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TKS K2 CombiCutter Operator's Manual

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TKS
Operator's manual
Operator's manual
K2
CombiCutter
K2 CombiCutter EN, issue 2 2013-06
988726
1

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Summary of Contents for TKS K2 CombiCutter

  • Page 1 Operator’s manual Operator’s manual CombiCutter K2 CombiCutter EN, issue 2 2013-06 988726...
  • Page 2 Operator’s manual...
  • Page 3 T. Kverneland & Sønner AS, Kvernelandsvegen 100 N-4355 Kverneland Norway declare that the product: TKS - K2 CombiCutter has been built in conformity with the Machine Directive 2006/42/EC and meets the relevant fundamental health and safety requirements. Kverneland, 20 June 2013 Tønnes Helge Kverneland...

  • Page 4: Guarantee

    Claims must be reported within the guarantee period. The dealer must complete a claims form for each case covered by a guarantee and send it to TKS or TKS’s distributor/ importer within the 10th of the month following the one in which the defect was reported.

  • Page 5: Table Of Contents

    Installing the reservoir ... . 55 K2 CombiCutter ....28 Use of the machine....57 2.1 Ceiling-mounted unit on .
  • Page 6 Operator’s manual 13 Frequency converter ... . . 66 20 Width adjustment on spreader unit . 89 13.1 Programming and operating ..21 Remote control .

  • Page 7: Introduction

    A network of helpful dealers will be able to advise you on its use, as well as provide servicing and spare parts. All TKS products are designed, tested and built in close cooperation with farmers and machine workshops to ensure optimal effi ciency and reliability.

  • Page 8: Machine Identifi Cation

    Operator’s manual Machine identifi cation The machine’s serial number and the address of the manufacturer are written on the machine. See the illustration on this page. Please use the information on the name plate when making any enquiries about spare parts or servicing.

  • Page 9: Dimensions Wide Combicutter

    Operator’s manual Dimensions wide CombiCutter All measurements are in mm 2670 TROLLEY (SHORT) 3170 TROLLEY (LONG) 1185 INTERNAL 1580 HEIGH STD. 2250 INTERNAL (LONG) 1750 INTERNAL (SHORT) 2922 EXTERNAL (SHORT) 3422 EXTERNAL (LONG) 1354 INTERNAL 1590 EXTERNAL 4624 EXTERNAL 1M SECTION 3448 INTERNAL M.

  • Page 10: Dimensions Narrow Combicutter

    Operator’s manual Dimensions narrow CombiCutter All measurements are in mm 2244 INTERNAL 1202 INTERNAL 1202 EXTERNAL INTERNAL K2_14...

  • Page 11: Important Dimensions When

    Operator’s manual Important dimensions when installing a K2 CombiCutter 3300 Long 2800 Short 2200 Long 1700 Short 3620 Long 3120 Short IK1_05 Floor-cart IK1_01...
  • Page 12 Operator’s manual K2 CombiCutter 1600 All measurements are in mm K2_51 K2 with 1.3 m cross conveyor and foot pack K2_52...
  • Page 13 Operator’s manual K2/R2 with frame cross conveyor K2_53 K2/R2 with frame, cross conveyor and conveyor K2_54...
  • Page 14 Operator’s manual K2 with weighing cell unit Weighing cell amplifi er Weighing cell foot Junction box 4 weighing 10 m cable, shielded 4x0.25 K2_55 Wiring diagram Junction box...
  • Page 15 Operator’s manual Confi guring the weighing cell amplifi er Code Value Function Filter Max. change in kg Number of weighing cells 2000 Weighing cell capacity 2,000 kg Min. voltage Voltage output (0–10 V) 8000 Max. weight Convert mV to kg Empty weight.
  • Page 16 Operator’s manual R2 with weighing cell unit Lug for making connection Weighing cell foot 2T Junction box 4 weighing 10 m cable, shielded 4x0.25 K2_55 Wiring diagram Junction box 2...
  • Page 17 Operator’s manual Confi guring the weighing cell amplifi er Code Value Function Filter Max. change in kg Number of weighing cells 2000 Weighing cell capacity 2,000 kg Min. voltage Voltage output (0–10 V) 12000 Max. weight Convert mV to kg Empty weight.

