OPERATORSMANUALFORKAFURTER ROTARYTOPPERS …tmihornet.com/products/inventory/TM-120/TM-120.pdf · MODEL TP110 TP140 TP160 Dimensions (LxWxH)mm 1100x1100x900 1400x1400x900 1600x1600x900

OPERATORS MANUAL FOR KAFURTERROTARY TOPPERS

MODELS: TP110, TP140, TP160, TP170

SAFETY WARNING: Do not use or operate this equipment untilthis manual and assembly instructions (where applicable) has

been read and understood.

CONTENTS

1.1 Safety First .................................................................................................................21.2 General Safety .......................................................................................................... 31.3 Operating Safety ....................................................................................................... 41.4 Storage Safety........................................................................................................... 51.5 Maintenance Safety .................................................................................................51.6 Safety Signs .............................................................................................................6 - 7

CHAPTER SERVICE AND MAINTENANCE ............................................................... ..8 - 192.1 Service…………..……………………………………..…………………..……...82.2 Maintenance…………………………………………….……………………. ....102.3 Trouble-shooting………………………………………...…………………… ....202.4 Assembly……………………………………………….………………………....202.5 Specification…………………………………………………….……………......22

CHAPTER MECHANICAL2.6 Mechanical……………………………………………..………………………......212.7 Bolt Torque Setting……………………………………...……………………... 102.8 Spare Parts Lists………………………………………………………………......22

THANK YOU FOR BUYING THIS KAFURTER TOPPER. THE KAFURTER SERIESOF TOPPERS HAVE BEEN DESIGNED TO CUT PADDOCKS, AREAS OFROUGH GRASS AND OTHER PLANTS. IT IS A SIMPLE AND RELIABLE

SYSTEM THAT REQUIRES MINIMAL MAINTENANCE.

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CHAPTER SAFETY INFORMATION

PLEASE NOTE

Make sure all potential operators of this equipment read this manual and allsafety messages contained within.

1.1 Safety FirstRead these safety rules attentively. Follow all suggested precautions to avoidpotential dangers and to safeguard your health and personal safety.The purpose of this manual is to familiarise the operator with the operation and regularservicing of the machine. Remember that the time spent on maintenance extends thelife of your Topper.The safety information given in this manual does not replace any other safetyrequirements or insurance requirements.

This safety alert symbol indicates important safety messages in thismanual. When you see this symbol, carefully read this message thatfollows and be alert to the possibility of personal injury or death.

YOU are responsible for the SAFE operation and maintenance of your Topper. YOUmust ensure that you and anyone else who is going to operate, maintain or workaround the Topper is familiar with these operating and maintenanceprocedures and related SAFETY information.This manual will take you step-by-step through your working day and alerts youto all good safety practices that should be adhered to while operating the Topper.Remember, YOU are the key to safety. Good safety practices not only protect youbut also the people around you. Make these practices part of your safetyprogramme.Most accidents can be prevented. Do not risk injury of death by ignoring good safetypractices.

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Topper owners must give operating instructions to operators or employeesbefore allowing them to operate the machine.The most important safety feature on this equipment is a SAFE operator. It is theoperator’s responsibility to read and understand ALL Safety and Operatinginstructions in the manual and to follow these.A person who has not read and understood all operating and safetyinstructions is not qualified to operate the machine. An untrained operator isa danger to himself and bystanders with the possibility of serious injury ordeath.Do not modify the equipment in any way. ANY modification may weaken thefunctionality and/or safety of the machines. It can also affect the life of theequipment and will invalidate its warranty.Think SAFETY! Work SAFELY!


1.2 General Safety1. Read the operator ’ s Manual and all safety signs carefully before operating,

maintaining, adjusting or hitching / un-hitching the Topper.2. Do not allow anyone to ride on the Topper.3. Operate only at a safe distance from bystanders. Clear the area of pets and

people, especially small children, before starting.4. Clear working area of stones, branches or hidden obstacles that might get

caught up in the blades5. Keep hands and feet away from underside of the Topper at all times.

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6. Keep all shields in place. If shield removal becomes necessary for repairs,replace the shield prior to use.

