turn off the engine, remove ignition key and
wait until all moving parts have come to a complete stop
and apply park brake.
Introduction
The machine must only be operated, maintained and repaired by qualified persons who are familiar with the
machines' operation and understand safety regulations and procedures for preventing accidents.
The operator must follow the safety instructions in this manual and in the warnings posted on the machine. The
operator is also obliged to respect current legislation concerning accident prevention, work safety and public
traffic circulation.
The intended use of the machine includes following all operation, maintenance and repair recommendations
given by the manufacturer, and using only genuine spare parts, equipment and accessories, as recommended
by the manufacturer.
The manufacturer is not held liable for any damage resulting from machine applications other than those
specified by the manufacturer. Any use other than the designated operation is at the risk and responsibility of
the operator.
The manufacturer is not held liable for any damage or accident resulting from machine modifications carried out
by the operator himself or by a third party without previous written agreement from the manufacturer.
BEFORE ADJUSTING
MAINTAINING OR REPAIRING
THE MACHINE, TURN OFF THE
ENGINE, REMOVE IGNITION
KEY AND WAIT UNTIL ALL
MOVING PARTS HAVE COME TO
A COMPLETE STOP.
599 004 20

8Safety
DM1160
Precautions to take before using the
machine
Do not wear loose clothing which could become caught
up in moving parts.
Wear appropriate protective clothing (gloves, shoes,
goggles, helmet, ear defenders, etc.).
Ensure that all operating controls (ropes, cables, rods,
etc) are placed so as they cannot be operated
unintentionally and cause damage or injury.
Before operating the machine, check tightness of nuts
and bolts, particularly on components that the machine
uses to process material (tines, forks, blades, knives,
etc). Retighten if necessary.
Before operating the machine, ensure that all the safety
guards are firmly in place and in good condition.
Immediately replace any worn or damaged guard.
Precautions when driving
Tractor handling, stability, performance and braking
efficiency are all affected by weight distribution, trailed or
mounted implements, additional ballast and driving
conditions. It is therefore of great importance that the
operator exercises caution in every given situation.
Drive speed must be adapted to ground conditions as
well as to roads and paths. Always avoid abrupt changes
of direction.
Be particularly cautious when turning corners, paying
attention to machine overhang, length, height and
weight.
Never use a narrow track tractor on very uneven or
steeply sloping ground.
Never leave the tractor seat while the machine is
operating.
Carrying people or animals on the machine when
working or in transport is strictly forbidden.

Safety 9
DM1160
Precautions when driving on public roads
Dimensions
Depending on the dimensions of the machine, contact
the relevant authorities to ensure that it can be legally
transported on public roads.
If the machine is over the maximum legal size, follow the
local regulations for special transportation of oversize
equipment.
Gross weight and weight per axle
Check that the tractor's authorized gross weight as well
as its lift capacity and maximum weight per axle are not
exceeded.
The front axle load (1) must never, under any
circumstances, be less than 20% ofthe tractor's unladen
weight. If necessary, add ballast weights to the front or
to the rear to preserve the steering and braking
efficiency.
Transport position
Before transporting the machine on public roads, place
the machine into its transport position, according to the
instructions in this manual.
Lights and indicators
Before transporting the machine on public roads, ensure
that all legally required lights and indicators are in place.
Ensure that lights and indicators are clean and in good
working order. Replace any missing or broken
equipment.
Maximum speed
Always keep to the legal speed limit for driving a tractor-
machine assembly on public roads.
Always obey current regulations for driving
on roads.
kg
lb
kg
lb
1

10 Safety
DM1160
Precautions when coupling
Before attaching the machine, make sure that it cannot
accidentally start moving (chock the wheels) and that the
parking stand is in the right position.
The machine must only be attached to the hitch points
provided for this purpose.
Never stand between the tractor and the machine when
operating the three point linkage.
Do not stand between the tractor and the machine
without ensuring that the parking brake is applied.
Hydraulic circuit
Caution! The hydraulic circuit is under high pressure.
Maximum pressure at work: 200 bar (2900 psi).
Before connecting hoses to the tractor hydraulics,
ensure that tractor and machine circuits are not under
pressure.Before disconnectinga hose, depressurize the
hydraulic circuit.
To avoid making incorrect connections, mark hydraulic
couplers and corresponding hoses with colors.
WARNING! Functions could be reversed (for example:
lift/lower) and cause accidents.
Regularly check the hydraulic hoses. In case of normal
wear, replace the hydraulic hoses every 5 years.
Damaged or worn hoses must immediately be replaced.
When replacing the hydraulic hoses, only use hoses with
the specification recommended by the manufacturer of
the machine.
To locate a leak, use appropriate means. Protect body
and hands from liquid under pressure.
Any liquid under pressure (particularly oil from
hydraulics) can penetrate the skin and cause severe
injury. If injured, see a doctor immediately, there could
be danger of infection.
Before any adjustments, maintenance or repairs are
carried out, lower the machine to the ground,
depressurize the hydraulics, turn off the engine, remove
ignition key and wait until all moving parts have come to
a complete stop.

