K2000 Modular Rotary Harrows Operator Safety Manual

INSTRUCTION MANUAL & MOUNTING GUIDE

K2000 MODULAR ROTARY HARROWS

ABN: 34 486 499 532 74 Young Road (PO Box 340) COWRA NSW 2794 Phone: 02 6340 0400 Toll Free Phone: 1800 194 131 Fax: (02) 6342 6913

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WARNING!!! SAFETY PRECAUTIONS

FAILURE TO OBSERVE THE FOLLOWING INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH

It is the responsibility of the user to:

 Maintain in as new condition all warning and safety signs and devices at all times.

 Ensure all operators are familiar with this manual and all safety devices and features of the machine.

 Take every reasonable precaution as is commonly expected in this industry and in the operation of the machine.

 Maintain the machine at all times in a condition that is safe to operate, and ensure it complies with any relevant safety acts of parliament, government authorities and regulations.  Before mounting, check with manufacturer of machine or consult engineer to ensure strength and balance of machine is adequate to accommodate the K-Line products you have purchased.

 You must conduct a risk assessment, taking all risks into consideration before commissioning machine for use.

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Dear Customer

Thank you for purchasing K2000 Modular Rotary Harrows made by K-Line Industries. We would like to assure you that you have made a good choice, and will be able to rely on this high quality piece of equipment. You are welcome to phone us on 1800 194 131 to discuss any feature of this mower. We ask you to follow the Instruction Manual closely, as this will ensure that you experience the benefits of using the machine without unnecessary down time caused by misuse. The return of the Warranty Registration Form will enable a prompt and efficient identification of your K2000 Modular Rotary Harrows and attention to any concern you may have.

IDENTIFYING THE MACHINE FOR REQUESTING SPARE PARTS

The machine is identified by the serial number on the metal plate on the machine. When requesting spare parts or maintenance service, please indicate the model and number of your equipment to ensure prompt and efficient attention.

AVAILABILITY OF GENUINE PARTS

K-LINE spare parts and accessorised have been specifically designed and developed for the machines produced. We would call your attention to the fact that non-genuine parts and accessories are not recommended by K-LINE . The use of such replacement parts frees K- LINE from all liability and makes the warranty void. The installation and/or use of non-genuine parts may, because of technical characteristics of construction, may modify or influence the performance of the machine negatively.

AFTER DELIVERY

When you receive the machine, make sure that no damage has been done to it during transportation and that no parts are missing. Only by giving us immediate advice can the necessary replacement parts be obtained. It should be ensured that all components are correctly adjusted.

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K2000 MOUNTING PROCEDURES

IMPORTANT Before mounting and fitting of K2000 Modular Rotary Harrows, machine should be correctly ballasted to compensate for weight of harrows. Ensure strength of machine is adequate to accommodate harrows. 1. Attach jack shafts to frame of machine with U-bolts supplied. (If underframe clearance is less than 650mm, turn jack shaft over to lift tool bar height) See Figure 1.

Figure 1

Distances shown are with tines sitting on top of the ground

Use one jack shaft for every rotor Exceptions: add extra jack shaft/s to high stress points. For example, wing of wing up machine; 3 point linkage machines 2. Attach tool bar. (Leave sufficient clearance between tool bars on wing up machines to allow for folding) 3. Attach centre mount bracket K2202 to pivot assembly K2203 using  1 x (M24 x 65 c/w Flat washer and nyloc) Pivot bolt  2 x (M14 x 50 c/w flat washer and nyloc) angle aggression bolts

NOTE: There are four different aggression angles. Most commonly used are the two centre positions

4. Attach centre mounts K2203 to rotor bows using M12 x 65 U bolts. See Figure 2. Tighten U-bolts after making final adjustments.

 Rotors have a clockwise and anticlockwise tine pattern. One way models have all clockwise rotors. Herringbone models have anticlockwise rotors on left hand side and clockwise rotors on right hand side .  All warning stickers should now be visible to the rear of the machine.

5. Attach chain anchor angles K2204 to chain (as per sample)

 Attach chain anchor angles K2204 to bow. See Figure 2.  Attach chain to centre mount using ½” D shackle. Adjust links to suit length required when operating

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6. Attach pivot assemblies to tool bar. (Working cover shown in Figure 2). Follow harrow format if supplied.

Figure 2

Use tool bar rear extension K22REX on herringbone models to set one rotor rearwards where direction changes. See Figure 3.

Tool bar extension

Figure 3

7. Visually check coverage of rotors

 Check for interference between rotors in working and folded positions

8. Tighten bolts securely. Retighten after 2 hours of operation.

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TYPICAL LAYOUT

Direction of travel

Wings

Centre

Wings

Jack shafts

Tool bar/s

Centre mounts

Rotors

Tool bar extension (REX)

Tips for setting up K2000 Rotary Harrows

□ Lower wings of machine (if applicable)

□ Lower whole machine to ground on flat surface

□ Check positioning of jack shafts for correct tool bar height. See Figure 1.

□ Attach jack shafts and tool bar. Do not tighten yet.

□ Attach centre mounts to rotor bows. Do not tighten yet.

