KUHN FC4000RG Operator's Manual
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KUHN FC4000RG Operator's Manual

KUHN FC4000RG Operator's Manual

Mower conditioner
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OPERATOR'S MANUAL
KN114CGB E
Mower conditioner
Original instructions
- English - 11-2010
KN114CGB E

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Summary of Contents for KUHN FC4000RG

  • Page 1 OPERATOR'S MANUAL KN114CGB E Mower conditioner Original instructions - English - 11-2010 KN114CGB E...

  • Page 3: Dear Owner

    Designated use of the machine The FC4000RG mower conditioner must only be used for the work for which it has been designed: mowing on the ground of hay fields, grass silage fields and improved pastures for the purpose of harvesting fodder for feeding livestock.

  • Page 4: Table Of Contents

    Mower conditioner FC4000RG $Contents Dear Owner ........................1 Contents..........................2 Identification of the machine..................4 Front view............................4 Rear view............................4 Model identification plate ........................5 Optional equipment..........................5 Safety..........................6 Description of symbols used in this document................6 Safety instructions ...........................7 Location and description of safety decals on the machine ............18 Road safety equipment and recommendations................21...
  • Page 5 Mower conditioner FC4000RG Instructions for work ....................37 Putting the machine into work position ..................37 Adjustments in working position....................39 Machine use............................ 45 Optional equipment ..................... 46 1 3/4 - 20 spline yoke........................46 Maintenance and storage.................... 47 Frequency chart ..........................47 Lubrication............................

  • Page 6: Identification Of The Machine

    Mower conditioner FC4000RG $Identification of the machine 1. Front view 2. Rear view Identification of the machine...

  • Page 7: Model Identification Plate

    Mower conditioner FC4000RG 3. Model identification plate Please write below the type and serial number of the machine. This information is to be indicated to the dealer for all spare parts orders. KUHN S.A. 67700 SAVERNE - FRANCE FC4000RG Type: TYPE N°...

  • Page 8: Safety

    Mower conditioner FC4000RG $Safety 1. Description of symbols used in this document This symbol indicates a potentially hazardous situation that if not avoided, could result in serious bodily injury. This symbol is used to identify special instructions or procedures which, if not followed strictly, could result in machinery damage.

  • Page 9: Safety Instructions

    Never let anyone operate the machine who is not trained to do so. Should you have any difficulties in understanding certain parts in this manual, please contact your KUHN dealer. Precautions to be taken before carrying out any operations on the machine...
  • Page 10 Mower conditioner FC4000RG Precautions to take before using the machine Do not wear loose clothing which could become caught up in moving parts. Wear the appropriate protective clothing for the work in hand (gloves, shoes, goggles, helmet, ear defenders, etc.).
  • Page 11 Mower conditioner FC4000RG Precautions when driving on public roads Dimensions Depending on the dimensions of the machine, contact the relevant authorities to ensure that it can be legally transported on public roads. If the machine is over the maximum legal size, follow the local regulations for special transportation of oversize equipment.
  • Page 12 Mower conditioner FC4000RG Description of symbols Description Units Description Tractor unladen weight PTAC Gross Combined Weight Rating Unladen load on tractor front axle Empty load on tractor rear axle Axle loads (Tractor + machine) Load on front axle (Tractor + machine)
  • Page 13 Mower conditioner FC4000RG Stage 2: - Couple the machine to the tractor. To measure: - Load on front axle (t1): • Tractor + machine (transport position). To do: - If the front axle load (t1) is below 20% of the tractor tare (T), add ballast weights (M1) to exceed the minimum load on the front axle.
  • Page 14 Mower conditioner FC4000RG Stage 4: To measure: - Load on rear axle (t2): • Tractor + machine (transport position). • Ballast weights. Checking: - Check in the tractor's operator's manual that the value measured is below the maximum allowed tractor rear axle load.
  • Page 15 Mower conditioner FC4000RG Precautions when coupling Before attaching the machine, make sure that it cannot accidentally start moving (chock the wheels) and that the parking stand is in the right position. The machine must only be attached to the hitch points provided for this purpose.
  • Page 16 Mower conditioner FC4000RG PTO shaft Use only PTO shafts supplied with the machine or recommended by the manufacturer. The protective shield of the tractor PTO stub, the PTO shaft guards and the protective covering of the machine input shaft must always be in place and in good condition.
  • Page 17 Mower conditioner FC4000RG Precautions during manoeuvres When moving the machine from the transport position to the working position and vice versa, make sure that nobody is within the machine pivoting area. Remote controlled components Danger of crushing and shearing can exist when components are operated by hydraulic or pneumatic controls.
  • Page 18 For your own safety and for correct machine operation, only use original manufacturer parts. It is strongly recommended to have your machine checked by your Kuhn dealer after each season, especially tools and their attaching hardware. Projection of stones and foreign objects For driver safety, always use a tractor equipped with a cab.
  • Page 19 Mower conditioner FC4000RG Never start a mower conditioner when other people are close. Even when the machine is used in accordance with its purpose, objects may be projected. Stones and other foreign objects projected by the moving parts can travel a considerable distance.

