SaMASZ KDF 390 User manual

SaMASZ Sp. z o.o.
Poland, 16-060 Zabłudów, ul. Trawiasta 1
Established – 1984
NIP PL-966-159-29-76
tel. (+48) (85) 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
IN235EN002
2013.04.18
VERSION 2

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
WARNING:
Keep this manual for future use.
Well-proven design with thousands of machines in regular use in many countries and quality
materials ensure high durability and reliability of SaMASZ mowers.
We congratulate you on the purchase of your new SaMASZ mower and wish you much pleasure and
the very best work results through the years to come.

Operator’s manual
Front disc mower
KDF 390
- 1 -
Contents page
1. IDENTIFYING THE MACHINE .............................................................................................2
2. INTRODUCTION.......................................................................................................................2
3. PROPER USE..............................................................................................................................3
3.1. Design and working principle..................................................................................................4
3.2. Technical data ..........................................................................................................................5
3.3. Standard equipmenet and spare parts.......................................................................................5
4. SAFETY ADVICE......................................................................................................................6
4.1. Safety rules and regulations .....................................................................................................6
4.2. Transport ..................................................................................................................................7
4.3. Safety decals.............................................................................................................................7
4.3.1. Residual risk evaluation.......................................................................................................7
4.4. Warning decals and their meaning...........................................................................................8
5. TRANSPORT AND OPERATION.........................................................................................10
5.1. Attaching the mower to self-propelled mower FORTSCHRITT...........................................10
5.2. Operation................................................................................................................................12
5.2.1. Adjusting the mower to work conditions...........................................................................12
6. MOUNTING AND ADJUSTMENTS .....................................................................................13
6.1. Mounting and timing of the knives ........................................................................................13
6.2. Replacing the knives ..............................................................................................................13
6.3. Meintenance and service........................................................................................................14
6.3.1. Checking the knives and knife holders..............................................................................14
6.3.2. Daily maintenance .............................................................................................................15
6.3.3. After-season maintenance..................................................................................................15
7. LUBRICATION........................................................................................................................15
7.1. Cutterbar.................................................................................................................................15
7.2. Intersecting axis gear..............................................................................................................16
8. DEFECTS AND THEIR REPAIRS........................................................................................17
9. DISASSEMBLY AND WITHDRAWAL FROM USE..........................................................18
9.1. Disassembly ...........................................................................................................................18
9.2. Scrapping................................................................................................................................18
10. WARRANTY CARD................................................................................................................18
11. WARRANTY TERMS..............................................................................................................18
11.1. Warranty claims procedures..............................................................................................18
11.2. Warranty repairs record.....................................................................................................20

Operator’s manual
Front disc mower
KDF 390
- 2 -
1. IDENTIFYING THE MACHINE
Data plate is mounted to the mower’s main frame in the place shown below (Fig. 1).
Fig. 1. Data plate
Data plate includes:
- name and adress of the manufacturer, - model year,
- CE marking means, that the produce - version number,
conforms to 2006/42/EC Directive and - machine weight,
harmonized standards, - id number,
- machine symbol, - barcode.
- date of manufacture,
CAUTION:
For more detailed information concerning the mower ask your dealer or
manufacturer.
2. INTRODUCTION
 This operator’s manual should be considered as the basic mower’s equipment. If the mower is
handed over to another operator, it should be in working condition and given away along with
operator’s manual and it’s other basic equipment.
 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.

