SaMASZ KDF 390 User manual

Firma SaMASZ
Firma SaMASZFirma SaMASZ
Firma SaMASZ
inŜ. Antoni stolarski
Poland, 15-161 Białystok, ul. Trawiasta 30
Rok załoŜenia – 1984
NIP PL-542-010-21-58
tel. (+48) (85) 654 45 84
654 45 82
664 70 31
fax (+48) (85) 664 70 41
e-mail: [e-mail]
www.samasz.pl
OPERATOR’S MANUAL
FRONT DISC MOWER
KDF 390 - 3,9 m
IN235EN000
23.04.2007
WYDANIE NR 0

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POCHYLENIE ODWROTNE POWODUJE TRWAŁE
USZKODZENIE LISTWY DYSKOWEJ
DOPUSZCZA SIĘ PRACĘ W POZYCJI POZIOMEJ
ZALECANE POCHYLENIE
KOSIARKI W POZYCJI
ROBOCZEJ
max. 7 cm
DANGER
TURNING THE DRIVE ON,
IF THE MOWER IS NOT
IN WORKING POSITION
DANGER
OPERATING WHEN ANY
PERSON REMAINS IN THE
DANGER AREA OF 50 m
Written and translated by: Łukasz Łapiński
Technical advice: mgr inŜ. Sławomir Rabiczko
Approved by: mgr inŜ. Andrzej Łapiński
Recommended inclination of cutterbar towards the
ground is 5°.
It is allowed to work in horizontal position.
Different position may damage the cutterbar.

Operator’s manual
Front disc mower
KDF 390
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Contents page
1. INTRODUCTION..................................................................................................................3
2. TECHNICAL DATA..............................................................................................................3
2.1. Specifications...........................................................................................................................3
2.2. Design and working principle...................................................................................................3
2.3. Proper use.................................................................................................................................5
2.4. Standard equipment and spare parts .........................................................................................5
3 . SAFETY ADVICE..................................................................................................................7
3.1. Safety rules and regulations......................................................................................................7
3.2. Safety decals ............……………………………………………………………………………8
4. TRANSPORT AND OPERATION........................................................................................9
4.1. Attaching the mower to self-propelled mower FORTSCHRITT................................................9
4.2. Operation ...............................................................................................................................11
4.2.1. Adjusting the mower to work conditions…………………………………………….. .............11
5. MOUNTING AND ADJUSTMENTS..................................................................................12
5.1. Mounting and timing of the knives .........................................................................................12
5.2. Replacing the knives...............................................................................................................12
5.3. Maintenance and service.........................................................................................................13
5.3.1. Checking the knives and knife holders....................................................................................13
5.3.2. Daily maintenance..................................................................................................................14
5.3.3. After-season maintenance.......................................................................................................14
6. LUBRICATION ...................................................................................................................14
6.1. Cutterbar ................................................................................................................................14
6.2. Intersecting axis gears.............................................................................................................15
7. DEFECTS AND THEIR REPAIRS.....................................................................................16
8 . DISASSEMBLY AND WITHDRAWAL FROM USE .......................................................17
9. WARRANTY CARD............................................................................................................17
10. WARRANTY TERMS.........................................................................................................18
10.1. Warranty claims procedures ...................................................................................................18
10.2. Warranty repairs record..........................................................................................................19

Operator’s manual
Front disc mower
KDF 390
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1. INTRODUCTION
 Operator’s manual is attached to every machine in order that the operator can familiarize
himself with design, working principles, service and adjustment of the mower. The user of the
mower should be familiar with common safety rules and procedures.
 The mower is manufactured according to international safety rules.
 Compliance with the warnings in this operator’s manual will ensure safe operation.
 Please contact your dealer if you have any queries relating to the operation and service of the
mower.
 Operator’s manual remains part of mower’s equipment.
GENERAL WARNING
When operating the mower please comply with the warnings
and safety regulations shown throughout this manual by this
safety alert symbol.
CAUTION:
Operation of the mower before reading the operator’s manual carefully
as well as operating by the unauthorized staff, especially by children, is
strictly forbidden.
2. TECHNICAL DATA
2.1. Specifications.
Tab. 1. Technical data
Model KDF 390
Working width 3,9 m
Number of knives [pcs.] 18 (2x9)
FORTSCHRITT PTO rpm 1000 obr/min
FORTSCHRITT power required 60 kW
(82 KM)
Transport width 3,9 m
Operation width 4,5 m
Weight 700 kg
2.2. Design and working principle
Fig. 1. Data plate.

