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5. MAINTENANCE

FRICTION CLUTCH

If you drive with a large tractor (more than 90 HP) you can ensure a long life for your
tractor and machine by mounting a PTO drive shaft with friction clutch between
tractor and machine.
The PTO drive shaft with friction clutch is standard on GX 3202 SM and is
available as option for the other models.

Fig. 5-2 The figure illustrates how the clutch protects the transmission against high torque

peaks and at the same time is capable of transmitting the torque while it is in function
(slips).

The friction clutch must be maintained at regular intervals. At the same time the
clutch must be checked after any long period of standstill. This especially applies
after winter storage before the machine is used for the first time in the season.

Maintaining the friction clutch:

Fig. 5-3

1)   Disassemble the clutch and clean all parts of possible rust.
2)   Check the clutch discs A for wear and replace if required.
3)   Clean and grease the freewheel clutch B.
4)   Assemble and mount the clutch again. See also the instruction manual for the

PTO drive shaft delivered by the supplier.

IMPORTANT: The outer metal band C indicates whether the tightening of the

springs is correct. Tighten the bolts D just so much that the
metal band C can be turned (max. 0.5 mm play).
The torque setting is not correct if the metal band is too tight or
deformed due to excessive tightening of the bolts.

WARNING:

If the clutch is overloaded it will slip and get heated, and hence
be worn quickly. Overheating will damage the friction plates. If
the clutch is blocked or partly put out of function in other ways,
the factory guarantee will be discontinued.

CONTROL OF BALANCE

WARNING:

When driving in the field you must always pay attention if the
machine starts vibrating more than usually or if it has jarring
sounds. The discs rotate with approx. 3000 RPM, and one
broken blade may cause serious injury to persons or material
damage resulting from unbalance.

If working with a modern closed cabin the symptoms may be
difficult to discover, and once in a while you have to get out and
check if all blades and rotor fingers are intact. In the long run
unbalance will cause fatigue fractures and serious damage.

PIGB-093X-06 GX 2402/2802/3202 SM-GX 2402/2802 SC 0410

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Содержание GX 2402 SC

Страница 1: ...Disc Mower GX 2402 SM SC I GX 2802 SM SC I GX 3202 SM Instruction Manual Original instructions Edition 6 I April 2010 ...

Страница 2: ...Type GX 2402 SM FR Modèle GX 2802 SC ES modelo GX 2802 SM PT Marca GX 3202 SM DA Typ PL Model FI Merkki EN ES DE PT IT DA NL PL FR FI to which this declaration relates corresponds to the relevant basic safety and health requirements of the Directive 2006 42 EC al cual se refiere la presente declaración corresponde a las exigencias básicas de la normativa de la y referentes a la seguridad y a la sa...

Страница 3: ...ction manual very carefully before using the machine Pay special attention to the safety instructions This instruction manual is made so that the information is mentioned in the order you will need it i e from the necessary operation conditions to use and maintenance Besides this there are illustrations with text Right and Left are defined from a position behind the machine facing the direction of...

Страница 4: ... 3 ADJUSTMENTS AND DRIVING 21 CONNECTION 21 SWITCHING BETWEEN WORKING AND TRANSPORT POSITION 21 PARKING 23 WORKING IN THE FIELD 23 Basic adjustments 23 Stubble height 23 Starting 23 Turning 25 The break away mechanism 25 Securing against overload 25 Flow caps 27 Swath guards 27 Equipment for wide spreading TOP DRY on SM models 27 FINGER CONDITIONER SM MODELS 29 Conditioner speed 29 Conditioner pla...

Страница 5: ...IN GENERAL 43 FRICTION CLUTCH 45 CONTROL OF BALANCE 45 CUTTER BAR DISCS AND BLADES 47 Blades 47 Replacement of blades 49 Cutter bar and discs 49 CONDITIONER 51 Tightening of roller chain 51 WINTER STORAGE 51 6 MISCELLANEOUS 52 DRIVING TIPS AND FAULT FINDING 52 OPTIONAL EQUIPMENT 53 High guide shoes 53 Sharp shearbars 53 SPARE PARTS ORDER 53 MACHINE DISPOSAL 53 PIGB 093X 06 GX 2402 2802 3202 SM GX ...

Страница 6: ... risk If changes are made on the machine and its construction without permission from JF Fabriken A S JF Fabriken A S cannot be held responsible for any damage resulting from this Intended use of course implies that you observe the prescriptions in the instruction manual and the spare parts book use original spare parts and contact an authorised workshop in so far as it is necessary The following ...

Страница 7: ...to others before you have made sure that they have the necessary knowledge to operate the machine safely DEFINITIONS The safety decals and the instruction manual of the machine contain a line of safety notes The safety notes mention certain measures which we recommend you and your colleagues to follow as to increase the personal safety as much as possible We recommend that you take the necessary t...