  • Page 18: Technical Data

    Operator’s manual Technical data WEIGHT K2 CombiCutter SHORT 1100 Kg WEIGHT K2 CombiCutter LONG 1160 Kg POWER KW (FREQUENCY- CONVEYOR BELT 0,55 POWERED SHREDDER DRUM CROSS CONVEYOR KW (FREQUENCY- CEILING RAILS (X2) 0,40 POWERED MOTOR FOR FEED BRUSH ELECTRICITY CONTROL CURRENT...

  • Page 19: Model Description

    1600 = 62 knifes 1200 = 24 knifes The K2 CombiCutter shreds/ cuts most types of round bales and silage, with the size it cuts to being dependent on the consistency and nature of the feed. The machine runs very silently, and due to its large drum the main engine only requires 7.5 kW of power.

  • Page 20: Safety

    Operator’s manual Safety Please pay particular attention to this symbol. It means that there is a safety risk, and describes precautions that should be taken in order to avoid accidents. Before operating, adjusting or repairing the machine, the user, technician or owner should familiarise himself with the safety instructions contained in this installation manual.
  • Page 21 Operator’s manual Guards Check that all shields are sound and correctly installed. Do not start the machine before doing this. Damaged screens must be repaired or replaced immediately. Spare parts For safety reasons we recommend that you only use original spare parts. The use of third-party spares invalidates the product guarantee.
  • Page 22 Operator’s manual Additional safety The machine is marked with warning instructions signs. If these signs are damaged, they must be replaced. The order number is shown on the illustrations in this section. See Fig. 6 for their location on the machine. Warning sign UH220532 (Fig.
  • Page 23 Operator’s manual Warning sign 988010 (Fig. 6) NB! The conveyor belt must be kept tight, and the screws on the belt must be retightened. Fig. 6...
  • Page 24 Operator’s manual Overview of safety risks IKO2_03 Fig. 7...
  • Page 25 Be particularly careful when starting a new machine for the fi rst time. Installation faults, incorrect operation, etc. may lead to expensive repairs and loss of earnings. The TKS product guarantee does not cover damage resulting from failure to follow the recommendations contained in the instruction manual.

  • Page 26: Installing The Rails

    1200 and 1600 Width from cradle edge - cradle edge Min. Width Min. Width Max. Width K2 CombiCutter without cross conveyor 1400 1800 K2 CombiCutter with short cross conveyor 1400 1800 2400 K2 CombiCutter with usual cross conveyor 1600 2000 3000...

  • Page 27: 1-Rail Suspension

    • The TKS rail system comes with full strength in the joints (IPE120/160/220). When TKS rails are used in rail tracks, most of the attachment points must be on the lower face of the rail. For rail tracks with a bend, there must be a suspension at the beginning, middle and end of the bend.

  • Page 28: Installing A Ceiling-Mounted

    3.5 m between fi xings or IPE 120 with up to 2 m between fi xings. To install the rails, use the TKS ceiling fi ttings for the relevant type of ceiling. The unit mounted on 1 rail has two powered trolleys.The trolleys have...

  • Page 29: Turning Corners On A Rail

    Operator’s manual 2.3 Turning corners Measure the clearances very carefully. Build a framework of boards with the correct external on a rail dimensions. See Fig. 11 Short Long 200 cm 220 cm 100 cm* 120 cm* 100 cm* 120 cm* 280 cm 320 cm 160 cm...

  • Page 30: Installing A Stationary Machine

    Install the machine somewhere that it will be easy to load it with feed. It is usual to use a rail system and a TKS electric hoist with a hook or hydraulic grab, a tractor with a spear for round bales or similar to fi...

  • Page 31: Installing The Power Supply

    Operator’s manual 2.5 Installing the All electrical installation must be done by a power supply qualifi ed electrician. Use power supply cables of a suitable diameter (at least 6 mm²). Attention! Please remove the plug socket and assure that the fuse box is disconnected before opening it.

  • Page 32: Installing A Power Cable On A Wire

    Operator’s manual 2.6 Installing a power cable on a wire Drill a hole in the wall at each end, or mount brackets, and attach wire tighteners. Then fi x the wire as tightly as possible using manual force, before tightening it further using the nuts. The wire must be right up against the milking pipe, or preferably above it, but no more than 50 cm above the shredder.