7. Do not stand between the tractor and the Topper.8. All rotary blades have the ability to discharge objects at high speeds, which

could result in serious injury to bystanders or passers-by, use with extremecaution.

9. Place all controls in neutral, stop tractor engine, set hand brake, removeignition key and wait for all moving parts to stop before servicing, adjusting,repairing or un-hitching.

10. Review safety related items regularly with all personnel who will operate ormaintain the Topper.

11. Do not operate the Topper if you feel unwell or physically unfit. Stop operationimmediately if you begin to feel unwell.

12. Our Toppers are designed with safety in mind; however, there is no realsubstitute for caution and attention in preventing accidents. Once an accidenthas happened, it is too late to think about what you should have done.

13. Use a tractor equipped with a Roll Over Protective Structure (ROPS). Alwayswear your seat belt. Serious injury or even death could result from falling off thetractor - particularly during a turnover when the operator could be pined under theROPS or the tractor.

14. Never exceed the limits of a piece of machinery. If its ability to do a job, or todo so safety, is in question - DON’T TRY IT.


1.3 Operating Safety1. Read and understand the Operator’s Manual and all safety signs before

operating, servicing, adjusting, repairing or un-hitching.2. Do not allow anyone to ride on the Topper.3. Install and secure all guards and shields before starting or operating.4. Keep hands, feet, hair and clothing away from moving parts.5. Place all controls in neutral, stop tractor engine, set park brake, remove

ignition key and wait for all moving parts to stop before servicing, adjusting,repairing or unplugging.

6. Place all tractor and machine controls in neutral before starting.7. Never start or operate the Topper unless sitting on tractor seat.

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8. Clear the area of bystanders, especially small children, before starting9. Stay away from PTO shaft and machine when engaging PTO. ENGAGE PTO

AT LOW REVS. Once engaged, bring revs up to 540 RPM.10. Clean reflectors, and lights before transporting.11. Use hazard lights on tractor when transporting.12. Do not operate the Topper in the raised position.13. Objects can be thrown out from under machine with sufficient force toseverely injure people and animals. Stay away from the Topper when it isrunning. Keep others away.14. Always know what you are cutting. Never operate the Topper in an area that hashidden obstacles. Remove sticks, stones, wire or other objects from working areabefore starting.15. Review safety instructions with all operators regularly.


1.4 Storage Safety1. Store the Topper in an area away from pedestrians.2. Do not permit children to play on or near the stored Topper.3. Store the machine in a dry, level area. Support the frame with wooden planks

if required.


1.5 Maintenance Safety1. Good maintenance is your responsibility. Poor maintenance is an invitation to

trouble.2. Follow good workshop practices.

Keep service area clean and dry.Be sure electrical outlets and tools are properly grounded. Useadequate light for the job at hand.

3. Make sure there is plenty of ventilation. Never operate the engine of the

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towing vehicle in a closed building. The exhaust fumes may causeasphyxiation.

4. Before working on this Topper, shut off the engine, set the hand brake, andremove the ignition key.

5. Never work under equipment unless it is supported securely.6. Use personal protection Equipment such as eye, hand and hearing protectors

when performing any service or maintenance work. Use heavy gloves whenhandling blades.

7. When replacement parts are necessary for periodic maintenance andservicing, genuine factory replacement parts must be used to restore yourequipment to original specifications. KAFURTER.com Limited will not beresponsible for injuries or damages caused by use of unapproved partsand/or accessories.

8. A fire extinguisher and first aid kit should be kept readily accessible whileperforming maintenance on this equipment.

9. Periodically tighten all bolts, nuts and screws and check that all pins areproperly installed to ensure unit is in a safe condition.

10. When carrying out maintenance or servicing, make sure all safety shields anddevices are installed before putting the Topper back into service.


1.6 Safety Signs1.6.1 Care of Safety Signs1. Keep safety signs clean and readable at all times.2. Replace safety signs that are missing or have become illegible.3. If a component with a safety sign(s) affixed is replaced with a new part, make

sure that new safety sign(s) are attached in the same locations as thereplaced components.