□ Place rotors in correct sequence behind tool bars and attach to tool bars. Do not tighten

□ Check rotor positions for correct cover, allowing for overlap approx. 50-60mm

□ Follow steps set out in K2000 Mounting Procedures (pages 4-5)

ROTOR TABLE Rotor Length

Working Cover (m)

Short

1200 1400 1625 1750

0.85 1.05 1.25 1.35

Medium

Long

Extra Long

N.B. Working cover - Standard aggression - Standard overlap

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INSTRUCTIONS FOR SAFE OPERATION

This Instruction Manual must be read and understood by all personnel who use, adjust or maintain the K2000 Series Harrows. This Instruction Manual must be supplied and explained to all users. At all times observe Occupational Health and Safety Regulations and Workcover Regulations.

1. Never attempt to adjust the machine when in operation

2. Never stand under harrows or within radius of wings of machine

3. Never stand on, near or under machine when in raised position or when in operation

4. Ensure everyone is clear of machine when folding or unfolding and when in operation

5. Use correct manual handling techniques and mechanical lifting devices

6. Check for height clearance when machine is lifted

7. Do not operate hydraulics until everyone is clear of the machine

8. Keep clear of machine when in working and vertical position

9. All bots, nuts and pins must be well secured

10. Never get under or on top of the machine when it is supported by jack. Keep feet & body clear when operating jack 11. Do not operate if any part of this machine is within 10 metres of overhead power lines

K-LINE Industries takes no responsibility or liability for any usage outside our recommendations and instructions

Do not attach any towable vehicle to the machine

It is absolutely forbidden to place any object on the machine beyond its maximum capacity The machine should only be used for the work for which it was manufactured

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SAFE WORK PROCEDURES

Ensure all bolts are correctly tensioned and pins are securely fastened.

Observe correct manual handling techniques.

For repairs and maintenance always:

 Lower machine to the ground  Use suitable jack stands for the frame support when servicing in raised position

NEVER GET UNDER MACHINE WHILST IN RAISED POSITION WITHOUT APPROVED JACK STANDS IN PLACE.

WARNING THE OPERATOR MUST ENSURE NO PERSONNEL ARE NEAR MACHINE WHEN LOWERING, RAISING OR OPERATING MACHINE.

Eye protection (safety glasses or goggles), foot protection (safety boots) hand protection (gloves) and any other protective equipment must be worn when adjusting machine.

N.B. Keep body well clear when attaching tractor to machine at all times. Follow all safety precautions set out on preceding pages

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SAFETY INSPECTION & LUBE SERVICE

□ All nuts and bolts must be checked and retightened after the first 2 hours of operation

□ Every 20 hours of operation, grease bearings using a good quality grease (2 pumps only). Clean nipples before attaching grease gun.

□ Check harrows regularly for signs of wear or breakages. For example mounting and U-bolts

□ Ensure all safety stickers are in place at all times. For re-order please telephone 1800 194 13

□ Instruction manual is supplied.

CONDUCT A SAFETY CHECK DAILY.

DECALS SUPPLIED WITH THIS MACHINE TO REORDER FREE CALL 1800 194 131 (Re-order codes below stickers)

(W03)

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RISK MANAGEMENT

Risk management is the process of finding out what may cause an injury, deciding what may happen as a result, and doing something about it.

The steps of risk management are:

 Identify the hazards to workplace health and safety arising from work activities  Assess the risks  Determine and implement control measures to reduce risk  Monitor and review the effectiveness of the control measures

IDENTIFYING HAZARDS

Prior to commencing work, all hazards related to the work tasks should be identified. The selection of the appropriate work procedure(s) will depend on the type of work procedure(s) and hazards involved. Regular safety inspections will also identify hazards and ensure that control measures are in place.

RISK ASSESSMENT

Risk assessment allows appropriate control measures to be developed. Once hazards have been identified, they should be assessed in terms of their potential to do harm. To assess risk, consideration should be given to probability and consequences. SEE RISK ASSESSMENT MODEL.

RISK CONTROL

Risk control is the process of eliminating or reducing risk factors. Control measures should be chosen and implemented to eliminate or reduce risk as far as practicable. When deciding on the most appropriate measures to use, practicality and acceptance of the control measures should be considered. Safe Working Procedures will be developed for all high – medium risk hazards.

MONITOR AND REVIEW CONTROL MEASURES

The risk identification, assessment and control process requires regular monitoring to ensure the implemented control measures perform as originally intended and continue to prevent or adequately control the risk of injury or incident. Control measures should also be checked carefully to ensure that new hazards are not created, directly or indirectly, by the original control measures.