Operator’s manual
Front disc mower
KDF 390
- 3 -
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. Is intended to mow green fodder: grass, alfalfa and such on
permanent grassland (pastures), on crop fields without rocks, and to form loose rows of cut fodder.
The pasture or field being mown should be even, best if prepared by rolling.
A mower without crop scarifier or rollers is equipped with the „Perfect Cut” cutting bar. In
table 1 the mowing height differences, depending on the tilt angle of the cutting bar are shown.
Tab. 1. Mowing height depending on the kind of the cutting bar and its tilt angle
„Perfect Cut”
cutting bar
No tilt 3° tilt 5° tilt
The rear mounted disc mower is intended to mow green fodder: grass, alfalfa and such on
permanent grassland (pastures), on crop fields without rocks, and to form loose rows of cut fodder.
The pasture or field being mown should be even, best if prepared by rolling. In the event of a
majority of tall grass the first and second mowing should be done at a height of 60 - 70 mm, while
with a majority of short grasses at a height of 50 mm. The last mowing should be done a little
higher - at 70 - 80 mm from the ground.
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.
Different use than the above mentioned will be considered as improper and
may lead to revoking of the warranty. Mower should be used, operated and
repaired only by people familiarised with its detailed specifications and with
safety rules and regulations. Wilful changes of the mower will lead to
revoking of the warranty.

Operator’s manual
Front disc mower
KDF 390
- 4 -
3
4
5
6
9
8 1
2
9
7
10
10
3.1. Design and working principle
Fig. 2. Parts of SaMASZ front disc mower KDF 390
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
The drive on the cutterbar (3) is transmitted from self-propelled mower FORTSCHRITT 300
rpm through jointed shaft (8), intersecting axis gear (4), PTO shaft (6) and 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 (1) is linked.
Suspension frame is connected to FORTSCHRITT by means of four pins. Over the cutterbar there
are safety guards (10).

Operator’s manual
Front disc mower
KDF 390
- 5 -
3.2. Technical data
Tab. 2. Technical data
Model KDF 390
Working width 3.9 m
Number of knives [pcs.] 18 (2x9)
FORTSCHRITT PTO rpm 1000 rpm
FORTSCHRITT power required 60 kW
(82 KM)
Transport width 3.9 m
Operation width 4.5 m
Weight 820 kg
3.3. 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,
 spray paint (150 ml).
Optional extra equipment:
 holders for warning plate and lights,
 warning plates with combined lights and reflectors,
 warning triangle.
Tab. 3. PTO shaft for front disc mower. Manufacturer Bondioli & Pavesi
Model Power Lenght Moment Symbol Clutch
Manufacturer
KM mm Nm
KDF 390 55 720-990 380 8G4NO72FX635002
Unidirectional
friction clutch
= 1200 Nm
Bondioli &
Pavesi
Fig. 3. PTO shaft lubrication points. Mounting directions
CAUTION:
Lubricate the PTO shaft with high quality multi-purpose grease every
50 shaft operating hours. If access holes are available, lubricate fittings
through access holes. See decal on guard if applicable.
50 h
50 h 50 h

Operator’s manual
Front disc mower
KDF 390
- 6 -
PTO shafts of other brands with equivalent parameters could be used after SaMASZ
permission.
CAUTION:
Optional extra equipment should be ordered separately.
4. SAFETY ADVICE
4.1. 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.
 No person nor object is allowed to be present on the mower or self-propelled machine
FORTSCHRITT when transported or operating.
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.
 During operation of the mower the Regulation of the Farm Ministry and Food Economy) from
12-01-1998 dealing with safety and hygiene during the operation of tractors, machinery, tools
andequipment used for farming (Dz. U. Nr 12/98 poz. 51), should be observed,

