Related Manuals for KUHN FC 4000 R
Summary of Contents for KUHN FC 4000 R
- Page 1 OWNER’S / OPERATOR’S MANUAL FC 4000 R - FC 4000 RG FC 4000 G N° 95109 C.GB – 10.2004...
- Page 2 Thank you for purchasing a new KUHN FC 4000 Disc Mower Conditioner. In purchasing a new KUHN machine, you have chosen wisely. Into it have gone years of research and develop- ment, and we hope that you will enjoy years of productive use from it. You will find, as have thousands of owners all over the world that you have the best that modern engineering, produc- tion, and field-testing can produce.
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Page 3: Table Of Contents
DRIVE CHAIN FOR THE UPPER ROLLS _________________________________________________ 53 HYDRAULICS ______________________________________________________________________ 54 ELECTRIC CONNECTORS ____________________________________________________________ 56 FASTENER TORQUE CHART _________________________________________________________ 57 OPTIONAL EQUIPMENT _______________________________________________________________ 58 STORAGE ___________________________________________________________________________ 59 TROUBLESHOOTING GUIDE ____________________________________________________________ 60 LIMITED WARRANTY __________________________________________________________________ 64 NOTES _____________________________________________________________________________ 67 Copyright 2002 KUHN S.A. - 1 -... -
Page 4: Safety Recommendations
It may also be used to alert against unsafe practices. If you have questions not answered in this manual or require additional copies or the manual is damaged, please contact your local KUHN dealer or call Kuhn Farm Machinery, Inc. at 1- 800-303-KUHN. -
Page 5: Designated Use Of The Machine
Proper uses” listed below. PROPER USES: The FC 4000 G - FC 4000 R - FC 4000 RG should be used only for the following purposes: Mowing of improved hay fields and grass silage fields for the purpose of harvesting fodder for feeding livestock. - Page 6 SAFETY RECOMMENDATIONS IMPROPER USES: The FC 4000 G - FC 4000 R - FC 4000 RG must not be used for the following: 1. DO NOT USE the mower to cut roadsides, ditches, parks, and banks. 2. DO NOT USE the mower to cut any unimproved fields or fields with obstacles (such as metal casings, wire, twine machine parts, exposed or buried rocks, etc.).
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Page 7: General Safety Recommendations
SAFETY RECOMMENDATIONS GENERAL SAFETY RECOMMENDATIONS Before operating the machine, always ensure that tractor and machine are in accordance with work safety and motor vehicle laws and regulations. BASIC PRINCIPLES 1. In addition to the recommendations given in this manual, legislation on work safety and accident prevention must always be respected. - Page 8 SAFETY RECOMMENDATIONS 15. Before transporting the machine on public roads, ensure that all legally required guards and indicators (lights, reflectors...) are in place and in good operation. 16. All operating controls (cords, cables, rods...) must be positioned so that they cannot be set off accidentally, risking accident or damage.
- Page 9 SAFETY RECOMMENDATIONS ATTACHMENT 1. When attaching or removing the machine to or from the tractor, make sure that it cannot move accidentally. (Put chocks under the wheels). 2. When attaching the machine to tractor lift linkage, ensure that diameter of link pins corre- sponds to diameter of ball joints.
- Page 10 SAFETY RECOMMENDATIONS 8. Before engaging PTO, ensure that PTO speed and direction of rotation are in accordance with manufacturer’s recommendations. 9. Before engaging PTO, keep all people and animals clear from the machine. 10. Never engage PTO drive when tractor engine is turned off. 11.
- Page 11 8. Service parts used must be in accordance with specifications and standards as defined by the manufacturer. Use only genuine KUHN parts! 9. Before any electric welding is carried out on tractor or attached machine, disconnect gen- erator and battery terminals.
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Page 12: Special Safety Recommendations
4. Each time before using the mower, inspect condition of cutting elements (blades, discs). Replace any missing, worn or damaged cutting elements immediately. Use only genuine KUHN service parts. 5. To avoid creating dangerous out of balance forces, always replace missing, damaged or worn blades in pairs. - Page 13 SAFETY RECOMMENDATIONS 13. Even when the machine is used in accordance with its purpose, objects may be projected. It is therefore imperative that everyone is kept away from the danger zone, that extra care be taken and that extra precaution (such as safety indicators) be taken when mowing pas- tures alongside roads or near public areas.