Safety 11
DM1160
PTO shaft
Do not wear loose clothing that could be caught in the
rotating PTO shaft.
Before attaching or removing a PTO shaft, or before
doing any work on the machine, disengage the PTO
drive, turn off the engine, remove ignition key and wait
for all moving parts have come to a complete stop.
If the primary PTO shaft is equipped with a torque limiter
or a free wheel, these must be fitted on the machine
side.
Ensure that the PTO shaft is always correctly fitted and
locked into place.
Before connecting the PTO shaft, ensure that the PTO
speed (rotational frequency) and direction of rotation are
in line with the machine manufacturer's
recommendations.
Before engaging the PTO drive, make sure all people
and animals are clear from the machine. Never engage
the PTO drive when the tractor engine is stopped.
Do not install any adapter device that results in a portion
of the tractor PTO stub, the rotating PTO shaft, or the
adapter to be unguarded. The tractor master shield shall
overlap the end of the splined shaft and the added
adaptor device as outlined in the table.
When uncoupling the machine, rest the PTO shaft onthe
support specially provided, and replace protective shield
on the PTO stub of the tractor.
Read and follow the instructions in the operator's manual
provided with the PTO shaft.
Use only PTO shafts supplied with the machine or recommended by the machine manufacturer.
The protective shield of the tractor PTO stub, the PTO shaft guards and the protective shield of the machine
input shaft must always be in place and in good condition.
Make sure that the PTO shaft guards are secured with the safety chains provided. Check that the PTO shaft
guard can turn freely a full rotation independent of the shaft.
Any worn or damaged guards must be replaced immediately. A worn guard or an unprotected PTO shaft can
cause a serious or even a lethal accident.
A
PTO type Diameter X splines
A
±5 mm (0.20’’)
135 mm
(1.378’’) 685 mm (3.35’’)
235 mm
(1.378’’) 21 85 mm (3.35’’)
345 mm
(1.772’’) 20 100 mm (4.00’’)

12 Safety
DM1160
Precautions during maneuvers
When moving the machine from the transport position to
the working position and vice versa, make sure that
nobody is within the machine pivoting area.
Remote controlled components
Danger of crushing and shearing can exist when
components are operated by hydraulic or pneumatic
controls. Keep away from these danger zones.
Safety decals
Safety warnings are placed in safety decal form on
various parts of the machine. They are there to warn you
of potential dangers and to tell you how to avoid
accidents.
Always keep the safety decals clean and readable, and
replace them when they are worn, damaged, missing or
illegible.
Waste disposal
Respect the environment! Never spill pollutants (oil,
grease, filters, etc.) on the ground, never pour them
down the drain and never discard them in any other
place where they could pollute the environment. Never
throw away or burn a tire. Always take waste to
specialized recycling or waste disposal centers.

Safety 13
DM1160
Precautions for maintenance and repair
work
Before leaving the tractor or before adjusting,
maintaining or repairing the machine, disengage the
PTO drive, turn off the engine, remove ignition key and
wait until all moving parts have come to a complete stop
and apply park brake.
Rest the machine on the ground, release the pressure
from the hydraulic circuit and leave the machine to cool
down.
Make sure that the parts of the machine that need to be
lifted for maintenance or repair work are firmly propped
up.
Before any work is done on the electric circuit or before
any electric welding is carried out on the attached
machine, disconnect the machine from the tractor
electrical circuit. Also disconnect alternator and battery
terminals.
Repairs on elements under pressure or tension (springs,
pressure accumulators, etc.) must only be carried out by
competent persons with regulation equipment.
Wear appropriate protective clothing (gloves, shoes,
goggles, helmet, ear defenders, etc.).
Do not solder, weld or use a blow torch near fluids under
pressure or flammable components.
For your own safety and for correct machine operation,
only use original manufacturer parts.
It is strongly recommended to have your machine
checked by your John Deere dealer after each season,
especially tools and their attaching hardware.