  • Page 20: Location And Description Of Safety Decals On The Machine

    Mower conditioner FC4000RG 3. Location and description of safety decals on the machine Location of safety decals 599011001 59900600 Safety...
  • Page 21 Mower conditioner FC4000RG Description of safety decals Operating instructions (1) The operators' manual contains all the information necessary for using the machine safely. It is imperative to read and comply with all instructions. Working on the machine (2) Before leaving...
  • Page 22 Mower conditioner FC4000RG Rotating cutting tools (5) Keep away from the mower knives all the time the engine is running, the PTO drive engaged and the moving parts have not come to a complete stop. Cutting tools (6) The cutting tools and their attachment hardware meet safety and reliability criteria set by standards and by the manufacturer.

  • Page 23: Road Safety Equipment And Recommendations

    4. Road safety equipment and recommendations The road safety equipment is mounted in the factory or by your authorized Kuhn dealer according to current safety regulations. Always keep to the legal speed limit for driving a tractor-machine assembly on public roads.

  • Page 24: Machine Specifications

    Mower conditioner FC4000RG $Machine specifications 1. Description and glossary Check chain Gyrodine hitch tube PTO shaft support Parking stand Side guard Gearbox Suspension spring Drawbar shift cylinder Cutterbar 10 : Front guard Machine specifications...
  • Page 25 Mower conditioner FC4000RG Drawbar Gyrodine gearbox Toolbox Secondary PTO shaft Suspension adjustment crank Conditioning roller Central gearbox Pitch angle adjustment rod Wheel 10 : Swath shield 11 : Lift cylinder Machine specifications...

  • Page 26: Technical Specifications

    Mower conditioner FC4000RG 2. Technical specifications Attachment type 3 point linkage category 2 and 3 Number of discs Working width 4.00 m (13’1’’) Width in working position 6.40 m (20’11’’) Height in working position 1.64 m (5’5’’) Length in working position 5.82 m (19’1’’)

  • Page 27: Putting Into Service

    Mower conditioner FC4000RG $Putting into service 1. Description of control elements The machine is supplied with an 18 mm box wrench (1) to carry out certain adjustment and maintenance tasks. 2. Coupling and uncoupling Description of coupling elements - A PTO shaft 1 3/8’’ - 21 splines.
  • Page 28 Mower conditioner FC4000RG Preparing the tractor The machine adapts to tractors fitted with a 3-point hitch coupler category 2 or 3. The tractor must be fitted with lower link stabilizers. The tractor PTO stub must rotate at a speed of 1000 min The tractor must be equipped with: - 1 double acting hydraulic outlet.
  • Page 29 Mower conditioner FC4000RG Coupling the machine The machine adapts to tractors fitted with a 3-point hitch coupler category 2 (a) or 3 (b). - Lower the tractor three-point linkage. - Place the lower links as close as possible under the hitch pins.
  • Page 30 Mower conditioner FC4000RG Hydraulic connections - Connect the 2 hydraulic hoses of the drawbar shift cylinder to a double acting valve (1). - Connect the mowing unit lift cylinder to a single acting valve (2). Electrical connections - Connect 7-pin plug to the tractor.
  • Page 31 Mower conditioner FC4000RG Primary PTO shaft Make sure that the PTO shaft is correctly adjusted, to avoid premature wear and tear. 1000 The direction of rotation is shown on a decal. Separate the two half PTO shafts and connect them to the machine's input shaft and to the tractor PTO stub.
  • Page 32 Mower conditioner FC4000RG Attach PTO shaft guard chain in hole (1) on machine side. Immediately replace any worn or damaged guard. Putting into service...
  • Page 33 Mower conditioner FC4000RG Primary PTO shaft Friction slip clutch The machine is fitted with a friction slip clutch. Before the machine is put into service and after a long period of non-use, check the function of slip clutch to ensure it is not locked up.
  • Page 34 Mower conditioner FC4000RG Adjusting the machine Lateral adjustment of the lower links. Balance the play on either sides of the lift linkage and lock lower link stabilizers. Frame height and check chains - Lower tractor lift linkage until hitch pins are at a distance (H) slightly over 600 mm (1’11’’) from the...
  • Page 35 Mower conditioner FC4000RG Uncoupling the machine Park the machine on an even fairly level ground. Preferably park the machine in transport position, with the mowing unit resting on the ground. - Lower the mowing unit on the ground using mowing unit lift cylinders.