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Page 14: Safety Decals
SAFETY DECALS PLEASE CHECK THE DIAGRAMS BELOW TO ENSURE THAT ALL SAFETY DECALS ARE LEGIBLE AND CORRECTLY INSTALLED ON THE MACHINE. IF ANY DECALS ARE DAMAGED, MISSING OR ILLEGIBLE REPLACE THEM BEFORE OPERATING OR DE- LIVERING THE MACHINE. THE FOLLOWING SAFETY PICTORIALS HAVE BEEN PLACED ON THE MACHINE IN THE AREAS INDICATED. - Page 15 SAFETY DECALS - 13 -...
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Page 16: Technical Specifications
TECHNICAL SPECIFICATIONS FC 4000 R FC 4000 RG FC 4000 G Attachment Straight Hitch 2 pt Gyrodine with extension swivel hitch Working width 13’ 1” Transport width 13’6” Number of oval discs Number of blades per disc Conditioning system Diamond Block™... - Page 17 1000 rpm only with 1-3/8" x 21 spline shaft. (A 1-3/4" x 20 spline yoke is available for the RG model through Kuhn Service Parts). Use only a tractor equipped with an enclosed cab and ROPS with windows made of safety glass and kept closed.
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Page 18: Attachment
ATTACHMENT ATTACHING TO THE TRACTOR 1. For Straight Hitch Model: (For attachment of the Gyrodine hitch go to page 19.) WARNING: The following procedure must be done carefully in order to pre- vent any damage to the PTO driveline. a) Drawbar height : - Put the lower arms of the three point hitch all the way up or all the way down so they will not interfere with the hitch or PTO of... - Page 19 (2). If provided install the safety chain* (3) as shown. * Drawbar safety chain (No 830 800 02) is available through KUHN Service Parts. - Remove the jack stand and place the jack in the storage position.
- Page 20 ATTACHMENT - The tongue of the mower must have an angle less then 90º to the tractor’s drawbar. DO NOT ALLOW THE MOWER TO TURN BEYOND 90º OR THE PTO DRIVE LINE WILL BE DAMAGED. - Check that the lower lift arms of the three point hitch are clear of the mower.
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Page 21: Gyrodine Swivel Hitch Model
ATTACHMENT 2. Attachment of the Gyrodine Swivel Hitch a) Connect the primary PTO shaft’s flanged yoke (1) to the Gyrodine slip clutch. Secure in place using 6 self locking bolts (2) (M12x25). Make sure bolts are torqued to 66 ft.lbs (9 daNm). To avoid accidents, which could be serious, make sure that the guards are always correctly in place and secured... - Page 22 ATTACHMENT e) Make sure the PTO shaft length is correct for the tractor being used. 1) Activate the tractor 3-pt linkage to line up the tractor PTO and the machine input shaft in the horizontal plane. 2) Attach the front half of the PTO shaft to the tractor and align both front and rear PTO shafts side by side (see second diagram).
- Page 23 ATTACHMENT g) Plug in the electrical connector; check that the lights and the turning signals are functioning properly. h) With the tractor’s hydraulic 3-point lift, posi- tion the Girodyne head in order to set the hitch pins at a distance of 700 mm/ 2’4" from the ground.