  • Page 33: Conversion Of Traverser Carriage

    Operator’s manual 2.9 Conversion of traverser carriage on rail with points In the case of a rail with points, you have to change to a diff erent bracket: from A to B. See fi gures 1 and 3 (bracket supplied). •...

  • Page 34: Installing The Power Supply

    3 Installing the power supply The most common and best method of supplying power to a K2 CombiCutter is to use powered rails. These consist of a rail with a copper strip on the inside, and a transformer (slide) that follows the unit during operation.
  • Page 35 Operator’s manual The wide fi xing must be attached at the correct distance from the rail holding the traverse carriage. See Fig. 16 IKO2_12 Fig. 16...

  • Page 36: Copper Wires 400V/230V

    Operator’s manual 3.1 Copper wires 400V/230V 400V 3-pole + N (Straight rail) Grounded (A) should be inserted where there is a yellow stripe (B) along the outside of the rail. The yellow stripe should be continuous along the entire length of the rail. = GROUNDED L1 = PHASE L2 = PHASE...

  • Page 37: Installing The Conductor Rail

    Operator’s manual 3.2 Installing the conductor rail PVC rail • The rail has 7 tracks for laying 2, 3, 4, 5, 6 or 7 copper conductors. • Temperature range for the rail: -30°C to +60°C • The rail is made from fi reproof plastic. See Fig.

  • Page 38: Installing Traverser Carriages

    Operator’s manual 4 Installing traverser carriages The traverser carriages for the cart are supplied loose. These are attached from the end of the rail. Motorised traverser carriages must be at the front of the cart. See Fig. 47 REAR FRONT IK2_18 Fig.
  • Page 39 Operator’s manual...

  • Page 40: Attaching The Cart

    Operator’s manual 5 Attaching the cart Before suspending the cart from the traverser carriages, it is a good idea to adjust the ceiling rails to the correct height, to avoid having to use a jack to adjust this later. Critical factors with regard to the istallation height are: •...
  • Page 41 Operator’s manual Height from the base (sidewall) and up to the upper edge of the rail channel. This is an absolute minimum measurement. See Fig. 49 A = recommended measure 350mm B = recommended measure 500mm L = minimum measurement 1650 mm, applies to a round bale diameter of 1250 mm. This measurement increases for larger round bale diameters.

  • Page 42: Installing Equipment On Traverser

    Operator’s manual 6 Installing equipment on traverser carriages on 2-rails Several items has to be mounted to the trolleys. See Fig. 51 These items are: • Currency transformer for power supply through the powered rails • Bar connecting the front and back traverser carriages together The back and front traverser carriages are CLAMP FOR POWER REAR...
  • Page 43 Operator’s manual Installing equipment on traverser carriages on 1-rail CLAMP FOR POWER BRACE BAR REAR FRONT REAR FRONT IK2_22 Fig. 51b...
  • Page 44 Operator’s manual Rear and front trolley are connected with a brace. The bar is fi rst attached to the traverser carriage, then the channels are screwed to the outside of the bar. This only applies to 2-rail systems. See Fig. 52 IK2_19 Fig.

  • Page 45: Installing The Reservoir

    This is to avoid spillage and to ensure the safest possible fi lling process. It is also important that the reservoir is in the right position with regard to the K2 CombiCutter in its width direction, so that the cart slides easily into the reservoir.
  • Page 46 The reservoir must be at a height that ensures that the carrier on the reservoir and the carrier on the K2 CombiCutter do not collide. The height of the reservoir is adjusted by loosening the screws and lowering the feet. Use a hydraulic jack or forklift truck to lift the reservoir.

  • Page 47: Use Of The Machine

    Operator’s manual 8 Use of the machine The drum can only turn one way. Round bales can be put in whatever way you like, but we recommend putting them in so that they can rotate in the direction of the dispenser. There must not be any round bales or silage up against the drum when you start it.

  • Page 48: The Combicutter Control

    Operator’s manual 9 The CombiCutter control Stationary machine: Emergency stop Activate Start/Stop drums Start/Stop conveyor belt Reverse conveyor belt Potentiometer for adjusting speed of conveyor belt Fig. 58 Fuctions Operate cross conveyor Operate reservoir Start/Stop drums Emergency stop Operate trolleys Reverse conveyor belt Start/Stop conveyor belt Fig.