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RISK ASSESSMENT MODEL

AT ALL TIMES COMPLY WITH RECOMMENDATIONS AND REQUIREMENTS OF THE MANUFACTURER AND THE ENVIRONMENTAL PROTECTION AUTHORITY

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K-LINE INDUSTRIES RISK ASSESSMENT

REVISED RISK SCORE

RISK SCORE

CODE

HAZARDS

CONTROL

Crushing – when adjusting and cleaning, as machine may drop without warning

Adjusting & cleaning must only be done when machine is lowered or in transport position and only after all chains and bolts have been checked for tightness & wear in the lower position. Ensure jack is installed correctly & jack receives regular maintenance. Keep feet and body clear when operating. Ensure no personnel are between tractor & harrow bar when hitching to tractor. Machine must be lowered into working position using suitable lifting equipment before priming is effected by slightly loosening fitting/s into cylinders and operating tractor hydraulics to achieve full uninterrupted travel of cylinder several times. Then retighten hydraulic tine fittings.

1

5

1(A).

Crushing - improper use of jack

1

5

1(B).

Crushing - when hitching tractor

2

5

1(C).

Crushing - prior to priming hydraulic system, as machine may drop without warning

1

5

1(D).

Sudden lift of drawbar causing severe injury, if machine becomes unhitched Penetration of oil - broken or badly maintained hydraulic lines Rupture of oil lines by over pressure when machine comes to sudden stop before

Ensure all three jacks are correctly positioned and taking weight before removing drawbar pin. Stickers warn operator.

1

5

1(E).

Maintain regular checks on hydraulic system for wear & check all fittings are secure.

2

5

2(A).

Ensure tractor oil flow is limited to reduce falling speed or do not interrupt machine falling until machine is fully in lowered position

2

5

2(B).

fully lowered to working position

Collision – hydraulics accidentally lowered

Safety pins must be put in place as soon as machine is put in transport position and if travelling on public roads to disconnect hydraulics from tractor.

1

5

3.

when machine is being operated in transport

ALL HAZARDS AND RISKS ARE CONTROLLED THROUGH SAFE WORKING PROCEDURES AND ADEQUATE SIGNAGE

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WARRANTY

K-LINE INDUSTRIES have been known since 1993 for supplying an ever expanding range of quality agricultural machinery.

K-LINE INDUSTRIES warrants the products it manufactures and distributes to be free of defective materials and workmanship for a period of twelve months from date of purchase, to the first owner. Any part of the goods manufactured and distributed by K-LINE INDUSTRIES that proves to be defective material, will be replaced or repaired by K-LINE INDUSTRIES when returned to K-LINE INDUSTRIES at cost to purchaser and at purchaser’s risk. Goods sold shall only have the benefit of this warranty if the purchaser has complied with the manufacturer’s instructions in relation to the maintenance and operation of the said goods. All conditions and warranties implied by Law or Statute are hereby expressly excluded and negatived so far as legally permissible. K-LINE INDUSTRIES is not otherwise liable for any direct, indirect or consequential loss or damage howsoever arising or occurring, whether founded in tort, contract, and statute or otherwise.

This warranty must be read as subject to the General Terms and Conditions and does not cover misuse, neglect or negligence.

ANY CLAIM FOR WARRANTY IS ALSO SUBJECT TO THE FOLLOWING CONDITIONS:

 Equipment must be handled, assembled, and operated, maintained and stored correctly and in accordance with the manufacturer’s instructions by competent personnel.

 Warranty registration form must be signed by reseller and purchaser and returned to K-LINE INDUSTRIES within 14 days of invoice.

 Normal wear and tear, routine maintenance costs and accidental damage are NOT covered by this warranty.

 Any alteration of equipment or negligence in maintenance renders this warranty null and void.

____________________

Signed on behalf of K-LINE INDUSTRIES

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PRE-DELIVERY CHECKLIST

 Conduct comprehensive risk assessment of machine with consideration for use and maintenance

 Ensure machine is delivered as per purchase order including options

 All pins and lynch pins are in place

 Hydraulic system is primed and operating properly (if applicable).

 Check gearboxes for oil (if applicable).

 Check belts for tightness (if applicable).

 Instruction manual is supplied and explained.

It is the responsibility of the purchaser to:

 Maintain in as new condition all warning and safety signs and devices at all times.  Ensure all operators are familiar with this manual and all safety devices and features of the machine.  Take every reasonable precaution as is commonly expected in this industry and in the operation of the machine.  Maintain the machine at all times in a condition that is safe to operate, and ensure it complies with any relevant safety acts of parliament, government authorities and regulations.  Before mounting, check with manufacturer of machine or consult engineer to ensure strength and balance of machine is adequate to accommodate the K-Line products you have purchased.  You must conduct a risk assessment, taking all risks into consideration before commissioning machine for use.

Reseller

Client

ADDRESS:

ADDRESS:

PHONE:

PHONE:

SIGNED:

SIGNED:

MACHINE MAKE

SERIAL NO:

& TYPE:

DATE OF

INVOICE

INVOICE:

NO:

To confirm registration for warranty, please fax this page (signed) to (02) 6342 6913. Thank you.

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NOTES

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DESIGNERS AND MANUFACTURERS OF QUALITY AGRICULTURAL MACHINERY

TOLL FREE PHONE NUMBER: 1800 194 131

PO BOX 340 * 74 YOUNG RD COWRA NSW 2794 * TEL: 1800 194 131 * FAX: 02 6342 6913 EMAIL: sales@k-line.net.au * WEB: www.k-line.net.au

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