Related Manuals for Kersten HyCut
Summary of Contents for Kersten HyCut
- Page 1 HyCut Order number: B00108 From mach. no.: Rev.: R01 Date: 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 duplicated, disseminated or made publicly accessible in any other way without prior written consent and except in cases permitted by the law.
- Page 3 Because the improper use of self-propelled equipment can result in accidents or pose other potential hazards, the initial commissioning of this Kersten machine requires mandatory training by competent, authorised personnel. Familiarise yourself with the machine’s basic functions and the handling by choosing an even, level area free of any obstacles when using the machine for the first time.
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Page 4: Table Of Contents
Preface Safety Symbols in this operating manual ...................... 7 Pictograms ............................9 Intended use ............................. 11 Work areas and danger zones ......................11 Safety during the work processes ....................12 Mowing on slopes ..........................14 Safety devices ..........................15 2.7.1 Emergency shutdown with the emergency stop button .............. - Page 5 Setting the chain tension ........................49 Charging the batteries ........................51 7.8.1 48-volt charging device ....................... 52 7.8.2 24-volt charging device ....................... 53 7.8.3 12-volt charging device ....................... 54 Cleaning the machine ........................55 7.10 Measures after maintenance has been performed ................55 7.11 Storage .............................
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Page 6: Preface
Preface Preface Dear Customer, Thank you for choosing a quality product from Kersten. This product was manufactured according to the most up-to-date production processes and using comprehensive quality assurance measures as our target is only achieved when you are satisfied with your machine. -
Page 7: Safety
Mähraupe HyCut Safety Safety Symbols in this operating manual Safety instructions The following occupational safety symbols are used with all information regarding occupational safety that indicate a risk to life and limb and usually consist of a pictogram, a signal word and a signal colour. - Page 8 Mähraupe HyCut Safety NOTICE Type and source of the machine or system damage This symbol warns of a hazardous situation and identifies a notice on how to handle the machine or system. Failure to follow the instructions and information provided may lead to extensive material damage.
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Page 9: Pictograms
Mähraupe HyCut Safety Pictograms Pictograms Follow the instructions in the operating manual Only use the identified machine after having read the operating manual. Wear protective workwear This sign indicates that protective workwear must be worn in the area concerned. Protective workwear is close-fitting work clothes with a low tensile strength, close- fitting sleeves and without any protruding parts. - Page 10 Mähraupe HyCut Safety Operating manual and safety instructions Read and observe the operating manual and all safety instructions before starting up the machine for the first time. Never open or remove any protective devices while the engine is running. Observe the information provided in the technical manual.
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Page 11: Intended Use
Adhering to the intended use includes complying with the manufacturer’s operating, maintenance and repair specifications. • The HyCut tracked mower may only be used, maintained and repaired by people who are familiar with it and who have been instructed about the associated hazards. -
Page 12: Safety During The Work Processes
If the safety measures are not complied with, this can result in injury and environmental and material damage (to the machine)! • Never leave the HyCut tracked mower unattended when it is moving. • Follow the information and instructions in this operating manual and comply with all general occupational safety and accident prevention regulations. - Page 13 Repair the malfunction immediately. • Check the machine’s operational safety before each use! • If the HyCut tracked mower starts slipping when on a slope, press the emergency stop button on the remote control immediately. 2021-01-27 13 / 65...
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Page 14: Mowing On Slopes
Follow the information and instructions in this operating manual and comply with all general occupational safety and accident prevention regulations. • If the HyCut tracked mower starts slipping when on a slope, press the emergency stop button on the remote control immediately. 2021-01-27 14 / 65... -
Page 15: Safety Devices
Mähraupe HyCut Safety • The operator must always be familiar with the local conditions, particularly the slopes, and change their position accordingly. The distances in relation to the danger area described must be observed (see Chapter 2.4 Work areas and danger zones on Page 11). -
Page 16: Emergency Shutdown With The Emergency Stop Button
(2). In an emergency, press the emergency stop button on the tracked mower (1) or remote control (2) immediately. • The HyCut tracked mower will come to a complete stop • The power supply to the engine controllers remains •... -
Page 17: Residual Risks
Mähraupe HyCut Safety WARNING Risk of injury due to illegible or missing signage! Missing and illegible stickers and signs can have serious health consequences or even cause fatal injuries. • All safety, warning and operating signs must always be legible. - Page 18 Mähraupe HyCut Safety • Read the applicable material safety data sheets and manufacturer instructions for the cleaning agents and substances • Wear corresponding personal protective equipment (e.g. gloves, safety shoes, protective suit, respirator, protective eyewear, etc.) • Ensure that the surrounding environment is sufficiently ventilated •...
- Page 19 Mähraupe HyCut Safety Moving parts DANGER Risk of death and injury due to moving parts! If moving parts are handled improperly, there is a risk of death and injury, as well as material damage to the machine and system. •...