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Page 24: Check List
ATTACHMENT CHECK LIST To avoid serious injury or death, stop tractor engine, disengage PTO, shift to “park” position or shift to neutral and set brakes. Before starting the mower: - Make sure the mower has been hooked up properly (see attachment chapter) and that : - the linch pins are in place. -
Page 25: Transport
TRANSPORT WARNING! Abrupt braking of towed loads from transport speeds can cause the towed load to swerve and upset. Reduce speed if towed load weighs more than the tractor and is not equipped with brakes. Follow recommended speed-weight ratio guidelines: - Maximum speed is 20 mph (32km/h) when towing load equal to or less than the tractor. -
Page 26: Adjustments
ADJUSTMENTS Before carrying out any operation such as adjustments or maintenance on the machine, stop the tractor engine, remove ignition key and wait for rotating discs and rotor to stop before leaving the tractor. CUTTING HEIGHT ADJUSTMENT(S) A graduated plate located on the adjustment rod indicates the cutting height in cm and in inches. -
Page 27: Header Floatation Adjustment
ADJUSTMENTS HEADER FLOATATION ADJUSTMENT Factory settings : 140 lb (65 kg) on each side of the header which corresponds to a distance (X) of 7” (190 mm) on the left side and of 9” (230 mm) on the right side. The FC 4000 is designed with : - CONSTANT FLOAT : This suspension system allows the header to travel throughout its wide floatation range (- 4”... -
Page 28: Pto Speed
ADJUSTMENTS b) To control the suspension adjustment: This suspension is a dynamic device, it has to be adjusted to the field conditions and the ground speed. Due to the “PRO-ACTIVE LIFT SYSTEM” increasing ground speed will make the header lighter. The force required to lift the header when static will always be greater than the effective ground pressure at working speed. -
Page 29: Forward Speed
ADJUSTMENTS FORWARD SPEED Recommended speed is between 5-8 mph. The forward speed must be adapted to the crop density and to the ground conditions : - In very heavy conditions a high forward speed may overload the mower conditioner. - In light conditions a high forward speed will narrow the windrow. Note : If the ground speed must change, shift the tractor gear up or down rather than changing the tractor engine speed. - Page 30 - Adjust the two swathing baffles (1) all the way up on both sides. - The FC 4000 R / RG can make a windrow from 3' to 5' by closing the two windrow forming shields (5) using handles (4).
- Page 31 ADJUSTMENTS 2) FC 4000 G To swath : - Lower the two swath flaps (1) on each side by folding levers (2) towards the ground. - Fully open the two windrow forming shields (3), and lock them using handles (4). To windrow : - Completely lift the two swath flaps (1) on each side by folding levers (2) upwards.
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Page 32: Adjusting The Conditioning Intensity
ADJUSTING THE CONDITIONING INTENSITY 1) FC 4000 R / 4000 RG Note : The FC 4000 R / 4000 RG have been designed with two sets of Diamond Block conditioning rolls. - Short rolls will allow higher roll pressures to increase conditioning when desired. - Page 33 ADJUSTMENTS Roll tension is adjusted by tightening the tor- sion rods. This is accomplished by tighten- ing the crank arm rod adjustment nut (3 in dia- gram at right) a specified number of turns from the point where tension starts. Recom- mended Roll tension is 10 - 15 full turns.
- Page 34 a) The rotational speed of the rotor Two conditioning rotor speeds are possible : 1000 and 660 rpm. The change from one speed to the other is made by simple selection with the lever located on the central gearbox shield. It may be necessary to slightly rotate a cutterbar disc once the selector lever has been moved...
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Page 35: Field Operations
FIELD OPERATIONS Before starting work, check that all safety guards have been lowered into work position. Make sure that the ground to be mown is free of obstructions or foreign objects subject to entering the cutterbar. Increase cutting height to clear any hidden debris. - Page 36 FIELD OPERATIONS For straight hitch, to make a 90° square corner and minimize interference between the tractor tire and mower : 1. Steer the tractor at first away from the uncut crop. 2. Swing the tongue half way toward the center of the machine while turning the tractor. It might seem like the tractor and the tongue are turning around the center pivot.
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Page 37: Lubrication
LUBRICATION To avoid serious injury or death, stop tractor engine, remove ignition key, disengage the PTO, shift to “park” position or shift to neutral and set brakes. LUBRICATION CHART GREASE POINTS AND INTERVALS : FOR LOCATION, SEE FOLLOWING PAGES. For proper machine operation, use a Quality Grade of Moly Grease or equivalent. COMPONENT LUBE POINTS SERVICE INTERVAL... -
Page 38: Grease Fittings
LUBRICATION GREASE FITTINGS - Put the header down, swing the header to the center position. Main PTO : a) Straight hitch : The straight hitch uses two constant velocity joints, pay particular attention to the grease fittings. - Every 10 hours of use or once a day : - Clean fittings before applying grease. - Page 39 LUBRICATION Gyrodine swivel hitch pivot points : - Every 100 hours of use or once a year : - Clean fittings before applying grease. - Lubricate grease fittings (1), (2). Intermediate PTO : Every 10 hours of use or once a day : - Clean fittings before applying grease.