Страница 8: ... 9 When connecting the PTO drive shaft check for 540 1000 rpm 10 Never start the tractor until all persons are safely away from the machine 11 Do not stand near the machine while it is working 12 Stop the machine if children are near 13 Never use the machine for other purposes than what it has been constructed for 14 Do not stand near or try to lift a guard until all revolving parts have stopped m...

Страница 9: ...istake It is highly dangerous to connect a machine intended for 540 rpm to a PTO delivering 1000 rpm Long term overload may damage the machine and at worst result in ejection of parts Choose a tractor with a suitable own weight and track width so that it can drive steadily on the ground Also make sure that the link arms and towing hook of the tractor are intended to carry machines with the own wei...

Страница 10: ...ments To ensure all the air has been expelled from the oil in the hydraulic cylinders test all the functions after the hydraulic connections are connected to the tractor Especially before driving on public road TRANSPORT Never drive faster than the conditions allow and maximum 30 km h It is important to block hydraulic transport adjustments An unintentional operation of the cylinders may cause the...

Страница 11: ...tightened to the correct torque When replacing parts in the hydraulic system always make sure that the cutting unit rests on the ground or the lifting cylinders are blocked Hydraulic hoses must be checked by an expert before use and after that minimum once a year If necessary they must be replaced The working life of hydraulic hoses should not exceed 6 years including maximum 2 years of storage Wh...

Страница 12: ...1 INTRODUCTION PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 12 2 1 2 3 4 5 6 7 8 9 10 11 12 12 1 3 4 5 6 STOP 2 MIN 7 8 9 10 11 12 Min 10 m ...

Страница 13: ...n 6 Children Never let children stand near the machine during operation Especially not small children as they have a tendency to do unforeseen things 7 Momentum After the PTO drive shaft has stopped the blades will have a momentum where they keep rotating for up to 2 minutes Wait until the blades have come to a complete stop before you remove the canvas and the guards for inspection and maintenanc...

Страница 14: ...ariable stubble height mm 45 90 45 90 Swath width interval m 1 0 2 2 1 2 2 6 Transport width m 3 3 Type Rubber rollers Chevron Rubber rollers Chevron Conditioner Speeds rpm 1000 1000 Stone release mechanical Standard Standard Freewheel clutch Standard Standard Friction clutch Option Option Setting on friction clutch Nm 1450 1450 Window closed 76 5 dB A Machine connected Window open 82 5 dB A Windo...

Страница 15: ...0 45 90 45 90 Swath width interval m 1 0 2 4 1 2 2 8 1 4 3 2 Transport width m 3 3 3 Type PE fingers PE fingers PE fingers Condition er Speeds rpm 700 860 Standard 700 860 Standard 700 860 Standard Wide spreading Top Dry Standard Standard Standard Stone release mechanical Standard Standard Standard Freewheel clutch Standard Standard Standard Friction clutch Option Option Standard Setting on fricti...

Страница 16: ... CONNECTION AND TEST DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 16 P R 1 1 0 3 3 3 a A D D B C Fig 2 1 Fig 2 2 PR12 0257a F I Fig 2 3 Fig 2 4 PR14 0053 B A B PR12 1192 Fig 2 5 Fig 2 6 ...

Страница 17: ... when lifting the machine with the link arms and optimal conditions for later connection and disconnection of the machine Fig 2 4 Connect the hydraulic hoses to a double acting hydraulic outlet Place the machine in working position by first raising the link arms then activate the double acting outlet and at the same time actuate the valve by pulling the cord Fig 2 5 Release the transport lock B Fi...

Страница 18: ...2 CONNECTION AND TEST DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 18 PR12 1169 B PR11 5017 Fig 2 7 Fig 2 8 PR12 1168 C B A D 100 Fig 2 9 Fig 2 10 ...

Страница 19: ...ust be dismounted After this the tubes are greased by disassembling the 2 half parts IMPORTANT For the warranty of the PTO shaft to be valid and to retain the durability the following rules must be observed Always start the machine with the engine running at low speed Always start the machine with the PTO shaft in a position of maximum 10o from horizontal A sudden increase in the number of rpm of ...

Страница 20: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 20 PR14 0054 A Fig 3 1 Fig 3 2 PR14 0053 B Fig 3 3 Fig 3 4 Fig 3 5 Fig 3 6 ...

Страница 21: ...c outlet SWITCHING BETWEEN WORKING AND TRANSPORT POSITION Fig 3 4 The transport lock B is released for working position and locked for transport position WARNING Conversion to transport position should not take place with revolving PTO shafts The PTO shafts cannot rotate in transport position Fig 3 4 The pendulum suspension must be locked with the transport lock B during transport to avoid traffic...