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Page 20: Environmental Protection
Mähraupe HyCut Safety 2.10 Environmental protection WARNING Risk of environmental damage due to the improper handling of operating materials and resources, as well as cleaning agents and substances! Handling operating materials, resources, cleaning agents and substances improperly can cause extensive environmental and material damage. - Page 21 Mähraupe HyCut Safety Improper transport NOTICE Material damage caused by improper transport Clean any parts, assemblies and components to remove any adhering oil, grease and other contaminants This can result in significant material damage. • Proceed carefully when unloading the transported objects upon delivery and during internal transport and observe the symbols and information on the packaging.
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Page 22: Functional Description
Mähraupe HyCut Functional description Functional description Overview The HyCut tracked mower has been designed for the following tasks. • Mowing and mulching Fig. 4: Overview 1 Right caterpillar track Exhaust Frame with emergency stop button, flashing light and antenna Mulching/mowing unit height adjustment... - Page 23 Mähraupe HyCut Functional description Fig. 5: Overview 2 Four back-up batteries connected in series Combustion engine Air filter Fuel tank Mowing drive electric motor Left caterpillar drive electric motor 2021-01-27 23 / 65...
- Page 24 Mähraupe HyCut Functional description Fig. 6: Overview 3 Disconnect switch Four motor controller Generator Toothed belt drive between the combustion engine and generator Right caterpillar drive electric motor 12-volt battery The remote-controlled tracked mover is primarily designed for mowing areas on slopes up to a gradient of 50°...
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Page 25: Transport, Packaging And Storage
Mähraupe HyCut Transport, packaging and storage Transport, packaging and storage The assembly, installation and initial commissioning should only be performed by an employee of the dealer or by a person authorised by them. However, it may be that operators or maintenance personnel may be entrusted with handling packages as part of the installation. -
Page 26: Transportation Of The Machine
Mähraupe HyCut Transport, packaging and storage Transportation of the machine NOTICE Material damage due to improper handling! Handling the machine improperly can cause damage. • The machine must not be allowed to tip over or rotate around the horizontal axis. - Page 27 Mähraupe HyCut Transport, packaging and storage Fig. 7: Transport lugs / lashing points on the machine Transport lugs Lashing points Only the existing transport lugs (1) should be used to transport / lift the machine. Only the existing lashing points (2) should be used to lash the machine.
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Page 28: Towing / Recovery
Mähraupe HyCut Transport, packaging and storage Towing / Recovery DANGER Risk of death or injury caused by manually disconnecting the engine brake for the two drives! When manually disconnecting the engine brake for the two drives, there is a risk... - Page 29 Mähraupe HyCut Transport, packaging and storage 2021-01-27 29 / 65...
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Page 30: Assembly, Setting Up, Installation, Initial Commissioning
Mähraupe HyCut Assembly, setting up, installation, initial commissioning Assembly, setting up, installation, initial commissioning Safety instructions Observe all safety instructions provided in the Safety chapter! (See Chapter 2 Safety on Page 7) 2021-01-27 30 / 65... -
Page 31: Operation
Observe all safety instructions provided in the Safety chapter! (See Chapter 2 Safety on Page 7) Wireless remote control All the functions of the HyCut tracked mower can be controlled via the supplied wireless remote control. Fig. 9: Wireless remote control... - Page 32 Mähraupe HyCut Operation The forwards / reverse drive lever (1) moves the tracked mover forwards or backwards. The further away from the neutral position the drive lever (1) is moved, the faster the tracked mower will move forwards or backwards.
- Page 33 Mähraupe HyCut Operation Fig. 10: Wireless remote control (side view) Lower the mowing unit Raise the mowing unit Work lights on / off No function Remote control on / off Acknowledge error Horn button The raise the mowing unit (12) and lower the mowing unit (11) buttons can be used to smoothly raise and lower the mowing unit electrically.
- Page 34 Mähraupe HyCut Operation Fig. 11: Wireless remote control (below view) Replaceable battery The battery (18) on the bottom of the remote control can be replaced with another battery. There are two batteries (18) and a charging device included in the scope of delivery.
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Page 35: Turning On The Tracked Mower
Mähraupe HyCut Operation Turning on the tracked mower DANGER Risk of death and injury due to escaping exhaust gases in enclosed spaces and movements during and after the start-up process! There is a risk of death and injury due to escaping exhaust gases in enclosed spaces and movements during and after the start-up process. -
Page 36: Moving Off / Turning On The Mowing Unit
Mähraupe HyCut Operation Recoil starter If the 48-volt voltage is too low, the combustion engine can be started manually. To do so, put the toggle switch in the middle position and start up the engine with the recoil stater (1). Slowly pull out the recoil starter (1) until you feel resistance and then pull it through with the longest possible stroke. -
Page 37: Turning Off The Tracked Mower
Mähraupe HyCut Operation Turning off the tracked mower DANGER Risk of death or injury due to escaping exhaust gas in enclosed spaces! There is a risk of death and injury, as well as a risk of material damage to the machine and system, due to escaping exhaust gases in enclosed spaces! •... - Page 38 Mähraupe HyCut Operation Notice If the tracked mower is inactive but the control unit is turned on, a horn signal will be sounded after a short amount of time. This is to alert the user to the fact that the control unit is still turned on.