  • Page 36: Instructions For Transport

    Mower conditioner FC4000RG $Instructions for transport Before placing the machine into transport position: - Wait until the rotating parts have come to a complete stop. - Check that nobody is within the machine pivoting area. - If there is someone, make sure the person moves away.
  • Page 37 Mower conditioner FC4000RG - Shut-off mowing unit lift cylinder lock valves (1). Opened position (1). Closed position (2). The machine is in transport position. Never engage the tractor PTO drive when the machine is in transport position. Instructions for transport...

  • Page 38: Conformity With The Road Regulations

    Mower conditioner FC4000RG 2. Conformity with the road regulations Before driving the machine on public roads, ensure that the machine complies with current highway code regulations. - Check that the light boards are clean and that the lighting equipment functions before transporting the machine on public roads.

  • Page 39: Instructions For Work

    Mower conditioner FC4000RG $Instructions for work Before placing the machine in working position: - Check that nobody is within the machine pivoting area. - If there is someone, make sure the person moves away. 1. Putting the machine into work...
  • Page 40 Mower conditioner FC4000RG - Operate drawbar shift cylinder to put drawbar in working position. - Lower the mowing unit using the machine lift cylinders. The machine is in working position. Instructions for work...

  • Page 41: Adjustments In Working Position

    Mower conditioner FC4000RG 2. Adjustments in working position Cutting height Place the machine on flat ground. The cutting height is adjusted with the machine attached, hitch pins 600 mm (1’11’’) from the ground. The height can be adjusted from 26 to 100 mm (1" - 4’’).
  • Page 42 Mower conditioner FC4000RG Reduced or increased ground pressure The mowing unit is suspended by means of floatation springs (1). To adjust the suspension From the working position: - Loosen chain (1) to release crank (2). • Turn clockwise to reduce the ground pressure until the mowing unit comes off the ground.
  • Page 43 Mower conditioner FC4000RG Conditioning intensity The machine is fitted with two sets of rollers. Conditioning intensity is determined by the pressure exerted by the two rollers. The pressure can be adjusted from 0 to 5 daN/cm (0 - 25 lbf/in).
  • Page 44 Mower conditioner FC4000RG Checking the roller parallelism and gap The machine is fitted with two sets of rollers Tie-rods (1) located on each conditioner are factory adjusted to ensure the parallelism and a minimum play between rollers. Fold and lock front guards.
  • Page 45 Mower conditioner FC4000RG Readjust if necessary: - Loosen counter nut (1). - Tighten nut (2) to increase gap between rollers. - Unscrew nut (2) to reduce gap between rollers. Check minimum gap between rollers: J = 1.5 à 3 mm (0.05’’ - 0.12’’) Check parallelism over the whole roller width.
  • Page 46 Mower conditioner FC4000RG Swathing system The swathing system comprises: - 2 swath shields (1). - 2 swath screens (2). swath width adjusted approximately 1.00 to 2.40 m (3’3’’ - 7’10’’). "Wide swaths" configuration Swath width adjustment: - Loosen 4 handles (3): •...

  • Page 47: Machine Use

    Mower conditioner FC4000RG 3. Machine use Before mowing and to reduce risks of projections, lower side guards and front guard. Check that nobody is within the machine pivoting area. Keep all persons and animals away from the machine danger zone.