Страница 22: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 22 PR12 1192 A B PR14 0053 B Fig 3 7 Fig 3 8 Fig 3 9 ...

Страница 23: ...ine is constructed to cut with a theoretical cutting height from 22 mm to 45 mm This means that the real stubble height will be from approximately 45 mm to 90 mm Usually the stubble height is 2 x theoretical cutting height Fig 3 9 Rough adjustment of the stubble height is made in 2 steps with the pin D at guide shoe E in the right and left hand side the bottom hole gives a low stubble Fine adjustm...

Страница 24: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 24 PR12 0018 Fig 3 10 Fig 3 11 ...

Страница 25: ...er tighten the spring so much that it blocks the mechanism due to insufficient spring travel SECURING AGAINST OVERLOAD IMPORTANT The tractor driver can secure the transmission against overload When using the machine the following should be considered 1 Always start the machine with the engine running at low speed This especially applies to tractors with electro hydraulic connection of the PTO shaf...

Страница 26: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 26 Fig 3 12 Fig 3 13 Fig 3 14 ...

Страница 27: ...cking up for a forage harvester or a baler Fig 3 13 The width of the swath can be adjusted by turning the swath guards The bolts handles on the top plate are loosened and the guards are moved either out or in EQUIPMENT FOR WIDE SPREADING TOP DRY ON SM MODELS The GX machines with finger conditioner SM models are fitted with a number of spreading plates which make it possible to place a full width s...

Страница 28: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 28 Fig 3 15 Fig 3 16 PR12 0646 E D Fig 3 17 ...

Страница 29: ... fingers C on the rotor The shorter the distance the stronger the conditioning of the crop Fig 3 17 The system is operated with the handle D which can be placed in 3 positions on the bracket E The distance of the conditioner plate to the rotor is changed by moving the handle D to one of the other holes in the bracket E If the handle is placed in pos A the distance between the conditioner plate and...

Страница 30: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 30 PR12 0991 A Fig 3 18 Fig 3 19 Fig 3 20 ...

Страница 31: ...is held in the hand The reason may be that the roller distance is too long that the roller pressure is too low and that the driving speed is too high It may be difficult to make out whether the conditioning is optimal but do not get tempted to exaggerate the conditioning It is usually sufficient even if it cannot immediately be seen on the grass ROLLER PRESSURE Fig 3 19 In order to obtain a suitab...

Страница 32: ...3 ADJUSTMENTS AND DRIVING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 32 PR11 1052 X X PR12 0991b Fig 3 21 Fig 3 22 PR11 1053 2 mm PR12 0991a Fig 3 23 Fig 3 24 ...

Страница 33: ...tion Tighten the bolts to 200 Nm 20 kpm DISTANCE BETWEEN THE ROLLERS Fig 3 23 The distance between the rollers must be minimum 2 mm and the rollers must run without any particular noise IMPORTANT The distance should be checked before starting and must be measured from behind and between the rollers where the dimension 2 mm is indicated on the figure Check this at several places on the roller Fig 3...

Страница 34: ...type GX SM and SC The below grease spots must be greased according to the operation time intervals indicated PR11 0976 1 1 2 2 8 h 40 h 8 h 40 h PR11 0992 GX SC PR11 0991 GX SC GX SM GX SM PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 34 ...

Страница 35: ...ing hours Pay special attention to the sliding PROFILE TUBES of the PTO shaft They must be able to slide back and forth when the torque is heavy If you neglect to lubricate the profile tubes sufficiently it will result in high frictional forces seizing which will damage the profile tubes and in time also connecting shafts and gearboxes The shaft between the tractor and the machine is lubricated th...

Страница 36: ...4 GREASING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 36 PR12 0407 D D Fig 4 1 Fig 4 2 Fig 4 3 Fig 4 4 ...

Страница 37: ...8 mm Average value This oil level must be an average of the level measured at both filling holes When the oil level has been checked wait 3 minutes if the oil is warm and check again If the oil is cold wait 15 minutes before checking the oil level again Oil change a The first change of oil in the cutter bar must be made after 10 working hours and then after every 200 working hours or at least once...

Страница 38: ...4 GREASING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 38 Fig 4 5 Fig 4 6 ...

Страница 39: ...rheating which in the long term will damage the bearings BEVEL GEARBOX ABOVE THE CUTTER BAR Fig 4 5 Oil content 0 9 l Oil type API GL4 or GL5 SAE 80W 90 Oil level n Check the oil level after every 80 hours of operation Oil change a First oil change after 50 working hours and then after every 500 working hours or at least once a year BEVEL GEARBOX ON THE HEADSTOCK Fig 4 6 Oil content 540 rpm 1 1 l ...