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Page 39: Maintenance
Mähraupe HyCut Maintenance Maintenance Safety instructions Observe all safety instructions provided in the Safety chapter! (See Chapter 2 Safety on Page 7) Spare parts Incorrect spare parts DANGER Risk of death or injury due to incorrect spare parts being used! This symbol warns users of an imminent danger to the life and health of personnel. -
Page 40: Daily Inspection
Mähraupe HyCut Maintenance Safety guards (covers) Interval When commissioning, when turning on the machine Scope Visual inspection for integrity Inspector Operating personnel • Measures to Block off the danger zone take in the • Carry out any repairs event of a... -
Page 41: Maintenance After 20 Operating Hours / Longer Periods Of Downtime
Mähraupe HyCut Maintenance • Check the track tension (see Chapter 7.7 Setting the chain tension on Page 49). • Carry out a trial run before each use. • Clean the machine after each use (see Chapter 7.9 Cleaning the machine on Page 55). -
Page 42: Maintenance After 100 Operating Hours / Longer Periods Of Downtime
Mähraupe HyCut Maintenance 7.3.4 Maintenance after 100 operating hours / Longer periods of downtime DANGER Risk of death or injury due to a machine in operation! A machine in operation can pose a risk of death and injury, as well as a risk of material damage to the machine and system! •... -
Page 43: Changing The Blades Of The Mowing Unit
Mähraupe HyCut Maintenance Changing the blades of the mowing unit WARNING Risk of injury / risk of environmental damage due to damaged and / or sharp mowing unit blades! There is a risk of injury and environmental and material damage (on the machine) due to damaged and / or sharp mowing unit blades! •... -
Page 44: Changing A Disc And All The Blades On It
Mähraupe HyCut Maintenance 7.4.1 Changing a disc and all the blades on it Fig. 14: Changing the disc of the mowing unit Mowing unit blade disc Washer Wedge lock washer Hexagon bolt To remove the blade disc (1), proceed as follows: Loosen and remove the hexagon bolt (4). -
Page 45: Changing Opposite Blades
Mähraupe HyCut Maintenance 7.4.2 Changing opposite blades Fig. 15: Changing the blades of the mowing unit Mowing unit blades Locking nut Spacer sleeve Hexagon bolt To remove the blades, proceed as follows: Loosen the locking nut (2) and remove it from the hexagon bolt (4). -
Page 46: Cleaning The Air Filter
Mähraupe HyCut Maintenance Cleaning the air filter Fig. 16: Air filter Perforated fan cover Engine air filter Care must be taken to ensure that both the perforated fan cover (1) and the engine air filter (2) are always free from foreign objects. To check the condition of the engine air filter, the engine air filter cover (2) must be opened at the two quick release fasteners. -
Page 47: Lifting Up The Chain
Mähraupe HyCut Maintenance Lifting up the chain If the rubber drive chain has fallen out of place or if a new one needs to be installed, then the drive chain needs to be lifted up. Fig. 17: Lift the mower up on the side Rectangular receptacle for the bolt of the lifting element Lifting element (jack;... - Page 48 Mähraupe HyCut Maintenance Fig. 18: Lifting up the drive chain Front diverting wheel Sliding element Drive wheel Rear diverting wheel Locking pin Manual clamping mechanism Connecting bolt Rollers Twist the manual clamping mechanism (9) together and push the sliding element (5) in fully.
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Page 49: Setting The Chain Tension
Mähraupe HyCut Maintenance Use the manual clamping mechanism (9) to tighten the drive chain to the necessary chain tension (see Chapter 7.7 Setting the chain tension on Page 49). Caution - component damage! Check the chain tension after lifting up the drive chain after 1, 2, 5, 10 and 20 operating hours. - Page 50 Mähraupe HyCut Maintenance Fig. 20: Chain when tensioned Manual clamping mechanism Sliding unit Disc springs Edge of the sliding unit Notch in the welded plate When the manual clamping mechanism (1) is turned, the sliding unit (2) is moved in the direction of the disc springs (3).