4. Safety signs are available from your authorised Distributor or Dealer PartsDepartment.

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1.6.2 Safety Signs locationsThe types of safety signs and locations on the equipment are shown in theillustrations that follow. Good safety requires that you familiarise yourself with thevarious safety signs, the type of warning and the area, or particular function relatedto that area.

Two of the following warning signs are located on either side of the topperheadstock just inside the skids - Danger of severe injury from rotating blades. Keephands & feet away from the underside of the topper.

Two of the following warning signs are located on the left and right hand cornerstowards the back of the topper just inside the skids. Danger of severe injury fromrotating blades. Keep hands & feet away from the underside of the topper.

The following warning sign is located towards the back edge of the topper directlyopposite the gearbox. Danger of severe injury, DO NOT RIDE ON THEMACHINE. DO NOT STAND BETWEEN THE MACHINE AND THE TRACTOR

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One of the following safety signs is located on the flail deck in front of the P.T.O. shaft.DO NOT OPERATE THIS MACHINE IN EXCESS OF 540R.P.M. Failure to comply willput yourself and others at risk. Your flail mower may fail and yourwarranty will become void.

Chapter 2. SERVICE AND MAINTENANCE

SERVICE

2.1 FLUIDS AND LUBRICANTSGrease:Use SAE multi-purpose high temperature grease with extreme pressure (EP)performance. An SAE multi-purpose lithium base grease.Gear Box Oil:Use EP90 gear oil. Fill gearbox to side bung level. Regularly check this level.Storing Lubricants:Your Topper can operate at top efficiency only if clean lubricants are used. Use cleancontainers to handle all lubricants. Store them in an area protected from dust,moisture and other contaminants.

GREASING1. Use the Maintenance Checklist provided to keep a record of all scheduledmaintenance.2. Use a hand-held grease gun for all greasing.3. Wipe grease nipples with a clean cloth before greasing, to avoid injecting dirt andgrit.4. Replace and repair broken grease nipples immediately, If grease nipples willnot take grease, remove and clean thoroughly. Also clean lubricant passageway.

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2.2 BLADE REPLACEMENT

A blade may become bent, chipped or broken when using and will have to bereplaced, when replacing a blade, follow this procedure:

• STOP PTO ANDWAIT FOR THE BLADES TO STOP ROTATING.• Raise the machine above the ground to provide access to the blades.• Stop engine, set hand brake, remove ignition key and wait for all moving

parts to stop before dismounting.• Support the machine with large wooden blocks or safety stands.• Remove the nut through the access hole.• Push or tap the blade pin down.• Remove the old blade and replace with a new one• Tap or drive the blade bolt back into position.• Tighten the mounting bolt to its specified torque.

ALWAYS replace blades in pairs to maintain balance. NEVER try to straighten or weldblades. Unbalanced blades are dangerous.

ALWAYS keep the blade carrier and blade bolts tight. Loose blades can easily piercethe steel plate housing and or cause injury.

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GEARBOX MAINTENANCE

The heavy duty gearbox used on the KAFURTER range of Toppers will give many years oftrouble-free service with minimal maintenance requirements. Maintain the gearbox byfollowing this simple procedure:

OIL LEVEL:

IMPORTANT:

The oil level should only EVER be checked when the machine is cold and on a level surface

* Remove the level plug from the side of the gearbox.* The oil level should be just below bottom lip of the thread. * Addoil through the top fill plug if required.

REPAIR:

When the gearbox noise level is unusually high, it may be necessary to replace worncomponents or the entire gearbox (depending on its condition). CONTACT YOUR LOCALDEALER IMMEDIATLEY.

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2.3 TROUBLE SHOOTING

This Topper is designed to cut grass or other plants. It is a simple and reliablesystem that requires minimal maintenance.In the following section, we have listed many of the problems, causes andsolutions to the problems that you may encounter.

Problem and PossiblecauseCutter does not turnPTO shaft slips

Poor cutting jobBlades dull.

Grooves in grass.Scalping.Grass being left un-cut.

VibrationOut of balance.

Solution

Repair tractor PTO clutch

Traveling too fast, slow down and sharpen blades.

