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Kersten HyCut Original Operating Instructions

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Original operating
instructions
HyCut.
Order:
from Masch.-Nr.:
Rev.: R01
As of: 2021-01-27

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Summary of Contents for Kersten HyCut

  • Page 1 Original operating instructions HyCut. Order: from Masch.-Nr.: Rev.: R01 As of: 2021-01-27...
  • Page 2 All rights reserved. This documentation is protected by copyright. Kersten Arealmaschinen GmbH reserves all rights that have not been expressly granted. This documentation may not be reproduced, distributed or otherwise made publicly available without prior written consent and except in cases permitted by law.
  • Page 3 Since self-propelled equipment emanates significant sources of accident or danger when not used properly, it is imperative to provide instruction to competent and authorised persons during the initial commissioning of the Kersten work equipment. The best way to familiarize yourself with its basic functions and its handling is to choose a free and level terrain for your first trip.

  • Page 4: Table Of Contents

    1 Foreword 2 Safety ........................2.1 Symbols in this guide ..........................2.2 Pictograms ..........................2.3 Appropriate use ....................... 2.4 Working and hazardous areas ...................... 2.5 Safety during the work process ........................2.6 Mowing on the slope ..........................2.7 Safety devices ................
  • Page 5 ........................7.7Setting chain voltage ........................7.8 Charging batteries ....................... 7.8.1 Charger with 48 volts ....................... 7.8.2 Charger with 24 volts ........................ 7.8.3 Charger with 12 volts ......................... 7.9 Cleaning machine ......................7.10 Measures after maintenance ............................. 7.11 Storage 8 Faults / Troubleshooting ........................
  • Page 6 HyCut Mower Preface Dear customer, Thank you for choosing a quality product from Kersten. This product has been manufactured according to state-of-the-art manufacturing processes and extensive quality assurance measures, because only when you are satisfied with your equipment is our goal achieved.

  • Page 7: Safety

    HyCut Mower Security Symbols in this guide Safety The following occupational safety symbols are indicated by all safety indications which indicate a danger to the life and limb of persons and are indicated by a pictogram, a signal word and a signal colour.
  • Page 8 HyCut Mower • Action that must be omitted so that the damage to the machine or plant does not occur Tips and recommendations This symbol highlights useful tips and recommendations, as well as information for efficient and trouble-free operation. Other markings...

  • Page 9: Pictograms

    HyCut Mower Pictograms Observe instructions Do not use the flagged machine until the manual has been read. Wear health and safety clothing This sign indicates that protective clothing must be worn in the area concerned. Workwear is tight-fitting work wear with low tear resistance, with tight sleeves and no protruding parts.
  • Page 10 HyCut Mower Operating instructions and safety instructions Before commissioning, read and observe the operating instructions and safety instructions. Never open or remove protective devices when the motor is running. Observe the notes in the technical manual. Lubrication point! only touch machine parts when they have come to a complete standstill.

  • Page 11: Appropriate Use

    Due to improper use of the machine there is a risk of injury, as well as danger for environmental and property damage (on the machine or plant)! • The HyCut mower is built for the usual or common mowing applications in agriculture and forestry, such as .B green space and plant maintenance. •...

  • Page 12: Working And Hazardous Areas

    In addition to the instructions in this manual, observe the general applicable safety and accident prevention regulations! • HyCut mower must not be operated by persons under the age of 16, even under the supervision of an adult! Children and adolescents must be instructed not to play with the device.
  • Page 13 • Do not operate the machine in humidity and rain in the slope. • In case of malfunction on the steering, stop the HyCut mower and turn off the motor immediately. Eliminate the fault immediately. • Before each commissioning, check the machine for operational safety! •...

  • Page 14: Mowing On The Slope

    In addition to the instructions in this manual, observe the general applicable safety and accident prevention regulations! • If the HyCut mower starts to slide in the slope, the emergency stop switch of the remote control must be immediately released. 2021-01-27...
  • Page 15 HyCut Mower The operator must always be aware of the local conditions, in particular the • gradient and adjust his position accordingly. The distances described in relation to the danger zone must be observed (see Chapter 2.4 Working and hazardous areas on page 14).

  • Page 16: Safety Devices

    (2). In the event of an emergency, immediately press the emergency stop switch of the mower (1) or the remote control (2). • The HyCut mower remains standing • The power supply to the motor controllers remains •...

