is one of the five largest global companies producing agricultural machinery. The company includes 13 enterprises, and production is based in 5 countries: Russia, Kazakhstan, Ukraine, Canada and the USA.
Rostselmash products are popular all over the world, as the company provides excellent equipment in terms of price and quality. According to the latest data, Rostselmash occupies more than 70% of the market for the production and sale of agricultural machinery in Russia.
The company produces 24 types of equipment, which is represented by a wide range of models. Combines and mowers are especially popular among farmers.
In this article you will learn about the universal self-propelled mower KSU-1. The development and production of a universal mower began in 2009, along with the production of a new TORUM class 7 grain harvester.
Specifications
The self-propelled universal mower KSU-1 is supplied by the plant in 2 modifications, differing in the presence or absence of a mechanical drive of the working element. The power unit is an in-line 6-cylinder diesel engine D-260. The engine is equipped with a turbocharger that provides reduced fuel consumption. Engine power is 157 hp.
The mower is equipped with all-wheel drive. To transmit torque, a hydrostatic drive with individual motors in the hubs is used. This transmission scheme ensures a smooth change in speed. The machine uses a split-type front axle. The unit is equipped with a cross member, which is part of the frame. The rear axle is a portal design, has 2 hydraulic cylinders to change the wheel alignment angle. The design has rods that form a steering trapezoid.
Dimensions and technical characteristics of the mower:
- length - 5360 mm;
- width - 3376 mm;
- height - 3637 mm;
- ground clearance - 1000 mm;
- operating weight - up to 4903 kg;
- fuel reserve - 340 l;
- width of the formed roll - 1800 mm;
- working/transport speed - 18/24 km/h.
The machines are equipped with the following equipment:
- conveyor windrowers with a hydraulic connector, 7.0 or 9.0 m wide;
- rotary installation with a working area of 3.5 m;
- chopper;
- flattener.
Installation of external equipment is carried out without the use of additional adapters. The use of quick-release clamps allows you to replace the front linkage in 15-20 minutes. Rotary and roller devices can have a mechanical drive or do without it. For mechanical drive, power take-off shafts are used. The hydraulic drive is carried out from a standard system equipped with a gear pump with variable displacement.
Equipment installation units ensure copying of field surface unevenness. This results in increased productivity.
The operator's workplace is located in a 2-seater cabin. The design ensures the tightness of the internal volume; the walls are lined with soundproofing materials. Standard equipment includes air conditioning, a small refrigerator and an audio system. The attachments are controlled using a multifunctional remote control with a liquid crystal display.
The equipment includes a pneumatic system connected to a compressor on the engine. The design includes an automatic pressure regulator and a receiver for storing a supply of compressed air. The machine is equipped with a quick-release coupling, which is used to connect attachments. It is also possible to use compressed air for repair or maintenance work.
Adapters
The KSU-1 hydraulic connector allows the equipment to work with the following types of adapters:
- DF 700/DF 900. These are conveyor type windrowers. The equipment is suitable for mowing all types of agricultural crops, placing the bevel in a right-left or central windrow.
- GH 500C. This is a conditioner, the cutting elements of which are made in the segment-finger version.
- JS 270. Mounted chopping mower. The equipment is designed for harvesting plant matter no more than 2 meters high, growing in flat fields. Typically used for preparing feed.
- DM 350C. This is a rotary front mower. It is used in fields with high yields; during harvesting, the plant mass is fluffed up and placed in a windrow. Please note that this equipment is not suitable for areas with difficult terrain and a high content of stones in the soil.
- The mower's hitch is equipped with a terrain following system, which significantly increases the productivity of the equipment. Average productivity indicators of KSU-1 vary between 6-10.5 hectares/hour.
Specifications
The self-propelled universal mower KSU-1 is supplied by the plant in 2 modifications, differing in the presence or absence of a mechanical drive of the working element. The power unit is an in-line 6-cylinder diesel engine D-260. The engine is equipped with a turbocharger that provides reduced fuel consumption. Engine power is 157 hp.