Bent blade. Straighten or replace blade.Machine too low. Raise machine.Traveling too fast. Slow down.Top link too short. Extend top link.

Check for bent, damaged or broken blades. Repair orreplace as required

2.4. ASSEMBLY

The machine is shipped from the factory in a partially assembled form that allowseasy and convenient shipping. Your dealer should assemble the topper, but youmay have opted for self assembly the topper yourself. In order to ensureoptimum performance and safety integrity, the following procedures MUST befollowed.

BEFORE ASSEMBLY, ADOPT SAFE WORKING PRACTICES. CLEAR THEWORKING AREA, ENSURE YOU HAVE THE CORRECT TOOLS AND WEAR

PROTECTIVE GLOVES AND PROTECTIVE CLOTHING.

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Slowly lower the topper to the ground. Carefully remove the mounting frame, pins anddriveline from the frame and lay to these to one side.

Using suitable lifting equipment place the topper on secure blocks and attach the sideskids securely at the required cutting height using the bolts provided.

Remove the bung on the side of the gearbox and top breather cap. Pour in thecorrect oil as specified until it reaches the lower level of the side bung hole.When this occurs, replace bung and top breather cap.

Remove the split pins from the P.T.O. guard supports on either side of the gearbox.Place the P.T.O. guard in position and re-insert the supports through the holes providedat the bottom of the P.T.O. guard. Re-insert the split pins.

Install the PTO driveline

Remove the bolts from the input yoke.

Attach driveline to yoke.

Tighten mounting bolts to their specified torque.

Attach 3 point hitch A frame to the front of the machine. Be sure to position 3 pointmounting pin to the front.

The topper is now ready to attach to your tractor.

CHAPTER 112.6 Mechanical

MODEL TP110 TP140 TP160Dimensions(L x W x H) mm 1100 x 1100 x 900 1400 x 1400 x 900 1600 x 1600 x 900Weight (Kg) 135 160 220Cutting Width (mm) 1040 1340 1540Cutting Height(mm) 50 to 200 50 to 200 50 to 200Input TurningSpeed (RPM) 540 540 540Power Required(HP) 16~30 20~35 25~40

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KAFURTER TOPPER MOWER - EXPLODED VIEW

Topping Mower AssemblySer.No123

Part No

SL110.120GB97.1-85GB93-87

Name QuantityRemarks

SpecificationPin 2

Plain washier24 2spring washier24 2

4 GB6170-86 Hex.nut M24 25 Circle Steel 16 SL110.108 Mounting bracket 1

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forfront supporting

7 Link 38 GB5783-86 Screw M16?0 59 GB97.1-85 Plain washier16 310 GB889-86 Lock nut M16 311 .SL120.00.118 Blade 212 SL110-133 Screw 213 GB97.1-85 Plain washier18 614 GB93-87 spring washier18 415 GB6170-86

16 SL110-132

Hex.nut M18 4Supporting board 1

for Blade17 Litter R pin 118 SL110-131 Blade seat 119 GB6170-86 Hex.nut M18 420 GB97.1-85 Plain washier18 1521 SL110.109 Adjusting Board 222 GB93-87 spring washier18 4 Bigger23 SL110-121 Protecting plate 124 GB70-85 Screw M10?10 225 GB6170-86 Hex.nut M10 226 GB5783-86 Screw M18?0 227 GB 6178-86 Hex.nut M24 128 GB6170-86 Plain washier24 129 GB 91-86 Pin4 x 40 130 GB93-87 Plain washier8 4

GB6170-86 Plain washier8 431 GB5783-86 Screw M8?6 432 SL140.00.012

33 SL110.109

Gearing Box 1Gearing Box 1

Cover34 GB5783-86 Screw M16?5 435 SL110.103 Front supporting 136 Link 8 137 Lock 238 SL110.110 Deck 1

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Documents

OPERATORSMANUALFORKAFURTER ROTARYTOPPERS …tmihornet.com/products/inventory/TM-120/TM-120.pdf · MODEL TP110 TP140 TP160 Dimensions (LxWxH)mm 1100x1100x900 1400x1400x900 1600x1600x900