  • Page 17: Remaining Hazards

    HyCut Mower Warning Risk of injury due to illegible or missing signage! Missing and illegible stickers and signs can have serious health effects and life- threatening injuries. • Keep all safety, warning and operating instructions in always easy-to-read condition. •...
  • Page 18 HyCut Mower • Read the material safety data sheets and instructions of the manufacturers applicable to the cleaning agents or substances • Wear the appropriate protective equipment (e.B. gloves, safety shoes, protective suit, breathing mask, goggles, etc.) • Ensure adequate ventilation of the environment •...
  • Page 19 HyCut Mower Moving components Risk Danger of life or injury due to moving components! Due to improper handling of moving components, there is a risk of life or injury as well as a risk of damage to the machine or plant •...

  • Page 20: Environmental Protection

    HyCut Mower 2.10 Environmental protection Warning Environmental damage hazard due to improper handling of operating equipment or operating materials as well as cleaning agents or cleaning agents! Improper handling of equipment or materials as well as cleaning agents or substances can result in extensive environmental and material damage.
  • Page 21 HyCut Mower Improper transport Note Damage to property due to improper transport In case of improper transport, items of transport may fall or overturn. This can cause material damage in a significant amount. Take care when unloading the items during delivery as well as during •...

  • Page 22: Functional Description

    HyCut Mower Description Overview The HyCut mower is used for the following tasks. Mowing and mulching • Fig. : Table 14 Caterpillar on the right Exhaust frames with emergency stop switch, flashlight and antennas Height adjustment Mulch mower caterpillar suspension on the left...
  • Page 23 HyCut Mower Fig. : Table 25 Four buffer batteries connected in series Internal combustion engine Air filters Fuel tank Electric motor mowing drive Electric motor caterpillar drive left 2021-01-27 23 / 67...
  • Page 24 HyCut Mower Fig. : Table 36 Circuit breakers Four motor Controller Generator Timing belt drive between internal combustion engine and generator Electric motor caterpillar drive right 12 Volt Battery The radio-controlled mowing was primarily designed for mowing areas on a slope up to a pitch angle of 50°...

  • Page 25: Transport, Packaging And Storage

    HyCut Mower Transport, packaging, and storage Installation, installation and initial commissioning are carried out exclusively by employees of the dealer or by persons authorised by him. However, it may happen that operators or maintenance personnel of the operator are entrusted with the handling of packages as part of the installation and further use.

  • Page 26: Transport Of The Machine

    HyCut Mower Transport of the machine Note Damage to property due to improper handling! Improper handling of the machine can lead to damage. • Do not tilt the machine or rotate it around the horizontal axes. • Vehicles, aids and stoppers must be suitable according to the weight of the transport units.
  • Page 27 HyCut Mower Fig. : 7Transport eyelets / edges of the machine Transport eyelets Feeding Points Only the existing transport eyelets (1) must be used for transport /lifting the machine. Only the existing feeding points (2) shall be used to to launder the machine.

  • Page 28: Towing

    HyCut Mower Towing Risk Danger of life or injury due to the manual disconnection of the engine brake for the two drive drives! Due to the manual disconnection of the engine brake for the two drive drives, there is a risk of life or injury, as well as a risk of damage to the machine or...

  • Page 29: Assembly/Installation, Installation, Initial Commissioning

    HyCut Mower Installation/installation, installation, initial commissioning Safety Be sure to observe all safety instructions listed in the chapter Security! (See Chapter 2 Security on page 10) 2021-01-27 29 / 67...

  • Page 30: Operation

    Be sure to observe all safety instructions listed in the chapter Security! (See Chapter 2 Security on page 10) Wireless remote control All functions of the HyCut mower are carried out via the supplied wireless remote control. Fig. : Wireless remote control 9...
  • Page 31 HyCut Mower The mower is driven forwards /backwards (1) via the driving lever. The further the lever (1) is moved forward or backward from the neutral position, the faster the mower travels forwards or backwards. Via the driving lever right / left (9) the direction of the mower is changed to the left or right.
  • Page 32 HyCut Mower Fig. : 10Wireless wireless remote control (side views) 11 Shutting down the mower Start up the mower Working lights Switch on / switch off Without function Remote control Power on/off Acknowledge errors Signal horn buttons Power up the mower (12) and shut down the mower (11) via the push-button mower (11) the mower is continuously up or down without any stages.
  • Page 33 HyCut Mower Fig. : 11Wireless wireless remote control (bottom) Replaceable replacement battery The battery (18) located on the bottom of the wireless remote control can be changed for another battery. The scope of delivery includes two batteries (18) and a charger.
  • Page 34 HyCut Mower Turning on the mower Risk Danger of life or injury due to leaking exhaust gases in confined spaces, as well as movements during and after the start-up process! Due to leaking exhaust gases in confined spaces, as well as through movements...