The mower is equipped with all-wheel drive. To transmit torque, a hydrostatic drive with individual motors in the hubs is used. This transmission scheme ensures a smooth change in speed. The machine uses a split-type front axle. The unit is equipped with a cross member, which is part of the frame. The rear axle is a portal design, has 2 hydraulic cylinders to change the wheel alignment angle. The design has rods that form a steering trapezoid.
Dimensions and technical characteristics of the mower:
- length - 5360 mm;
- width - 3376 mm;
- height - 3637 mm;
- ground clearance - 1000 mm;
- operating weight - up to 4903 kg;
- fuel reserve - 340 l;
- width of the formed roll - 1800 mm;
- working/transport speed - 18/24 km/h.
The machines are equipped with the following equipment:
- conveyor windrowers with a hydraulic connector, 7.0 or 9.0 m wide;
- rotary installation with a working area of 3.5 m;
- chopper;
- flattener.
Installation of external equipment is carried out without the use of additional adapters. The use of quick-release clamps allows you to replace the front linkage in 15-20 minutes. Rotary and roller devices can have a mechanical drive or do without it. For mechanical drive, power take-off shafts are used. The hydraulic drive is carried out from a standard system equipped with a gear pump with variable displacement.
Chassis
The chassis is made in the form of motor wheels. This scheme provides stepwise speed control depending on the load. The mower's clearance is 1,000 millimeters, which ensures unhindered passage over windrows of any height. The rear axle is steerable; it is a balancing structure with a free swing angle around the ground. The beam is characterized by increased resistance to dynamic loads. In addition, the balanced design of the rear axle ensures better maneuverability in areas with difficult terrain and has a positive effect on vehicle handling. A well-thought-out steering design reduces the turning radius, allowing you to turn literally in one place.
Ksu 1 technical specifications
Imported sample tests
To the attention of agricultural machinery manufacturers
The North Caucasus MIS Federal State Budgetary Institution accepts applications from individuals and legal entities for the provision of public services in the field of assessing the consumer properties of agricultural machinery under real operating conditions.
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Self-propelled universal mower KSU-1
Self-propelled universal mower KSU-1 in working position. Front left view
Self-propelled universal mower KSU-1 in working position. Rear left view
Conveyor header ZHT 7-14. Rear right view
Self-propelled universal mower KSU-1 with conveyor header header ZHT 7-14 on transport trolley RSM-142.29
Manufacturer: KZ Rostselmash LLC Address: 344029, Russia, Rostov-on-Don, st. Menzhinsky, 2
Purpose
The self-propelled universal mower KSU-1, consisting of an ES-1 power unit and a conveyor header header ZHT 7-14, is designed for mowing and placing cereal grains, leguminous and cereal crops, grass seeds and herbs into haylage in a central, left-handed or right-handed windrow, and also for laying the mass from two passes into a double windrow when harvesting the grain-stem mass of cereals using a separate method.
The mower is intended for use in areas with a temperate climate, placement category I according to GOST 15150.
Description of design
Self-propelled universal mower KSU-1 as part of an ES-1 power unit and an adapter (conveyor header header ZHT 7-14).
The ES-1 power vehicle consists of a frame, chassis, operator’s workplace (cabin, controls and controls, access means and service points), motor unit, power take-off shaft drive (hereinafter referred to as PTO), hitch system, towing device, hydraulic equipment , electrical equipment and electronic control systems.
The ZHT 7-14 conveyor header header consists of a housing, a cutting device, conveyors, a reel, and a hydraulic system for driving the cutting device.