Operator’s manual
Front disc mower
KDF 390
- 7 -
4.2. Transport
 Every position change of the mower can only be done when there is nobody around (pay
particular attention to children).
 The driver and the carrier are responsible for mower’s transport safety. Equipment and parts
must be secured during transport.
To put the mower onto another vehicle in a safe way, please obey the following rules:
 seize the mower by any lifting devices only in the places indicated by the hook sign (Fig. 4),
 for mower lifting use only lifting devices with hoisting capacity bigger than mower’s weight
shown in data plate. It also concerns ropes and chains used for lifting,
 collapsible parts should be blocked in transport position,
 during putting the mower onto another vehicle it is forbidden for anybody to remain in
transport area,
 on the vehicle’s trailer the machine should be secured against moving.
4.3. Safety decals
Despite the fact, that company SaMASZ Białystok – the manufacturer of that mower takes
responsibility for design and manufacturing of the mower, in order to eliminate dangerous
situations, certain risk during mower operation is unavoidable.
Major source of risk follows performance of these operations:
 operation of mower by minors as well as not being familiarized with operator's manual,
 operation of mower by persons under influence of alcohol or other abusive substances,
 not keeping caution while transportation and shifting of 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.
CAUTION:
Residual risk always results from incorrect behaviour of mower’s operator.
4.3.1. Residual risk evaluation
When keeping such recommendations as:
 thorough familiarizing with operator’s manual,
 no persons remaining on the machine when operating and during drives,
 no persons remaining within the mower operation range,
 adjustment, maintenance and lubrication of the machine with engine off,
 performing repairs of the machine only by skilled persons,
 operation of the machine by persons, which are familiarized with operator’s manual,
 in the event of the machine protection against children and unauthorized personnel residual risk
when operating the mower may be limited to necessary minimum.
When the risk of exposing to noise cannot be avoided or eliminated by any group
protective means or organization of work, employer (farmer) must:
1) provide the operator with individual means of noise protection, if the noise
level in work place exceeds 80 dB.
2) provide the operator with individual means of noise protection and supervise
the correctness of its usage, if the noise level in work place reaches or exceeds
85 dB.

Operator’s manual
Front disc mower
KDF 390
- 8 -
4.4. Warning decals and their meaning
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:
Mower’s nominal rpm: +5 ÷-10% tj. 1050 ÷900 rpm.
N-1
Be extremely careful when PTO
shaft is rotating!
N-2
Caution – cutting knives.
Approach during operation is
forbidden!
N-3
Caution – read the operator’s manual
before putting the mower into
operation!
N-4
Caution – while making repairs
the machine must be stopped!
N-6
Caution – rotating parts N-7 Operating is forbidden when any
person is within the danger area of
50 m!
N-28 N-11 N-40
Signs indicating transport
holders
N-48 N-50
Do not get under the mower N-52 Use protective gloves

Operator’s manual
Front disc mower
KDF 390
- 9 -
N-30 – Cutterbar "Perfect Cut" N-31
P-2
N-53
P-3
N-109 – Quick knife replacementy
N-162

Operator’s manual
Front disc mower
KDF 390
- 10 -
Fig. 1. Warning decals placed on the mower KDF 390
5. TRANSPORT AND OPERATION
5.1. Attaching the mower to self-propelled mower FORTSCHRITT
Fig. 5. Front disc mower KDT 390 attached to FORTSCHRITT

Operator’s manual
Front disc mower
KDF 390
- 11 -
Fig.
6
.
Mounting the mower to self-propelled
mower FORTSC HRITT
Fig.
7
.
Mounting the mower to self-propelled
mower FORTSCHRITT
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) (Fig. 6, Fig. 7).
Intersecting axis gear (1) is mounted on the special bracket (3) welded to self-propelled
machine over the right wheel (Fig. 6).
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:
The articulated telescoping shaft should remain connected only during
mower operation. During transport o rany servicing operations the shaft
should be disconnected from the PTO of the FORTSCHRITT.
CAUTION:
If need be, shorten the PTO shaft according to its operator’s manual given by
the shaft’s manufacturer (Fig. 8).
3
2 1
4 5

Operator’s manual
Front disc mower
KDF 390
- 12 -
Fig. 8. Instruction of PTO shaft shortening
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.
5.2. Operation
Cutting height is adjusted by the regulating bars (Fig. 2, pos. 9), 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.
Swath guides with adjustable swath width mounted in the mower allow the machine
FORTSCHRITT to drive on not causing crush to grass by the wheels.
1.2 m – 1.6 m wide swath may be collected with self-collecting trailer or baler.
5.2.1. Adjusting the mower to work conditions
 Optimum inclination of the cutterbar towards the ground is between 0° 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.