  • Page 49: Wireless Radio I/R Operation K2

    Off Return Fig. 60 To activate the radio, point the remote control at the TKS sticker on the operating panel. See Fig. 60 • Press and hold button (A) while holding the remote control 10 cm from the operating panel (TKS sticker).

  • Page 50: I/R Operation K2 For All Functions

    Operator’s manual 10.1 I/R operation K2 for all functions Operation of side dispenser The side dispenser will start at the same time as the drum when switch C is pressed. The direction is random. To change the direction of the side dispenser, stop the drum by pressing switch D. The direction of the side dispenser will change when the drum is restarted.
  • Page 51 Operator’s manual...

  • Page 52: Autofi Lling K2 Combicutter

    Operator’s manual 11 Autofi lling K2 CombiCutter Control panel External control of K2 CombiCutter with and without magazine and cross conveyor. Se Fig. 62 1 PLC 2 Switch for side elevator - turn left or right 3 Push button - return magazine...
  • Page 53 Operator’s manual Status: Stand by – ready Start feed dispensing – feed dispensing starts Feed dispensing – feed dispensing in progress Stop feed dispensing – feed dispensing stops Filling – fi lling from tank is activated Menu: Manual control Settings Manual control Keys: 1 –...

  • Page 54: Multi-Function Time Relay

    Operator’s manual 12 Multi-function time relay With the factory settings, the machine works as follows: If the pressure against the cutting drum becomes to high, the conveyor belt stops for 2 seconds before restarting. The speed of the conveyor belt can be adjusted (infi...

  • Page 55: Motor Protection Device

    Operator’s manual 12.2 Motor protection device for cutter motor Adjustment knob for current strength. See Fig. 66/A Check that the motor protection device has been set to the same as the A value on the motor’s rating plate (maximum of 10% above) This may vary from motor to motor.

  • Page 56: Frequency Converter

    Fig. 68b The converter determines how the conveyor belt presses the feed against the drum. The converter is pre-programmed by TKS. If access is required to check the setting, this is performed in the following manner: Press the blue mode button. The indicator light will move from left to right.
  • Page 57 13.1 Programming and operation of the frequency converter The frequency converter comes supplied pre-programmed by TKS and must not be modifi ed under normal conditions. However, if access is required to check the settings, this is performed in the following manner: arameters are confi...

  • Page 58: The Converter

    Operator’s manual Rail equipment V1000 230V 1PH 1,5kW Index Description Value Units B1-01 Frequency Reference 0: Digital Option C1-01 Acceleration Time 1 C1-02 Deceleration Time 1 D1-01 Frequency Reference 1 40,00 D1-02 Frequency Reference 2 70,00 E1-01 Input Voltage Setting E1-04 Max Output Frequency 70,00...

  • Page 59: Troubleshooting The Combicutter

    Operator’s manual 15 Troubleshooting the CombiCutter This troubleshooting guide deals with the most likely problems that may occur with the machine. Description of fault: • Cutter/ shredder drum has a • tendency to get stuck when you run the conveyor belt. •...

  • Page 60: Maintenance And Care

    Operator’s manual 16 Maintenance and care Always pull out the plug before inspecting, maintaining or repairing the machine. • You should clean the conveyor belt, cogwheels, axles and bearing casings as required and at least once a year. IMPORTANT! • Do not tighten the conveyor belt to tight or askew.
  • Page 61 Operator’s manual Lubrication Component/ location Quantity Action Operating 1 Grease nipple - bearing operating side conveyor Lubrication 10 h 2 Grease nipple - bearing return side conveyor belt Lubrication 10 h 3 Grease nipple- bearing for drum Lubrication 10 h 4 Grease nipple- bearing drum Lubrication 10 h...
  • Page 62 Operator’s manual Tightening the conveyor belt It is important to keep the conveyor belt tight. This should be checked at regular intervals. Tighten the conveyor belt by turning the adjustment screw on the back of the machine. See Fig. 70 OBS! It is important to retighten it after only 1-2 bales/ cut bales because of varnish etc.
  • Page 63 Operator’s manual Tightening the chain of the drum and conveyor belt Check the tightness of the drum’s chain at regular intervals and retighten the drive chain at the same time. See Fig. 72 • A Adjusting screw • B Sprocket The chains must be lubricated once a week.
  • Page 64 Operator’s manual Service instructions for K2 CombiCutter General Safety instructions. • Turn off main powerswitch • Disconnect main powersupply or turn off master fuse. • When working under rail-suspended machine, use safetyramp under to prevent crushing. • Do not work under unsecured machine.
  • Page 65 Operator’s manual • • • • • • • Drum • • (Roller:) • • • • • • • • Rail- • • • suspension: • • •...
  • Page 66 Operator’s manual • • • • • • • Side- • • conveyor: • • • K2 – worm • K2 – • drum return • drum drive • • • • • Electrical • system: • • • Conductor •...
  • Page 67 Operator’s manual • • •...