  • Page 48: Optional Equipment

    Mower conditioner FC4000RG $Optional equipment 1. 1 3/4 - 20 spline yoke Kit no. 4503713 A specific yoke is available as option for tractors equipped with a 20 spline pto stub. Optional equipment...

  • Page 49: Maintenance And Storage

    Mower conditioner FC4000RG $Maintenance and storage Before carrying out any maintenance or repairs on the machine, switch off the tractor engine, remove ignition key, wait until all moving parts have come to a standstill and remove PTO shaft. 1. Frequency chart...

  • Page 50: Lubrication

    Mower conditioner FC4000RG 2. Lubrication Except for the secondary PTO shaft lubrication, the machine must be placed in transport position for all maintenance operations (knife replacement, lubrication, etc). - Clean grease nipples before greasing. Lubricate with multi-purpose grease grade NLGI 2.
  • Page 51 Mower conditioner FC4000RG Intermediate PTO shafts - Every 20 hours: • universal joints (1). • transmission tube (2). - Every 100 hours: • guide rings (3). The pictorials show the points to be greased (1): Tertiary PTO shaft - Every 100 hours: •...
  • Page 52 Mower conditioner FC4000RG Oil change The cutterbar Before draining oil, operate the machine for a few minutes so that the oil warms up. The cutterbar is lubricated with 2.6 L (0.69 US gal) of extreme-pressure gear oil with viscosity grade SAE 80W90 and API grade GL5.
  • Page 53 Mower conditioner FC4000RG Central gearbox Before draining oil, operate the machine for a few minutes so that the oil warms up. The main gearbox is lubricated with 3.5 L (0.92 US gal) of extreme-pressure gear oil with viscosity grade SAE 80W90 and API grade GL5.
  • Page 54 Mower conditioner FC4000RG Gearbox Before draining oil, operate the machine for a few minutes so that the oil warms up. The angle gearbox is lubricated with 0.4 L (0.11 US gal) of extreme-pressure oil for mechanical transmissions with viscosity grade SAE 80W90 and API grade GL5.
  • Page 55 Mower conditioner FC4000RG The Gyrodine gearbox Before draining oil, operate the machine for a few minutes so that the oil warms up. The Gyrodine gearbox is lubricated with 5.5 L (1.45 US gal) of extreme-pressure gear oil with SAE 80W90 viscosity grade API and GL5.
  • Page 56 Mower conditioner FC4000RG Grease - The drawbar pivot pin (1). - The Gyrodine hitch tube pivot pins (1) and (2). - The suspension rock levers (1). - The pitch angle rod (1). Maintenance and storage...
  • Page 57 Mower conditioner FC4000RG Roller bearing housings (1). The pivot cylinders (1). The roller drive chains: - Remove cover (1). - Clean cover and chain. - Pack chain and cover with grease. - Install cover (1). - Torque bolts to (2).

  • Page 58: Maintenance

    Mower conditioner FC4000RG 3. Maintenance Checking cutterbar oil level Regularly check the cutterbar oil level: - Place the cutterbar in horizontal position (with regards to X and Y axis). - Remove filler plug (1) and (2) as well as their seals.
  • Page 59 Mower conditioner FC4000RG Checking the oil levels Gyrodine gearbox - Check oil level in lower gearbox: • The "MAX" level corresponds to the mark on the dipstick plug (A). • The "MIN" level corresponds to the end of the dipstick plug (B).
  • Page 60 Mower conditioner FC4000RG Inspection of knives and securing elements Immediately replace worn or damaged parts with genuine KUHN parts. Knives Inspect systematically all knives before the machine is operated to: - guarantee the cutting quality. - guarantee safety in use.
  • Page 61 Mower conditioner FC4000RG Fixing elements Check the fixing elements: - After hitting an obstacle. - When replacing knives. - At the beginning of each season. The fixing bolts should be changed in the following cases: - When there is visible distortion.
  • Page 62 Mower conditioner FC4000RG Knife replacement Replace knife lock-nuts and bolts when they have been removed 5 times. Replace immediately all worn or distorted knives. Never straighten a bent knife. Always replace both knives per disc. Clean the nut case. Place a wooden wedge between two discs to stop them from rotating.
  • Page 63 Mower conditioner FC4000RG Upper roller drive chains Checking the chain for wear Preliminary operation - Check play between rollers (Factory setting): • J = 3 mm (1/8’’) - Readjust if necessary: • Loosen counter nut (1). • Tighten or loosen nut (2).
  • Page 64 Mower conditioner FC4000RG Stage 2: - Rotate upper roller back and forth by hand. - Check that there is no contact between the two roller profiles. - Otherwise, replace the chain. - Proceed the same way on the other side.
  • Page 65 Mower conditioner FC4000RG - Rotate the roller to tension the lower chain strand. - Mark sprocket (1) and shaft end (2). - Mark sprocket (3), shaft end (4) and holder (5). marks enable start roller synchronization operation correctly. - Remove sprockets (1) and chain (2).
  • Page 66 Mower conditioner FC4000RG Roller synchronization Lugs of the upper roller should be centered withing lugs of lower roll with lower span of chain tight. - Remove the wooden wedge. - Slowly rotate the disk to check the timing at several locations.