Operator’s manual
Front disc mower
KDF 390
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Fig. 2a. Parts of SaMASZ front disc mower KDF 390.
Fig. 2b. Parts of SaMASZ front disc mower KDF 390.
The drive on the cutterbar 3is transmitted from self-propelled mower FORTSCHRITT 300 rpm
through jointed shaft, intersecting axis gear 4, PTO shaft 6and intersecting axis gear 5. On the
cutterbar there are discs with two knives each. The extreme discs have additional forming drums.
Cutterbar is connected to the main frame 2, to which the suspension frame 1is linked. Suspension
frame is connected to FORTSCHRITT by means of four pins. Over the cutterbar there are safety
guards 10.
1 – Suspension frame
2 – Main frame
3 – Cutterbar
4 – Intersecting axis gear
5 – Intersecting axis gear
6 – PTO shaft
7 – Swath discs
8 – Joint shaft
9 – Regulating bars
10 – Safety guards
6 5
4 9
10
2
7 9 1
7
5 8
3
9
10
10

Operator’s manual
Front disc mower
KDF 390
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2.3. Proper use
SaMASZ front disc mower is designed for mowing standing grass on meadows and in stone free
fields. It is a machine for hay and green fodder production. The mower is adjusted to work with
FORTSCHRITT E 301; E 302; E303.
CAUTION:
The mower is designed to work only with FORTSCHRITT E 301; E
302; E 303.
CAUTION:
Use of the mower for other purposes than above mentioned
is forbidden.
Well-proven design with thousands of machines in regular use in many countries and
quality materials ensure high durability and reliability of SaMASZ mowers.
2.4.Standard equipmenet and spare parts
The mowers are sold with the following standard equipment:
 warranty card,
 operator’s manual with spare parts list
 cutting knives – aditional set,
 mounting lever for quick knife changing,
 PTO shaft with friction clutch,
Optional extra equipment:
 holders for warning plate and lights,
 warning plates with combined lights and reflectors,
 warning triangle,

Operator’s manual
Front disc mower
KDF 390
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Tab.2 PTO shaft for front disc mower. Manufacturer-Weasler
Model Power Length Moment Symbol Clutch Notes
KM mm Nm
KDF 390 36 860-1319 540 904-00920 Friction clutch = 1250 Nm Slide lock
Fig.3. PTO shaft lubrication points. Mounting directions.
CAUTION:
Lubricate the PTO shaft with high quality multi-purpose
grease every 8 shaft operating hours. If access holes are
available, lubricate fittings through access holes. E-kits
need lubrication every 50 hours. See decal on guard if
applicable.
PTO shafts of other brands with equivalent parameters could be used afer SaMASZ permission.
CAUTION:
Optional extra equipment should be ordered separately.
8h
8h
8h8h
PTO shaft’s end without
clutch – To be mounted
on the tractor’s side.
PTO shaft’s end with friction
clutch –
To be mounted on
mower’s side.

Operator’s manual
Front disc mower
KDF 390
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3. SAFETY ADVICE
3.1 Safety rules and regulations
 Operation without safety guards as well as with the damaged or raised guards is not allowed
(danger of the stones, etc. being thrown out).
 Start mowing only when the tractor’s PTO reaches its normal 1000 rpm.
 DO NOT exceed 1050 PTO rpm.
 Nobody is allowed to remain within the danger area of at least 50 m. Particular caution is
necessary when operating near roads and in stoney areas.
 Any maintenance and adjustment work should only be done after the drive has been
disconnected and when the cutting discs have come to a complete standstill.
 Always check mower before starting work, in particular for damaged, missing and/or worn
knives and knife holders. Damaged or worn parts must be replaced.
 When driving on public roads always comply with local traffic regulations, especially
concerning warning lights.
CAUTION:
All service and repair operations must be done only after
the FORTSCHRITT’s engine has been stopped, all rotating
parts have come to the complete standstill and the cutterbar
is on the ground.
CAUTION:
Be certain that children and animals are at a safe distance
away from the machine. Never allow anyone to ride on a
machine or self-propelled mower FORTSCHRITT.
 The bolts and other fasteners have to be periodically checked and, if necessary, tightened or
replaced. DO NOT work with damaged or worn fasteners.