1 pageIntroduction
| When making an informed choice, when purchasing agricultural machinery, one way or another, you have to compare four key components (consumer properties): — price -reliability -operational characteristics — quality of the technological process. The priority of one over the other is determined by everyone for himself. But only their balance gives a positive effect from owning technology as a tool of labor. Difficulties in the effective use of high-performance combines in the zone are the naturally low grain yields, and the risky farming zone forces the use of separate harvesting to reduce losses. And here the problem arises of the lack of reliable wide-cut self-propelled harvesters of domestic production in MTP farms. In August 2022, the Altai MIS Federal State Budgetary Institution acquired ownership, for the purpose of testing high-performance grain harvesters, of a self-propelled universal mower KSU-1, serial number ROKSU 165001011, manufactured by KZ Rostselmash LLC. On the Altai MIS website, we are creating a blog for the KSU-1 self-propelled mower. In this blog, we will post in chronological order the information obtained during the operation of the mower. The information will contain operating time, a description of the technological operations performed and the conditions for their implementation, productivity and fuel consumption, operating recommendations, labor intensity and cost of maintenance, reliability and maintainability will be assessed, that is, everything that directly relates to operation. This will be the mower's logbook. The information will be updated every 50 engine hours and as work progresses. We guarantee independence and objectivity in reporting the results of long-term operation of the mower. I also hope that this blog will become a platform for discussion of mower operation issues between the manufacturer, buyer, seller, and tester. Sincerely, Director of the Federal State Budgetary Institution Altai MIS A.A. Bodryzlov |
Self-propelled universal mower KSU-1 at Altai MIS
For the first time, the harbingers of KSU-1: ZhKhT-9-18 conveyor header-headers in a unit with two versions of EC-1 power equipment (with D-260 and D-245 engines) were presented to the Altai MIS in 2007 for acceptance comparative tests in order to select engine with optimal power for the vehicle.
Since then, there have been significant changes in design and name (the ZHT header was renamed KVT - a roller conveyor mower), and the self-propelled energy vehicle EC-1 (ES-1) in the self-propelled ShS-150 chassis, while the D-260 engine was used until recently, when it was replaced by the domestic YaMZ-53435 engine.
At the time of conclusion of the contract (June 2022), the price of the KSU-1 mower (ShS-150 + KVT-9-18 without transport trolley) was 6,140,000 rubles; for comparison, in October 2016 its price was about 5,737,538 rubles.
Unfortunately, our institution is not subject to the program of Government Decree No. 1432, because does not apply to agricultural producers and it is easy to calculate how profitable it would be to purchase a mower in 2016 using credit resources.
According to the agreement, we paid 40% of the cost and 10 days later the mower was delivered from Rostov-on-Don by rail to Barnaul.
Manufacturer's warranty 24 months or 600 m-h. Whichever comes first.
Part I
Characteristics of the KSU-1 mower
What is this mower? Here is the manufacturer's data
Technical characteristics
Name of indicators
| Indicator values* | |
| Product type | Self-propelled |
| Brand | KSU-1 |
| Engine brand, type | YaMZ-53435, four-stroke with compression ignition and turbocharging* |
| Chassis drive | Hydrovolume (GST)* |
| Aggregated (adapters) | KVT-9-18* |
| Working width of structural mower KVT-9-18, m | 9,0 |
| Overall dimensions of KSU-1 (ShS-150 + KVT 9-18), mm: | |
| - in working position: | |
| length | 7800±100 |
| width | 9383±90 |
| height | 3637±80 |
| in the position of nearby transport: | |
| length | 7396±100 |
| width | 9383±90 |
| height | 3637±80 |
| Ground clearance, mm | 990, no less |
| Base, mm | 3450±25* |
| Track, mm: | |
| — driving wheels | 2800+25* |
| - steered wheels | 2800+25* |
| Weight of the machine in working configuration, kg | 7268±215 |
| including: | |
| — ShS-150 | 5368±160 |
| — KVT-9-18 | 1900±60 |
| Working brake | GTS inhibition* |
| Steerable bridge | Portal type* |
| Main bridge | Portal type, combined with frame, with hydraulic motors* |
| Type of electrical equipment | Single wire |
| Fuel tank capacity, l | 340, no less* |
| Cutting apparatus | Segment-finger with non-adjustable gap in cutting pairs |
| Fingers | Stamp-welded |
| Knife drive | Epicyclic with hydraulic motor |
| Stroke of the cutting apparatus knife, mm | 85, no more |
| Reel | Five-bladed, eccentric with double spring fingers |
| Reel drive | Hydraulic motor |
| Conveyor rotation direction | Reversible |
| Moving conveyors along the frame | Hydraulic motor |
| Width of ejection windows, mm: | |
| - central | 1276 |
| - left, right | 1216 |
*-Characteristics are given only for this sample.