14 Safety
DM1160
Projection of stones and foreign objects
For driver safety, always use a tractor equipped with a
cab. Keep the ground to mow free of foreign bodies.
Avoid mowing on stony or rocky grounds. If this is not
possible, take extra safety precautions, such as:
- Fit polycarbonate screens inside the tractor cab's side
and rear windows, or install narrow mesh guards on
their exterior.
- Increase the cutting height to avoid contact with
stones or rocks.
Never start the machine when there are people nearby.
Even when the machine is used properly, objectsmay be
thrown. Stones and other foreign objects thrown by the
moving parts can travel a considerable distance. Keep
all persons and animals away from the danger zone.
The protection covers help reducing risks of projections.
Therefore, make sure that all mower protection devices
are in place and good condition prior to using the
machine.
Regularly check the condition of the protection covers.
Immediatly replace any worn, damaged or missing
cover.

Safety 15
DM1160
Precautions for machine use
After each use, check the cutting tools (disks, knives)
and their attachment hardware in accordance with the
instructions given in the present manual. Immediately
replace any worn, damaged or missing cutting tool or
element. To do this, use the tool outfit supplied with the
machine. For your safety, only use genuine KUHN
parts !
Regularly check the condition of the protection covers.
Immediatly replace any worn, damaged or missing
cover. Before engaging the PTO, rest the cutterbar on
the ground. Make sure all the guards are in place. Keep
all persons and animals away from the danger zone.
Stay a safe distance from the machine when the cutting
tools are in movement.
Never work in reverse.
After disengaging the PTO drive, cuttings tools can
continue rotating for some time. Stay away from the
machine until all moving parts have come to a complete
standstill.
If the machine hits an obstacle, disengage the PTO
drive, stop the tractor engine, remove the ignition key
and wait for all moving parts to come to a complete
standstill. Check the entire machine for any damage
before resuming work.

16 Safety
DM1160
3. Location and description of safety
decals on the machine
Location of safety decals
BEFORE STARTINGTHE
MACHINE READ OPERATOR’S
MANUAL AND SAFETY
INSTRUCTIONS.
REQUEST COPY IF NOT
SUPPLIED.
CAUTION
BEFOREADJUSTING
MAINTAININGOR REPAIRING
THEMACHINE, TURN OFF THE
ENGINE,REMOVE IGNITION
KEYAND WAIT UNTIL ALL
MOVINGPARTS HAVE COME TO
ACOMPLETE STOP.
599004 20
1
2
3 4 5
6
7
DANGER
Avoid contact with
rotating parts
Entanglement in rotating
driveline can cause serious
injury or death
Keep all shields in place
099262 10
099 257 10
Operate only with
540 rpm PTO
CAUTION
099261 10
1. Keep all shields in place
2. Disengage and shut off al
engine and/or motor power
before servicing or unclog-
ging machine
3. Keep hands, feet and cloth-
ing away from power-
driven parts.
CAUTION
8
10
9
Avoidserious injury from injection of
pressurizedhydraulic fluid.
Alwaysrelieve pressure before
performingser vice or maintenace
orany hydraulic components.
Referto tractor and implement
Operator’sManuals.
Donot use hand to search for leaks.
Usecardboard or similar material.
0992762
CAUTION
11

Safety 17
DM1160
Description of safety decals
Operating instructions (1)
The operators' manual contains all the information
necessary for using the machine safely. It is imperative
to read and comply with all instructions.
Working on the machine (2)
Before leaving the tractor or before adjusting,
maintaining or repairing the machine, disengage the
PTO drive, turn off the engine, remove ignition key and
wait until all moving parts have come to a complete stop
and apply park brake.
Projections (3)
Stones and other debris projected by the moving parts
can travel a long distance. The protection covers must
always be in position and in good condition. Always stay
at a safe distance from the machine.
BEFORE STARTING THE
MACHINE READ OPERATOR’S
MANUAL AND SAFETY
INSTRUCTIONS.
REQUEST COPY IF NOT
SUPPLIED.
CAUTION
BEFORE ADJUSTING
MAINTAINING OR REPAIRING
THE MACHINE, TURN OFF THE
ENGINE, REMOVE IGNITION
KEY AND WAIT UNTIL ALL
MOVING PARTS HAVE COME TO
A COMPLETE STOP.
599 004 20

18 Safety
DM1160
Rotating cutting tools (4)
Keep away from the mowerknives all the time the engine
is running, the PTO drive engaged and the moving parts
have not come to a complete stop.
Body crushing (5)
Stay a safe distance from the machine.
Crushing hazard.
Do not step on the machine (6)
Do not step on the machine : Risk of falling or damaging
the protection device.
Uncoupling the machine (7)
Always park the machine with the cutterbar in horizontal
position.