Operator’s manual
Front disc mower
KDF 390
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3.2. Safety decals
CAUTION:
a) all warning decals should be clean and legible,
b) lost or damaged decals must be replaced,
c) please order new decals from your dealer or supplier.
CAUTION – read the
operator’s manual before
putting the mower into
operation!
CAUTION – while making
repairs the machine must be
Stopped!
Operating is forbidden when any
person is within the danger area of
50 m!
CAUTION - Be extremely
careful when PTO shaft is
rotating!
CAUTION – pulling-in parts! CAUTION – cutting
knives! Approach
during operation is
forbidden!
.

Operator’s manual
Front disc mower
KDF 390
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4. TRANSPORT AND OPERATION
4.1. Attaching the mower to self-propelled mower FORTSCHRITT
See also separate mounting instructions
Fig 4. Front disc mower KDT 390 attached to FORTSCHRITT
Fig.5. Mounting the mower to self-propelled Fig.6. Mounting the mower to self-propelled
mower FORTSCHRITT mower FORTSCHRITT
Caution
rotor
min = 900
1
/min
max = 1050
1
/min
1000
1
/min
3
2 1
4
5
WORKING WITHOUT SAFETY GUARDS
IS FORBIDDEN
DANGER OF THE STONES, ETC. BEING
THROWN OUT

Operator’s manual
Front disc mower
KDF 390
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1. Intersecting axis gear
2. Joint shaft – before mounting of the safety guard.
3. Bracket.
4. PTO shaft.
5. Mower.
Drive from self-propelled mower FORTSCHRITT is transmitted on mower’s cutterbar through
joint shaft (2), intersecting axis gear (1) and PTO shaft (4).
Intersecting axis gear (1) is mounted on the special bracket (3) welded to self-propelled machine
over the right wheel.
Mounting of the bracket may be done by SaMASZ crew or you can do it by yourelf according to the
manual provided by the manufacturer.
The mower id driven by the PTO shaft with friction clutch (4).
When connecting PTO shaft between self-propelled machine and mower make sure, that external
guard tube of the shaft is on FORTSCHRITT’s side. The PTO shaft plastic guards have to be
secured by fastening their small chains to immovable parts of tractor and mower.
CAUTION:
If need be, shorten the PTO shaft according to its operator’s
manual.
CAUTION:
PTO shaft’s end with friction clutch should be mounted on
mower’s side.

Operator’s manual
Front disc mower
KDF 390
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CAUTION :
Use the machines with PTO shafts designed to drive them.
Before the work begins, check the safety guards (in tractor,
mower and PTO shaft), if they are placed correctly and are not
damaged. Damaged or lost parts must be replaced with genuine
ones. Make sure the PTO shaft is properly mounted. It is
forbidden to approach the rotating parts, because it may lead to
serious injuries or even death. All service and repair operations
must be done only after the tractor engine has been stopped, all
rotating parts have come to the complete standstill and the
cutterbar is on the ground. Before the operation begins, read
operator’s manuals of both the machine and PTO shaft.
4.2. Operation
Cutting height is adjusted by the regulating bars, which connect suspension frame to the main
frame. It enables proper cutterbar inclination and cutting height adjusment.
Drive should be turned on, when the cutterbar comes to conntact with the ground.
Slowly engage the PTO clutch and wait until the cutting unit reaches its rated speed. engage tractor
gear and drive slowly into the grass-field.
4.2.1.Adjusting the mower to work conditions.
- Optimum inclination of the cutterbar towards the ground is between 4° to 5°. If the inclination
exceeds 5°, there might be a slight unevenness of the mowed grass. It impairs slightly the quality
of mowing and has an influence on mower’s operation. When the cutterbar is pulled in the other
way, it significantly impairs the quality of mowing and in some cases the mower stops mowing.
Besides, it may lead to premature wear or even damage of the slides and cutterbar.
- Too high PTO rpm whirl the air, which may cause the inclination of the grass in front of the discs.
It impairs the quality of mowing.
- Too low PTO rpm impair the quality of mowing and in some cases the mower stops mowing.(too
low linear velocity of the knife).
- In case of mowing low grass, front safety guard should be lifted to reduce blasts of wind around
the discs and reduce the pressure of the safety guard on the grass.
- In case of mowing soft meadows the pressure of the cutterbar on the ground should be reduced by
adjusting support springs.