Part II Operation
On August 1, 2022, the KSU-1 mower was received from the site of TK Europe LLC, Barnaul (self-propelled chassis ShS-150 with an operating time of 2 m-h and a roller mower KVT-9-18). The mower is not equipped with a transport trolley, so KVT -9-18 was delivered to MIS by road.
Computer monitor for monitoring the operation of units
On the same day, the chassis of the self-propelled ShS-150 was moved to the village of Pospelikha for a distance of 250 km along the federal road A-349 at night. It passed without incident, the presence of rear lighting when moving in the general flow of vehicles did not lead to “dazzle” of drivers of vehicles moving behind it, and did not cause difficulties when overtaking it. It should be noted that the low beam of the chassis moving at a maximum transport speed of 20 km/h is quite sufficient, and the high beam or overhead lighting, as practice has shown, allows you to work comfortably in the field at night. The transfer of the chassis is completed. There are no refusals. 165 liters of diesel fuel were spent on the haul.
KSU-1 controls
The KVT-9-18 mower was delivered to MIS by road without any damage.
At the technical examination site, additional assembly of the KSU-1 mower was carried out, which consisted mainly of aggregating (hanging) the KVT-9-18 roller conveyor mower on the ShS-150 self-propelled chassis and connecting hydraulic units and electrical equipment. The labor intensity was 3 people per hour. During the connection process, oil leakage was detected into the quick-release coupling of the hydraulic lift line of the KVT-9-18 mower due to deformation of the rubber sealing ring during assembly at the factory. The ring has been replaced.
Operating time 12 hours
From August 03 to August 6, KSU-1 was tested on a lentil mowing area in a volume of 99 hectares with a shift operating time of 25 hectares. On August 07, oats were mowed on an area of 25 hectares. Fuel consumption per 1 hectare was 2.5 l/ha. When harvesting lentils, we encountered the problem of high contamination and laying of the main crop and crop lifters were installed
After maintenance, the mower was used to mow fields. 10 hectares processed.
Operating time 58 hours
As of August 8, the harvested area amounted to 137 hectares and at the 58th hour a specialist from the service center carried out maintenance after running in. The oil in the engine lubrication system, the engine oil filter and the oil in the power take-off gearbox were replaced.
The labor intensity of TO-50 was 1.21 person-hours, 23,172.18 rubles were spent, including:
- for work - 1694.00 rubles;
— for the cost of materials — 11944.11 rubles;
— for transportation costs — 6000 rubles (500 km);
— VAT (18%) - 3534.86 rub.
During the maintenance process, it was revealed that it was inconvenient to check the oil level in the engine, since the dipstick handle is located high - at the level of the valve cover and pouring (topping up) oil into the YaMZ engine (through the valve cover), despite the fact that only the sides of the hood and the filler neck of the KSU are raised located in the middle, so the use of an oil blower is required. To eliminate this drawback, it is necessary to equip a hatch in the hood roof opposite the filler neck.
Engine oil level dipstick
Location of the filler neck for adding oil to the engine
At 64 hours of operation (148 hectares of mowed area), the water pump failed, which was indicated by a signal on the monitor “Generator failure”. The signal was caused by coolant leaking into the engine water pump seal drain and splashing onto the generator.
Specialists from the service center in Barnaul promptly, within two hours, determined the serviceability of the generator and replaced the water pump assembly. The probable cause is an insufficient amount of grease supplied during assembly, which led to the destruction of the closed double-row ball-roller bearing, which is integral with the water pump shaft.