- Page 40 LUBRICATION Conditioner roll bearing : (FC 4000 R / RG) Every 10 hours of use or once a day, on each side of the mover : - Clean fittings before applying grease. - Lubricate the grease fitting (1). Center pivot Bushings : Every 10 hours of use or once a day : - Clean fittings before applying grease.
- Page 41 - Clean fitting before applying grease. - Lubricate grease fittings : (1). Roller drive chains : (FC 4000 R / RG) Every 200 hours of use or once a year : - Remove the chain cover. - Clean the chain and the chain cover to remove the old grease.
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Page 42: Gearboxes
LUBRICATION GEARBOXES - Change the oil in all the gearboxes after the first 10 hours of use to remove any contaminants from the breaking-in process. - Thereafter, oil must be changed every 200 hours of work, or at least once per year. IMPORTANT - Periodically check oil level. - Page 43 LUBRICATION b) Draining the cutterbar (After the first 10 hours then every 200 hours or once a year) : Note : The cutterbar must be drained when the oil is warm. It is preferrable to drain the oil at the end of a day’s work.
- Page 44 LUBRICATION Central gearbox (FC 4000 R / RG) : The oil reservoir of the central gearbox is located above the service trap (4) and can be drained by the drain plug (2). From this reservoir an oil pump lubricates all the bearings and gears of the gearbox.
- Page 45 LUBRICATION Central gearbox (FC 4000 G) : The central gearbox has a capacity of 5 qt. (5 litres). An oil pump lubricates all the bearings and gears of the gearbox. a) Checking the oil level : - Unscrew and remove the dip stick (1). Two marks show the maximum and minimum levels.
- Page 46 LUBRICATION Bevel gearbox : (Cutterbar drive) a) Checking the oil level : Oil level must be checked with the dipstick fully screwed in the gearbox. - Clean area around, then remove plug (1). - Check oil level using the dipstick (3) with groove (4) indicating oil level.
- Page 47 LUBRICATION Gyrodine gearbox : a) Checking the oil level : Oil level must be checked with the dipstick fully screwed in the gearbox. - Clean, then remove plug (1). - Check oil level using the dipstick (3) with groove (4) indicating oil level. - Refill if necessary using 80W-90 GL5 oil.
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Page 48: Maintenance
8. Spare parts used must be in accordance with specifications and standards as defined by the manufacturer. Use only genuine KUHN parts! 9. Before any electric welding is carried out on tractor or attached machine, disconnect alter- nator and battery terminals. -
Page 49: Blade And Bolt Inspection
MAINTENANCE BLADE AND BOLT INSPECTION Blades should be inspected systematically each time before the machine is operated. Cutting quality as well as safe operation de- pend on the regular inspection and care given to the blades. INSPECT THE NUTS, BOLT AND BLADES IMMEDIATELY AFTER HITTING AN OBSTRUCTION 1. - Page 50 - When the contact washer has lost its elas- ticity or when it has become loose from the nut. - When wear on the nuts reaches a= 3/16" (5 mm). For the correct operation of the machine always use genuine KUHN spare parts. - 48 -...
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Page 51: Blade Replacement
To change a blade : - Prevent the cutterbar from rotating by putting a block of wood between two discs. - Using the Kuhn wrench supplied or an 18mm socket to loosen the nuts. - Rotate the disc to drop the bolt through the hole in the disc guard. -
Page 52: Discs
DISCS The FC 4000 G is fitted with symmetrical discs able to turn clockwise and counter-clockwise. The FC 4000 R - FC 4000 RG are fitted with right lifter discs that turn clockwise and left lifter discs that turn counter-clockwise. -
Page 53: Skid Shoes
MAINTENANCE Half discs: (Used on all cone discs) - Raise the header and lock the lift cylinders in transport position. Put a stand under the cutterbar. - Remove the skid shoe under the cone disc to be serviced. (See instructions below) - Prevent the cutterbar from rotating by put- ting a block of wood between two discs. -
Page 54: Friction Slip Clutch
MAINTENANCE FRICTION SLIP CLUTCH The friction slip clutch is fitted to the rear of the primary PTO shaft. This clutch provides a protection to the drive component and should slip when: - the PTO is engaged at high rpm. - the mower is locked. - the cutting conditions require more than 140 PTO horsepower. -
Page 55: Drive Chain For The Upper Rolls
MAINTENANCE DRIVE CHAIN FOR THE UPPER ROLLS (FC 4000 R / RG) a) Checking the chain for wear : 1 - First check for correct roll gap. See page 30, “Adjusting Conditioning Intensity.” 2 - Rotate upper roll back and forth by hand. If the lugs of the upper roll contact lugs on lower roll in both directions, the chain needs to be replaced. -
Page 56: Hydraulics
MAINTENANCE HYDRAULICS 1- Lift cylinders : The lift cylinders are connected in a master-slave arrangement (see hydraulic schematic next page), the left cylinder is the master cylinder. If the frame doesn’t raise horizontally, or if a hose has been changed the system must be bled: - Raise the header fully and continue applying pressure to the raise circuit for several sec-onds to allow the oil to feed to the slave cylinder. - Page 57 MAINTENANCE 2- Hydraulic schematic : - 55 -...