Operator’s manual
Front disc mower
KDF 390
- 13 -
 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.
6. MOUNTING AND ADJUSTMENTS
6.1. Mounting and timing of the knives
The knives should be mounted as shown in Fig. 9, Fig. 10 and Fig. 11, according to the rule,
that the cutting edges should be directed towards ground, so that a knife will lift the grass after
cutting.
Fig. 9. Mounting of the knives on the mowing discs
6.2. Replacing the knives
Worn and/or damaged knives should be immediately replaced. Replace knives, if necessary,
only in sets (Fig. 10). 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 (Fig. 12).
CAUTION:
When replacing knives the engine must be stopped and the cutterbar must lie
on the ground. PTO shaft must be disconnected. Discs should be
perpendicular to cutterbar (max. rotation ± 20°).
Right turn
Right knife Left knife
Left turn

Operator’s manual
Front disc mower
KDF 390
- 14 -
Fig. 10. Quick replacing of the knives with mounting lever
Fig. 11. Disc turns KDF 390
CAUTION:
Check disc turns, before you change the knife (Fig. 11).
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.
6.3. Meintenance and service
6.3.1. 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. 12).
1
2
3 4 5
6 7 8
9

Operator’s manual
Front disc mower
KDF 390
- 15 -
10min.
Fig. 12. Permissible wear of knife holder pin
6.3.2. 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,
 clean the mower each day after working, especially between discs and the cutterbar, because
grass with mud may damage bearings in the disc module,
 if necessary, lubricate the parts and units according to lubrication instructions (pkt 7).
6.3.3. 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.
7. LUBRICATION
7.1. Cutterbar
Refilling the oil of the cutterbar is done through the inlet A(Fig. 13). Proper oil level is
5÷7 mm from the cutterbar bottom. Oil capacities are show in tab. 4. Always change the oil just
after finished work, when it is still warm.

Operator’s manual
Front disc mower
KDF 390
- 16 -
Fig. 13. Cutterbar oil inlet
Tab. 4. Oil capacities
Model Oil capacity [L] Oil type Lubrication frequency
KDF 390 7.0 80W90 Once every 3 seasons
(if working intensively)
7.2. 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. 14). 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. 14. Intersecting axis gears’s lubrication points
A
A
B
A

Operator’s manual
Front disc mower
KDF 390
- 17 -
Tab. 5. Oil capacities
Model Oil capacity [l] Oil type Lubrication frequency
KDF 390 about 1 (SAE 80W/90, API GL-4) 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.
8. DEFECTS AND THEIR REPAIRS
Tab. 6. Defects and their repairs
Defect Reason Reapair
Mower stops working or
leaves uncut grass between
the disco
Worn knives Replace knives
Improperly mounted knives Put on knives strictly acc. to
instructions.
Too high PTO rpm Reduce PTO rpm
Damaged FORTSCHRITT’s PTO Repair
Lying grass Always mow low
Mower is blocked
Damaged gears in the cutterbar Check all the gears
Damaged bearings in the disc hub Replace the bearing
Swath guides wre set too narrow Widen swath guides to the
maximum
Mower does not work, even
though the drive is transmitted
from self-propelled mower.
Torn off shaft of intersecting axis gear Replace intersecting axis gear
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
Leaking cylinder Dirty oil in hydraulic unit of the tractor
Replace oil in hydraulic unit of
the tractor (recommended class of
cleanliness of oil according to
NAS 1638 is minimum 9-10).
Purchase repair kit of the cylinder
and replace damaged sealings
Excesive vibration during
work Damaged PTO shaft Check the condition of PTO shaft and if need be replace
Oil leak in gear Not tight assembly Examine tightness and check oil
level.

Operator’s manual
Front disc mower
KDF 390
- 18 -
9. DISASSEMBLY AND WITHDRAWAL FROM USE
9.1. 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.
9.2. 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.
10.WARRANTY CARD
FRONT DISC MOWER
The product quality has been checked and meets the required standards and regulations and is
permitted for use.
CAUTION:
A warranty card without the required information or with corrected or
illegible information – is invalid.
11.WARRANTY TERMS
11.1. 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 14 days.
Serial number
Date of manufacture
Manufacturer’s stamp
QC signature
Date of purchase
Dealer’s stamp
Dealer’s signature