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Page 51: Charging The Batteries
• Always set the charging device to OFF before disconnecting the connection cable from the battery to avoid any dangerous sparks. There are two systems with different electrical voltages used in the HyCut tracked mower. • Control voltage ➔ 12 volts •... -
Page 52: 48-Volt Charging Device
Mähraupe HyCut Maintenance 7.8.1 48-volt charging device Warning - risk due to the electrical current! The engine voltage system should only be charged with a 48-volt charging device! Fig. 21: 48-volt charging device Four 12-volt batteries ➔ Engine voltage 48 volts One 12-volt battery ➔... -
Page 53: 24-Volt Charging Device
Mähraupe HyCut Maintenance 7.8.2 24-volt charging device Warning - risk due to the electrical current! The engine voltage system should only be charged with a 24-volt charging device! Fig. 22: 24-volt charging device Four 12-volt batteries ➔ Engine voltage 48 volts One 12-volt battery ➔... -
Page 54: 12-Volt Charging Device
Mähraupe HyCut Maintenance 7.8.3 12-volt charging device Fig. 23: 12-volt charging device Four 12-volt batteries ➔ Engine voltage 48 volts One 12-volt battery ➔ Control voltage 12 volts One 12-volt charging device Four charging devices, each with 12 volts Four 12-volt (4) charging devices must be connected to the battery terminals of the 48-volt engine voltage (1) as in the figure above. -
Page 55: Cleaning The Machine
Mähraupe HyCut Maintenance Cleaning the machine When cleaning the HyCut tracked mower, the following points must be observed. WARNING Risk of injury / risk of environmental damage due to the transmission of electrical current during cleaning work! There is a risk of injury and environmental and material damage (on the machine) if electrical current is transmitted during cleaning work! •... -
Page 56: Storage
Mähraupe HyCut Maintenance 7.11 Storage If the machine will not be used for a long time, proceed as follows: Clean the machine (see Chapter 7.9 Cleaning the machine on Page 55) Preserve the engine. To do so, follow the instructions provided in the engine manufacturer’s manual! -
Page 57: Malfunctions / Troubleshooting
Mähraupe HyCut Malfunctions / Troubleshooting Malfunctions / Troubleshooting The following chapter describes possible causes for malfunctions and the steps that must be taken to remedy them. If malfunctions occur repeatedly, shorten the maintenance intervals according to the actual load. If you experience a malfunction that cannot be remedied by the information provided, contact the manufacturer. - Page 58 Mähraupe HyCut Malfunctions / Troubleshooting Malfunction Possible causes Remedy The petrol engine cuts out Ignition cable loose Plug the spark plug connector firmly into the ignition cable Clamp the ignition cable fastening Connect the spark plug connector firmly to the spark plug...
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Page 59: Control System Malfunction Table
Mähraupe HyCut Malfunctions / Troubleshooting Control system malfunction table Malfunction Possible causes Remedy The towed mower control Battery disconnect switch is off Turn on the battery disconnect switch system does not start 12V battery empty or defective Charge or replace the 12V battery... -
Page 60: Mowing Unit Drive Malfunction Table
Mähraupe HyCut Malfunctions / Troubleshooting Mowing unit drive malfunction table Malfunction Possible causes Remedy Mower drive V-belt slips V-belt tension too low Check the spring tension through Edges of the V-belt are hard and Replace the V-belts cracked Blade spindles/pendulum blades... -
Page 61: Dismantling, Disposal
Mähraupe HyCut Dismantling, disposal Dismantling, disposal Safety instructions Observe all safety instructions provided in the Safety chapter! (See Chapter 2 Safety on Page 7) Dismantling Before dismantling the machine: • Turn off the machine and secure it against being turned on again. - Page 62 Mähraupe HyCut Dismantling, disposal Batteries and accumulators CAUTION Batteries and accumulators pose a risk to the environment! Certain components of batteries and accumulators are toxic and pose a risk to the environment. • Never throw batteries and accumulators away with household waste and only dispose of them in accordance with the regulations applicable to the operating site.
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Page 63: Technical Data
Mähraupe HyCut Technical Data Technical Data 10.1 General information Unit Working / Mowing width 1150 50 – 180 Cutting height Width 1500 Length approx. 1600 Height Weight approx. 660 approx. 0 – 7 Speed km/h When mowing forwards continuously Sound pressure level on <... -
Page 64: Wireless Remote Control
Mähraupe HyCut Technical Data 10.3 Wireless remote control Unit Control system On / Off Forwards / Reverse Left / Right Safety 2 emergency stop buttons Automatic tilt monitoring Engine Start / Stop Mowing unit On / Off Batteries Alternating system Range max. -
Page 65: Declaration Of Conformity
Mähraupe HyCut Technical Data 10.5 Declaration of Conformity Kersten Arealmaschinen GmbH Empeler Straße 95 D-46459 Rees, Germany, hereby declare that the product tracked mower HyCut complies with all applicable regulations of the EC Machinery Directive 2006/42/EC. The machine also complies with all the applicable regulations from the following...