Operator’s manual
Front disc mower
KDF 390
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5. MOUNTING AND ADJUSTMENTS
5.1. Mounting and timing of the knives
The knives should be mounted as shown in Fig. 7, 8 i 9, according to the rule, that the cutting edges
should be directed towards ground, so that a knife will lift the grass after cutting.
Fig. 7. Mounting of the knives on the mowing discs.
5.2. Replacing the knives
Worn and/or damaged knives should be immediately replaced.
Replace knives, if necessary, only in sets. Make sure all knives in a set are of the same length and
weight. The knife holders must not be damaged or deformed. If the knife holder pin is worn too
much, please replace it immediately.
CAUTION:
When replacing knives the engine must be stopped and the
cutterbar must lie on the ground. PTO shaft must be unmounted.
Fig. 8. Quick replacing of the knives with mounting lever.
Right turn
Right knife
Left knife
Left turn

Operator’s manual
Front disc mower
KDF 390
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Fig.9. Disc turns KDF 390.
CAUTION:
Check disc turns, before you change the knife (Fig. 9)
CAUTION:
Different mounting of the knives will block the mower. When
mounting pay particular attention to loose rotation of the knife on
the knife holder pin.
CAUTION:
Because of high discs rpm, knife holders should be changed in
sets of the same weight – on every holder there is its weight
written. Improperly changed knife holders will damage disc
bearings.
5.3. Meintenance and service
5.3.1.Checking the knives and knife holders
All knives should have the same lengths and weights. Always check mower before starting work for
damaged, missing and/or worn knives. Replace them, if necessary, only in sets. Make sure all
knives in a set are of the same length and weight.
If the knife holder pin is worn too much and/or the knife holder is worn or deformed, please replace
it immediately (Fig. 10)

Operator’s manual
Front disc mower
KDF 390
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Fig. 10. Permissible wear of knife holder pin.
5.3.2.Daily maintenance
Everyday after work please carry out the following maintenance:
 remove grass and mud,
 check all visible units and parts and their connections; tighten all loose bolts and nuts and
replace all damaged and/or worn parts with new genuine ones,
 check the cutterbar,
 grease PTO shaft tubes with STP grease,
 if necessary, lubricate the parts and units according to lubrication instructions (pkt 6.).
5.3.3.After-season maintenance
At the end of the season the mower should be cleaned, washed and dried. Carefully grease
unpainted surfaces and 3-point linkage pins.
After that the following work should be carried out:
 Remove any traces of rust and paint the area affected.
 Check lubrication of intersecting axis gear and cutterbar. If leaks occur, remove them
immediately. If water is discovered in the oil, it must be changed, otherwise the gears, bearings
and shafts could be damaged..
6. LUBRICATION
6.1. Cutterbar
Refilling the oil of the cutterbar is done through the inlet A(Fig. 11a.). Proper oil level is 5÷7 mm
from the cutterbar bottom. Oil capacities are show in tab. 3. Removing the worked oil from the
cutterbar is done through the outlet B (Fig. 11b. ) situated at the end of the cutterbar. Always
change the oil just after finished work, when it is still warm.
A

Operator’s manual
Front disc mower
KDF 390
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Fig. 11. Cutterbar oil inlet (A) and outlet (B).
Tab.3. Oil capacities.
Model Oil capacity [L] Oil type Lubrication frequency
KDF 390 8,0
80W90
Once every 3 seasons
(if working intensively)
6.2. Intersecting axis gear.
Everyday before starting work please check the oil level and, if needed, please refill after having
removed the vent Aon the top of the gear (Fig. 12.). The oil level can be checked through the check
opening Bon the side of the gear. Please refill the oil until it is visible in the check opening B. The
oil capacity: about 1 l.
Fig. 12. Intersecting axis gears’s lubrication points.
A
a
B
b
A
A
B