  • Page 35: Switching The Mower

    HyCut Mower If the 48 volt voltage is too low, the internal combustion engine can be started by hand. For this purpose, place the toggle switch in the middle position and tighten the motor via hand starter (1). Put on the hand starter (1) slowly until a resistor occurs and then pull through with the greatest possible stroke.

  • Page 36: Switching Mowers

    HyCut Mower Switch off the mowing caterpillar Risk Danger of life or injury due to leaking exhaust gases in confined spaces! Due to leaking exhaust gases in confined spaces, there is a risk of life or injury, as well as a risk of damage to the machine or plant! •...
  • Page 37 HyCut Mower In case of inactivity of the mower, but switched on control, a honking signal sounds after a short time. This honk signal is intended to inform the user that the controller is still switched on. When the motor is switched off and the controller is switched on, the batteries are discharged within a short time.

  • Page 38: Maintenance

    HyCut Mower Maintenance Safety Be sure to observe all safety instructions listed in the chapter Security! (See Chapter 2 Security on page 10) Spare parts Incorrect spare parts Risk Danger of life or injury due to the use of incorrect spare parts! This symbol warns of an immediate danger to the life and health of individuals.

  • Page 39: Daily Exam

    HyCut Mower Separating protective devices (covers) Interval When commissioning, when the machine is switched on, Scope Visual inspection for integrity Auditor Operators Measures in • Lock the danger area case of errors Repair • Emergency stop switch Interval when the system is switched on, in addition every four years as...

  • Page 40: Maintenance After 20 Operating Hours / Longer Downtime

    HyCut Mower Control battery voltage 12 volts and 48 volts (see Chapter 7.8 Charging batteries • on page 53 7.3.3 Maintenance after 20 operating hours / longer downtime Risk Danger of life or injury due to a machine in operation!

  • Page 41: Maintenance After 100 Operating Hours / Longer Downtime

    HyCut Mower 7.3.4 Maintenance after 100 operating hours / longer downtime Risk Danger of life or injury due to a machine in operation! Due to a machine in operation, there is a risk of life or injury, as well as a risk of damage to the machine or plant! •...

  • Page 42: Knife Change Of Mower

    HyCut Mower Knife change of the mower Warning Risk of injury / risk of environmental damage due to damaged and / or sharp mower knives! Damaged and / or sharp mower knives risk injury, as well as danger for environmental and property damage (on the machine)! •...

  • Page 43: Swap Plates With All Knives Attached To Them

    HyCut Mower 7.4.1 Swap plates with all knives attached to them Fig. : Plate change of the mower14 knife plate of the mower Washer Wedge locking disc hexagonal screw The disassembly of the knife plate (1) is carried out according to the following procedure.

  • Page 44: Swapping Opposite Knives

    HyCut Mower 7.4.2 Swap opposite knives Fig. : Knife change of the mower15 knife of the mower Lock nut Distance sleeve hexagonal screw The knife is dismantled according to the following procedure. Loosen the hexagonal nut (2) and remove it from the hexagonal screw (4).

  • Page 45: Clean Air Filter

    HyCut Mower Clean air filters Fig. : Air filter16 perforated sheet cover fan Motor air filter Care must always be taken to ensure that both the perforated sheet cover of the fan (1) and the motor air filter (2) are free of foreign objects. To check the motor air filter condition, the lid of the motor air filter (2) must be opened on the two quick- release fasteners.

  • Page 46: Chain Pulling

    HyCut Mower Pulling up the chain If the rubberized drive chain has bounced off or if a new rubberized drive chain is to be used, the drive chain must be wound. Fig. : 17Lift the mower on the side Rectangular holder for the thorn of the lifting element lifting element (jack;...
  • Page 47 HyCut Mower Fig. : Pulling up the drive chain18 deflection steering wheel in front Sliding element Drive wheel Rear steering wheel Locking Pin Hand clamping device connecting bolts rollers Turn the hand clamping device (9) together and re-energise the sliding element (5) completely.

  • Page 48: Setting Chain Voltage

    HyCut Mower Drive chain with the help of the manual clamping device (9) to clamp the necessary chain tension (see Chapter 7.7 Set chain tension on page 51). Caution - Damage to components! Check the chain tension after the drive chain has been pulled up after 1, 2, 5, 10 and 20 operating hours.
  • Page 49 HyCut Mower Fig. : 20Chain in tense state hand clamping device movable unit disc springs Edge of the movable unit notch in the welded plate By turning the hand clamping device (1) the movable unit (2) is moved in the direction of the disc springs (3).