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Page 58: Electric Connectors
MAINTENANCE ELECTRIC CONNECTORS - 56 -... -
Page 59: Fastener Torque Chart
All the hardware used on the FC4000 is metric sized, and the minimal class quality hardware used is 8.8. If any hardware is missing, replace it only with genuine Kuhn spare parts. Use the following values if nothing has been specified :... -
Page 60: Optional Equipment
OPTIONAL EQUIPMENT 1) DRAWBAR SAFETY CHAIN (Code no 830 800 02) (see page 17) 2) QUICK HITCH (code 1086930) for category II, 1086940 for category III This equipment enables coupling the FC 4000 to tractors equipped with a « Quick hitch «. -
Page 61: Storage
Be sure to lubricate all grease points and change fluids after power washing. 2. Check the condition of the machine. List the replacement parts that will be needed. Order replacement parts early from your Kuhn dealer so that they may be fitted during the off sea- son. -
Page 62: Troubleshooting Guide
A thorough understanding of the machine is required to correct operating problems. IF UNSURE OF THE CAUSE OR CORRECTION TO A PROBLEM, ALWAYS CONTACT YOUR LOCAL KUHN DEALER. PROBLEM POSSIBLE CAUSES... - Page 63 Install other set of skids Damaged leaves Not enough gap between Increase the gap between the rolls and crushed stems the rolls (FC 4000 R / RG) Too much roll pressure Adjust the roll tension Insufficient PTO speed Maintain rated PTO speed Roll plugging...
- Page 64 Replace the blades Disc guard damage Replace the disc guard Conditioner rolls are out Adjust timing, see chain replace- of time (FC 4000 R / RG) ment in Maintenance Section Drawbar not adjusted Adjust the length of the tractor’s properly...
- Page 65 Bring PTO speed up to 1000 rpm and set it with the hand throttle Uneven or Conditioning roll gap Increase roll gap windrow too (FC 4000 R / RG) wide Swathing baffles not in Put the swathing baffles all the windrow position way up...
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Page 66: Limited Warranty
THE CUSTOMER WILL BE RESPONSIBLE FOR AND BEAR THE COSTS OF : 1. Normal maintenance such as greasing, maintenance of oil levels, minor adjustments, etc. 2. Transportation of any kind of any KUHN product to and from the place the warranty work is performed. - Page 67 V belts, discs, knives, wear plates, disc guards, tires, torque limiters, hydraulic hoses, pitman shafts, swath sticks, blades, tines and tine holders. KUHN Limited Warranty will not apply to any product which is altered or modified without the expressed permission of the Company and/or repaired by anyone other than Authorized Ser- vice Distributors or Authorized Service Dealers.
- Page 68 KUHN S.A. reserves the right to incorporate any change in design in its products without obliga- tion to make such changes on units previously manufactured.
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Page 69: Notes
NOTES - 67 -... - Page 70 - 68 -...
- Page 71 The Operator should respect all Health and Safety regulations as well as the Highway Code. For your own safety, use only genuine KUHN spare parts. The manufacturer disclaims all responsibilities due to incorrect use or non-compliance with the recommendations given in this manual.
- Page 72 FOR YOUR SAFETY AND FOR THE PROPER OPERATION OF THE MACHINE, USE ONLY GENUINE KUHN PARTS. KUHN S.A. KUHN FARM MACHINERY, INC. 4, impasse des Fabriques 5390 East Seneca Street 67706 SAVERNE CEDEX (FRANCE) VERNON, NY, 13476 Tél. : 03 88 01 81 00...
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