  • Page 67: Storage

    Mower conditioner FC4000RG 4. Storage At the end of each season - Clean the machine thoroughly. - Drain all gearboxes and cutterbar and refill with new oil (see "Lubrication" chapter). - Touch up any areas of damaged paintwork. - Put the machine under cover in a dry place.

  • Page 68: Trouble Shooting Guide

    Mower conditioner FC4000RG $Trouble shooting guide Problem Cause Remedy Dull or broken knives. Replace knives. Make sure the arrow on the Knives not installed correctly. knife upper face is pointing in the disc's direction of rotation. Excessive ground speed. Reduce ground speed.
  • Page 69 Mower conditioner FC4000RG $Appendix 1. Calculating the load on an axle When coupling a tool to the front and rear 3-point lift linkage, the maximum authorized payload must not be exceeded. The load on the tractor front axle must always represent 20 % of the tractor unladen weight.
  • Page 70 Mower conditioner FC4000RG Rear tool or front-rear combination: 1) Calculation of the minimum front ballast weight M1 minimum M2 x (c+d) - T1 x b + 0.2 x T x b minimum Write the minimal additional weight in the chart.
  • Page 71 Mower conditioner FC4000RG Table: Actual value obtained Value authorized Double value of the by calculation according to authorized capacity operator's manual per tyre (2 tyres) Minimum front/rear ballasting kg ≤ Total weight kg ≤ kg ≤ Load on front axle kg ≤...
  • Page 72 Mower conditioner FC4000RG Determining the machine weight (M2) and the position of its centre of gravity (d) If the data required to calculate the total weight, axle loads and minimum ballasting are not supplied, use the following method. Tractor only: - T1: Load on front axle.
  • Page 73 Mower conditioner FC4000RG - T: Axle loads. • Tractor only. T=_______kg T=_______kg Appendix...
  • Page 74 Mower conditioner FC4000RG Rear tool or front-rear combination: If the total unit weight exceeds the tractor Gross Combined Weight Rating in accordance with the countrie's legislation, empty the hopper to travel on public roads. In any case, we recommend to travel on public roads with empty hoppers and tanks.

  • Page 75: Limited Warranty

    KUHN equipment from an authorized KUHN dealer, that such equipment is, at the time of delivery to such purchaser, free from defects in material and workmanship, and that such equipment is covered under this Limited Warranty providing the machine is used and serviced in accordance with the recommendations in the Operator's manual.
  • Page 76 - The warranty claim is completed on line via extranet - www.kuhn.com or submitted on a KUHN warranty claim form and returned to the Company within one month after the date of failure or the date of problem becoming apparent.
  • Page 77 $Specimen of the "Declaration of conformity" EC Declaration of conformity (European directive 2006/42/CE) The manufacturer: KUHN S.A., 4 impasse des fabriques B.P. 50060 F - 67706 SAVERNE CEDEX declares that the product described hereafter: Type: ’’Machine name’’ Serial no.: ’’Machine serial number’’...
  • Page 80 Société Anonyme au Capital de 2 530 000 Euros KUHN-BLANCHARD SAS - 24, route de Nantes - F - 44680 CHEMERE (FRANCE) Tél. : + 33 (0) 2 40 21 30 24 - Fax : + 33 (0) 2 40 64 80 11 Société...

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