  • Page 50: Charging Batteries

    • Always set the charger to OFF before removing the connecting cables from the battery to avoid dangerous sparks. Two systems with different electrical voltages are used in the HyCut mower.  Control voltage 12 volts •...

  • Page 51: Charger With 48 Volts

    HyCut Mower 7.8.1 Charger with 48 volts Warning - Dangers from electric current! Only the motor voltage system can be charged with a 48 volt charger! Fig. : 21Charger with 48 volts Four 12 volt batteries Motor voltage 48 volts A 12 volt battery control voltage 12 volts...

  • Page 52: Charger With 24 Volts

    HyCut Mower 7.8.2 Charger with 24 volts Warning - Dangers from electric current! Only the motor voltage system can be charged with a 24 volt charger! Fig. : 22Charger with 24 volts Four 12 volt batteries Motor voltage 48 volts A 12 volt battery control voltage 12 volts...

  • Page 53: Charger With 12 Volts

    HyCut Mower 7.8.3 Charger with 12 volts Fig. : 23Charger with 12 volts Four 12 volt batteries Motor voltage 48 volts A 12 volt battery control voltage 12 volts One chargeable 12 volts Four chargers with 12 volts each Four chargers of 12 volts (4) each must be connected to the battery poles of the 48 volt motor voltage (1) according to the figure above.

  • Page 54: Cleaning Machine

    HyCut Mower Cleaning the machine When cleaning the HyCut mower, the following points must be observed. Warning Risk of injury / risk of environmental damage due to transmission of electrical power during cleaning work! Due to the transmission of electrical power during cleaning work, there is a risk of...

  • Page 55: Storage

    HyCut Mower 7.11 Storage If the machine is no longer in use for a long time, the following steps must be followed: 1. Cleaning (See chapter 7.9 Cleaning machine on page 57) motor. For this, follow the instructions of the engine manufacturer! Insinuate the machine -To avoid corrosion, protect the machine from weathering.

  • Page 56: Faults / Troubleshooting

    HyCut Mower Faults / Troubleshooting The following chapter describes possible causes of disturbances and the work to eliminate them. In the event of increased disturbances, shorten the maintenance intervals according to the actual load. In the event of malfunctions which cannot be remedied by the following instructions, contact the manufacturer.
  • Page 57 HyCut Mower Disorder Possible causes Remedy ignition cable fastening clamp loose candle plug firmly on spark plug Fuel line clogged or bad fuel Change fuel filters, clean fuel line or refuel fresh fuel Ventilation in the fuel tank lid closed...

  • Page 58: Fault Table Control

    HyCut Mower Fault table control Disorder Possible causes Remedy Control of the mower worm Battery circuit breaker switched off Switch on the battery disconnector does not start 12V battery empty or defective 12V battery charge or replace Remote control does not...

  • Page 59: Fault Table Mower Drive

    HyCut Mower Fault table mower drive Disorder Possible causes Remedy V-belt of the mower drive V-belt tension too low Control spring tension slips through Flanks of the V-belts are hard and Renew V-belts cracked Knife spindles/pendulum knives are Examine the mowing device for foreign...

  • Page 60: Disassembly, Disposal

    HyCut Mower Disassembly, Disposal Safety Be sure to observe all safety instructions listed in the chapter Security! (See Chapter 2 Security on page 10) Dismantling Before the disassembly begins: • Turn off the machine and secure it against re-switching. •...
  • Page 61 HyCut Mower Batteries and accumulats Caution Danger to the environment from batteries and batterie components! Components of batteries and batteries are toxic and pose a danger to the environment. • Never put batteries and batteries in household waste and only dispose of them in accordance with the regulations in force at the site of use.

  • Page 62: Technical Data

    HyCut Mower Technical data 10.1 General Unit Working / mowing width 1150 Cutting height 50 – 180 Width 1500 Length c. 1600 Height Weight approx. 660 Speed approx. 0 - 7 Km/h forward / forward Continuously Sound pressure level on <...

  • Page 63: Radio Remote Control

    HyCut Mower 10.3 Wireless remote control Unit Control On / Off Before / Back Left / Right Security 2 x emergency stop switch Automatic tilt monitoring Engine Start / Stop Mower On / Off Batteries Change system Range max. 300...

  • Page 64: Declaration Of Conformity

    HyCut Mower 10.5 Declaration We, the Kersten Arealmaschinen GmbH Empeler Straße 95 D- 46459 Rees explain that the product Tracked Mower HyCut in accordance with all relevant provisions of the EC Machinery Directive 2006/42/EC. The machine is also in accordance with all relevant provisions of the following EC...

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