Operator’s manual
Front disc mower
KDF 390
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Tab.4. Oil capacities.
Model Oil capacity [l] Oil type Lubrication frequency
KDF 390 about 1
Transol 680 1000
(acc. to ISO 3448 oil viscosity
grade : VG-680 – 1000 )
Once every 3 seasons
(if working intensively)
CAUTION:
The above instructions should be strictly followed. If the discs in the
cutterbar rotate loosely, do not worry about the high intersecting axis
gear temperature; after long working time it may reach even 60-80
o
C.
7. DEFECTS AND THEIR REPAIRS
Rodzaj usterki Reason Reapair
Worn knives Replace knives
Improperly mounted knives Put on knives strictly acc. to
instructions.
Too high PTO rpm Reduce PTO rpm (recommended
1800-2000 rpm)
Damaged FORTSCHRITT’s PTO Repair
Lying grass Always mow low
Mower stops working or leaves
uncut grass between the disco
Normal symptom in case of low grass
or after the rain
Damaged gears in the cutterbar Check all the gears
Mower is blocked Damaged bearings in the disc hub Replace the bearing
Torn off shaft of intersecting axis gear Replace intersecting axis gearMower does not work, even
though the drive is transmitted
from self-propelled mower. Torn off or or cut off key in the
cutterbar drive shaft Put on new, genuine key
The mower cause too much noise Too low oil level in the cutterbar Check the oil level and refill, if
needed
The mower slows down, even
though the rpm are stable Burnt clutch in PTO shaft Replace the clutch

Operator’s manual
Front disc mower
KDF 390
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8. DISASSEMBLY AND WITHDRAWAL FROM USE
8.1. Disassembly
Before starting any repair or service the mower should be cleaned and any grass or dirt removed.
Carefully check nuts and bolts for correct tension and the pins for wear. Replace as necessary.
8.2. Scrapping
If the mower cannot be repaired anymore, it should be withdrawn from use .
For this purpose oil from intersecting axis gear and cutterbar should be drained and delivered to a
proper waste treatment company. Clean the mower parts, dismantle and dispose properly of all
plastic parts. After that, the mower could be sold to breaker’s yard.
CAUTION:
Before disassembly the mower should be disconnected from the
tractor.
9. WARRANTY CARD
FRONT DISC MOWER
The product quality has been checked and meets the required standards and regulations and is
permitted for use.
Serial number
Date of manufacture
Manufacturer’s stamp
QC signature
Date of purchase
Dealer’s stamp
Dealer’s signature

Operator’s manual
Front disc mower
KDF 390
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CAUTION:
A warranty card without the required information or with corrected or
illegible information – is invalid.
10. WARRANTY TERMS
10.1. Warranty claims procedures
1. The manufacturer guarantees its products against faults in materials or production.
2. The warranty period is for two years from the date of sale to the purchaser, stated above.
3. Any repair which is subject to warranty should be carried out by an authorised SaMASZ dealer.
Upon completion of the repair the dealer must submit a warranty claim within 21 days.
4. Warranty claims regarding replacing of the product or repayment are considered within 14 days by
the manufacturer.
5. The following cases are not covered by warranty:
a) Use for any other purpose than those described in the operator’s manual,
b) Improper use,
c) Transport damage,
d) Accidental damage,
e) Insufficient maintenance,
f) Use of non - original parts,
g) Normal wear and tear,
h) Wearing parts, e.g. knives, knife holders.
6. The Purchaser bears the costs of technical estimation - when the manufacturer finds that a claimed
product is free of defects and a technical report will confirm that.
7. The manufacturer has the right to cancel a warranty in the following cases:
a) interference of the interior of the mower, changes of its mechanical design or intentional damages,
b) damage caused by accidents or other events, for which the warrantor is not responsible,
c) use of the mower not in accordance with operator’s manual or for incorrect purpose,
CAUTION:
Please ask your dealer to complete and return the warranty card,
otherwise you may loose your warranty rights.
CAUTION:
The warranty card is valid only when there are the following
information: address, date and place of purchase, mower type and
invoice number.

Operator’s manual
Front disc mower
KDF 390
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CAUTION:
When the warranty expires, repairs can be done for a payment by the
entitled repair shops pointed by the dealer. The dealer is obliged to
indicate them.
CAUTION:
The manufacturer reserves the right to alter technical design and
specification without prior notice and without liability.
10.2. Warranty repairs record
Repair description and changed spare parts :
Date, stamp and signature of repair shop .
Date, stamp and signature of repair shop .
Date, stamp and signature of repair shop .