  • Page 68: Model Description And Area Of

    A back plate is fi tted to the rear of the K2 CombiCutter, the purpose of which is to keep the spreading material in place and the back plate forces the spreading material forwards.

  • Page 69: With Spreader Unit

    Operator’s manual Technical data Weight of standard K2 CombiCutter 1650 Kg with spreader unit Weight of K2 CombiCutter with 1850 Kg spreader unit with 1 m extension POWER KW (FREQUENCY CONVEYOR BELT 0,75 -DRIVEN) SHREDDER DRUM KW (FREQUENCY CEILING RAIL OPERATION (X2)
  • Page 70 Operator’s manual 18 Use of the machine with spreader unit The drum can only turn one way. Round bales can be put in whatever way you like, but we recommend putting them in so that they can rotate in the direction of the dispenser. OBS! There must not be any round bales or silage up against the drum when you start it.
  • Page 71 Operator’s manual Spreader unit (VZAB1P5-PRG1020 (V100)) Index: Description: Value: Units: B1-01 Frequency Reference 0: Digital Option..C1-01 Acceleration Time 1 Sec. C1-02 Deceleration Time 1 Sec. D1-01 Frequency Reference 1 E1-01 Input Voltage Setting E1-04 Max Output Frequency E1-05 Max Output Votage E2-01 Motor Rated Current 6,30 E2-04 Motor Rated Current...
  • Page 72 Operator’s manual 19 Main measurements for machine with spreader unit • The distance from the ground to the suspended cart must be at least 1,500 mm. • Alternative round bale sizes: 1,200 – 1,500 – 1,800 mm • Max. size of square bales: 3,200x1,250 mm All measurements are in mm Fig.

  • Page 73: Width Adjustment On Spreader Unit

    Operator’s manual 20 Width adjustment on spreader unit • The spreading width can be adjusted by changing the angle of the side plates A. Once the side plates have been adjusted, you can achieve a spreading width which can vary from 2 to 7 m. •...

  • Page 74: Remote Control

    Operator’s manual 21 Remote control Functions Start roller START/STOP conveyor belt STOP all Roof operation – outward Roof operation – return Activated – maintain roof operation Conveyor belt – return Emergency stop Fig. 76...
  • Page 75 Operator’s manual 22 Use of radio-controlled spreader unit • To activate radio control, release the emergency stop and activate radio con- trol by pressing F. • Fit end switch 1 to the traversing carriage as shown in the drawing. • Fit resets 2 and 3 to the rail at each end of the track.

  • Page 76: Maintenance And Care

    • NB! Keep the machine clean of dust as this constitutes a fi re hazard. It is important to clean the machine’s drums, spreading discs, conveyor belt and rear shields once a week. TKS recommends cleaning with pressurised air rather than using a high pressure washer.

  • Page 77: Recycling - Waste To Resource

    - waste to resource - TKS’s products rely on electrical and electronic components in order to work. These fall under the generic term of EE products. TKS’s products use typical components such as cables, switches, motors, control units, etc. When TKS products are thrown away those components containing contaminants should be treated and sorted in such a way that they do not pollute the environment.
  • Page 78 Operator’s manual...

  • Page 79: Notes

    Operator’s manual Notes...
  • Page 80 Operator’s manual TKS is a family owned company with a strong brand name. We are providing our customers with a unique and complete range of high quality products. www.tks-as.no T. Kverneland & Sønner AS, Kvernelandsvegen 100 N-4355 Kvernaland Norway e-post : post@tks-as.no...

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