Operating time 105 hours
As of August 22, the harvested area amounted to 351 hectares and at 105 engine hours a specialist from the service center carried out maintenance-100 (after the first 100 engine hours) The oil in the hydraulic system was replaced with the filters of the hydraulic tank and hydraulic fluid and in the power take-off gearbox replaced
The labor intensity of TO-100 was 1.21 person-hours, 20,965.48 rubles were spent, including:
— for work – 2,674.00 rubles;
- for the cost of materials - 12,093.36 rubles;
— for transportation costs – 3,000 rubles (250 km);
— VAT (18%) - 3198.12 rub.
After the maintenance, control shifts were carried out on a wheat field to determine productivity and fuel consumption per 1 ha. subject to the optimal quality of the technological process
On August 28, 551 hectares were mowed with the mower, with 127 hectares of lentils, 60 hectares of oats, 364 hectares of wheat, and after operating 165 operating hours, control shifts were carried out on bent wheat
On September 01, when operating 225 operating hours on a buckwheat crop, the air intake facing shield broke on the left side and, as a consequence, the heads of the air pressure seals broke due to insufficient strength of the shield lifting hinge bracket
Breakage of the facing panel on the air intake
Destruction of the shield lifting hinge bracket
Operating time 260 hours
Operating time 260 hours
As of September 6, the harvested area amounted to 1090 hectares and at 260 engine hours, service center specialists carried out TO-250 (TO-2) The following was replaced:
— oils in the engine lubrication system with replacement of the engine oil filter;
— oils in the power take-off gearbox
— coarse and fine fuel filters.
The labor intensity of TO-250 (TO-2) was 1.49 person-hours, 22,821.84 rubles were spent, including:
— for work – 2,086.00 rubles;
- for the cost of materials - 14,254.54 rubles;
— for transportation costs – 3,000 rubles (250 km);
— VAT (18%) - 3481.30 rub.
In addition to the above, the service center specialists determined the cause and eliminated the failure in the external working lighting system that occurred the day before - the relay was replaced.
Operating time 310 hours
Operating time 310 hours
After carrying out TO-250 (TO-2), testing of the KSU-1 mower (ShS-150 + KVT 9-18) continued until September 17, when the bulk of harvesting work in the fields of the Altai MIS was completed.
The operating time of the mower for this period was 310 engine hours or 205 hours of main time. Over the entire harvest season, the harvested area amounted to 1304 hectares, while the following were mowed: lentils 127 hectares, oats 60 hectares, wheat 698 hectares, buckwheat 352 hectares, soybeans 67 hectares.
The mower is reliable in operation; during testing, one failure of the first and two failures of the second complexity group, noted earlier, were revealed.
The time between failures of complexity group II was 102.5 hours, which corresponds to the specifications (100, no less), the operational time availability factor was 0.99 (according to the specifications, 0.98, no less).
During the tests, 1.5 kg of Litol-24 lubricant, 12.8 liters of transmission oil, 35 liters of motor oil, 70 liters of hydraulic oil were consumed for replacement in the components and systems of the mower provided for in the maintenance regulations after 100 and 250 m-hours of operation.
Based on the results of the final technical examination, the self-propelled universal mower KSU-1 is suitable for further use.
After seasonal maintenance and an assessment of the technical condition, the mower was dismantled and separately (self-propelled chassis ShS-150 and conveyor roller mower KVT 9-18) put into storage until the 2022 harvest season
2018
Operating time 310 hours
On April 16, 2022, specialists from service EUROPA, by order of the manufacturer, as part of the design modernization program, replaced the hinges of the canopy of the cladding panel (see the failure noted earlier and eliminated by welding at 225 m.h.)
For this purpose, the ShS-150 chassis was removed from storage and, under its own power, installed under the crane beam
At the same time, the shield hinges were replaced with hinges of a new design.
1- was 2- became
Shield hinges of a new reinforced design with an additional plate were installed. A technological hole was drilled for its installation and fastening.
Air intake facing panel after replacing canopy hinges
Two service center specialists spent 3,020 man-hours on the work.
Upon completion of the work, the ShS-150 chassis was returned to its storage location under its own power.