Страница 40: ...4 GREASING PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 40 PR11 0045 E Fig 4 7 Fig 4 8 ...

Страница 41: ...is could block the oil supply Turn on the oil when starting the machine by turning the tap at F until it is approximately half open IMPORTANT Remember to turn off the tap taps again when stopping the machine The drip interval must be 2 3 drip minute This corresponds to a consumption of approximately 0 2 l oil per working day 10 hours Therefore adjust the drip interval by turning the tap to approxi...

Страница 42: ...0 M 12 80 120 135 M 12x1 25 90 125 146 M 14 135 180 215 M 14x1 5 145 190 230 M 16 200 280 325 M 16x1 5 215 295 350 M 18 270 380 440 M 20 400 550 650 M 20x1 5 430 615 720 M 24 640 900 1100 M 24x1 5 690 960 1175 M 30 1300 1800 2300 Fig 5 1 PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 42 ...

Страница 43: ...r if mounted and the machine according to the GENERAL SAFETY INSTRUCTIONS items 1 20 in the beginning of this instruction manual IMPORTANT Screws and bolts on your new machine must be retightened after some hours of operation This also applies if repairs have been made Fig 5 1 Correct torque moment MA if nothing else stated PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 43 ...

Страница 44: ...5 MAINTENANCE PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 44 Fig 5 2 PR12 0709 A B D C Fig 5 3 ...

Страница 45: ...e instruction manual for the PTO drive shaft delivered by the supplier IMPORTANT The outer metal band C indicates whether the tightening of the springs is correct Tighten the bolts D just so much that the metal band C can be turned max 0 5 mm play The torque setting is not correct if the metal band is too tight or deformed due to excessive tightening of the bolts WARNING If the clutch is overloade...

Страница 46: ...5 MAINTENANCE PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 46 Fig 5 4 Fig 5 5 PR12 1193 G H PR12 0040 I Fig 5 6 Fig 5 7 Fig 5 8 Fig 5 9 ...

Страница 47: ...de bolts and blades are made of high alloyed hardened materials This heat treatment provides especially hard and ductile material which is able to withstand extreme stress If a blade or a disc is damaged do not attempt to weld the parts together again as the generation of heat will weaken the parts Damaged blades discs blade bolts and nuts must be replaced by original JF spare parts to obtain a sa...

Страница 48: ...5 MAINTENANCE PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 48 Fig 5 10 Fig 5 11 Fig 5 12 Fig 5 13 PR11 1194 90 Fig 5 14 Fig 5 15 ...

Страница 49: ... and sharp Replacement of blades is made by dismounting the blade bolt and pull it out from beneath the disc This is easily done when the blade is in the front position so that the bolt can fall out through the hole in the stone protector Remove the old blade and mount the new one together with the blade bolt The blades can be used on both sides by moving the blades from one disc to another with o...

Страница 50: ...5 MAINTENANCE PIGB 093X 06 GX 2402 2802 3202 SM GX 2402 2802 SC 0410 50 Fig 5 16 Fig 5 17 Fig 5 18 ...

Страница 51: ...r to get out of balance which for instance will result in reduced life of the bearings TIGHTENING OF ROLLER CHAIN Fig 5 18 Press the sprocket wheel Z down towards the chain and tighten it WINTER STORAGE When the season is over the preparation for winter storage should be made immediately after First clean the machine thoroughly Dust and dirt absorb moisture and moisture increases the formation of ...

Страница 52: ...Conditioner fingers may be worn or missing The distance between the conditioner plate and the conditioner rotor is too long Replace worn fingers and mount new ones where these are missing Adjust the conditioner plate to shorter distance to the rotor Increase the driving speed The machine vibrates uneven operation Blades may be deformed damaged or missing Defective PTO drive shafts Defective bearin...

Страница 53: ...n on the first page in the spare parts book supplied with the machine as soon as possible so that you have the information at hand when ordering spare parts PR11 0344 MACHINE DISPOSAL When the machine is worn out it must be disposed of in a proper way Observe the following The machine must not be placed somewhere outside it must be emptied of oil gearboxes and hydraulic system These oils must be h...

Страница 54: ......

Страница 55: ...e such as expenses for oil grease and minor adjustments 2 Transport of machine to and from workshop 3 The dealer s travelling expenses or freight charges to and from the user Warranty is not granted on wearing parts unless it can clearly be proved that JF has committed a fault The following is regarded as wearing parts Protective canvases blades blade suspensions shearbars guide shoes stone protec...

Страница 56: ...t of experience from right around the world and more importantly unique regional requirements We also receive important inspiration in our development work through a close and continuous dialogue with customers dealers and agricultural researchers No matter which type of JF STOLL machine you chose you can be sure to obtain the best result to obtain a top result in the shape of high performance and...

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