On July 28, 2022, the ShS-150 chassis was removed from storage and, after inspection, transported to a field camp for mounting the KVT 9-18 mower, which was also removed from storage and, after checking the operability, the KSU-1 mower was put into operation
From July 30 to August 12, KSU-1 was used for mowing fields and mowing lentils on an area of 105 hectares. In lentil harvesting technology, a necessary condition for reducing losses is the minimum cutting height, which is associated with frequent contacts of the cutting apparatus with the soil and led to the need to replace 50 segments with a worn cutting edge. Since the beginning of operation, mowing has been carried out on an area of 1409 hectares
Operating time 544 hours
Operating time 544 hours
During the 2022 harvest season, KSU-1 is used for harvesting lentils, wheat, buckwheat and soybeans.
KSU-1 on lentil crop
As of September 17, the harvested area since the beginning of operation amounted to 2362 hectares and at 544 operating hours, service center specialists carried out TO-500 (TO-3). The following was replaced:
— oils in the engine lubrication system with replacement of the engine oil filter;
— oil in the hydraulic system with replacement of: the filter element of the linear filter of the hydraulic system, the filter of the main hydraulic system, the GTS filter;
— oils in the power take-off gearbox;
— oils in the bevel gearbox;
— oils in the cylindrical gearbox;
— coarse and fine fuel filters
The labor intensity of TO-500 (TO-3) was 3.83 person-hours, 62,316.73 rubles were spent, including:
— for work – 5,362.00 rubles;
- for the cost of materials - 38,748.79 rubles;
— for transportation costs – 7,500 rubles (500 km);
— travel expenses – 2,000 rubles.
— VAT (18%) — 9505.94 rub.
Carrying out maintenance-3 (T-500m.h)
In addition to the above, the service center specialists determined the cause and eliminated the failure in the air conditioning system - the receiver with the pressure sensor was replaced, and the evaporator filter was purged, which was not provided for and not specified in the operating instructions (with its disassembly).
Determining the cause of air conditioner failure
The evaporator filter was purged (with its disassembly) not provided for and not specified in the operating instructions.
Filter status
Observations continue...
Operating time 590 hours
On September 29, the mowing of grain legumes in the fields of Altaika MIS was successfully completed. The operating time of the mower since the beginning of operation was 720 m/h, the harvested area was 3034 hectares, while in the 2018 season it was 1730 hectares.
In 2022, there was a failure of the air conditioning system, which was promptly repaired by specialists from the dealer KZ Rostselmash LLC -TK Europe
After seasonal maintenance and conservation work, the mower was individually (the self-propelled chassis ShS-150 in the exhibition hall, and the roller conveyor mower KVT 9-18 at the field camp) put into storage until the harvest season of 2022
TO THE BEGINNING CONTINUED 2 pages
Cabin
The operator's cabin is equipped with the latest technology. This is an all-metal frame, with panoramic glazing and roll bars. For ease of work, the cabin has reliable sound and noise insulation, a built-in air conditioner and heating system. There is even a refrigerator and a sound system. It is worth mentioning separately about the ADVISER system. This is a built-in program that displays the current state of the main components on the on-board computer screen. In particular, it controls fuel consumption, reminds about maintenance time, calculates the work performed, and monitors the technical condition of components and elements.
Clean work
The KSU-1
universal mower uses a patented terrain following system. The uniqueness of this system and the adapter kit is that it successfully combines simplicity and high efficiency. Its advantages:
- high-quality transverse and longitudinal copying of the relief with all adapters used;
- changing the angle of attack from the cockpit;
- quick assembly of headers and accessories;
- does not require adapters;
- connecting adapters and adjusting the copy mechanism without special tools;
- simple and minimal maintenance.
In terms of efficiency, this self-propelled universal mower
is much superior to trailed units, since tractors do not allow adapters to copy the field topography clearly enough. On grain-producing farms, the machine can significantly speed up and reduce the cost of the harvesting process. Firstly, due to the high speed of work. Secondly, due to its own efficiency. Thirdly, by creating more favorable conditions for the combine to operate on low-yield backgrounds, the double roller allows you to optimize the loading of the combine thresher and halve the number of machine passes across the field.
