KUHN FC3160TCD, Operator'S Manual

Page 1: ...Original instructions KN284BGB A OPERATOR S MANUAL Mower conditioner FC3160TCD 3560TCD 4060TCD KN284BGB A English 11 2013 ...

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Page 3: ...parts are manufactured and carefully inspected in the same factory that builds the machine to assure high quality and accurate fitting of any necessary replacements About improvements We are continually striving to improve our products It therefore reserves the right to make improvements or changes when it becomes practical to do so without incurring any obligations to make changes or additions to...

Page 4: ...ment 7 Safety instructions 8 Location and description of safety decals on the machine 21 Road safety equipment and recommendations 25 Machine specifications 28 Description and glossary 28 Technical specifications 31 Required equipment 32 Sound levels 32 Putting into service 33 Description of control elements 33 Coupling and uncoupling 34 Instructions for transport 47 Putting the machine into trans...

Page 5: ...tion 50 Adjustments in working position 51 Machine use 61 Optional equipment 62 Check chains 62 Lifters 62 Swath shields for offset swathing 63 1 3 8 21 spline yoke 63 Maintenance and storage 64 Frequency chart 64 Cleaning the machine 65 Lubrication 66 Maintenance 74 Storage 101 Troubleshooting guide 102 Limited warranty 104 ...

Page 6: ...Mower conditioner 4 FC3160TCD 3560TCD 4060TCD Identification of the machine KN284BGB A Identification of the machine 1 Front view 2 Rear view ...

Page 7: ...elow the type and serial number of the machine This information is to be indicated to the dealer for all spare parts orders Type FC3160TCD Serial no Type FC3560TCD Serial no Type FC4060TCD Serial no TYPE MASSE kg KUHN S A 67700 SAVERNE FRANCE N MADE IN FRANCE TY PE MA SS E kg KUHN S A 67 70 0 SA VE RN E FR AN CE N MA DE IN FRA NCE ...

Page 8: ...3160TCD 3560TCD 4060TCD Identification of the machine KN284BGB A 4 Optional equipment Tick box corresponding to the equipment fitted on your machine Check chains Lifters Swath shields for offset swathing 1 3 8 21 spline yoke ...

Page 9: ...is 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 This symbol is used to communicate technical information of particular interest ...

Page 10: ...safety regulations for preventing accidents The operator must imperatively respect safety instructions in this manual and in the warnings posted on the machine The operator is also obliged to respect current legislation concerning accident prevention work safety and public traffic circulation Designated use of the machine also means following operation maintenance and repair recommendations given ...

Page 11: ... 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 Ensure that all operating controls ropes cables rods etc are placed so as they cannot be operated unintentionally and cause damage or injury Before operating the machine check tightness of nuts and bolts particularly on fi...

Page 12: ...e operator exercises caution in every given situation Groundspeed must be adapted to ground conditions as well as to roads and paths Always avoid abrupt changes of direction Be particularly cautious when turning corners paying attention to machine overhang length height and weight Never use a narrow track tractor on very uneven or steeply sloping ground Never leave the tractor seat while the machi...

Page 13: ...weight its lift capacity or the permissible maximum load on the attachment and the maximum load per axle The front axle load 1 must never under any circumstances be less than 20 of the tractor s unladen weight If necessary add ballast weights to the front or to the rear to preserve the steering and braking efficiency Do not exceed the gross machine weight rating or the maximum machine axle load al...

Page 14: ...Replace any missing or broken equipment Maximum speed Always keep to the legal speed limit for driving a tractor machine assembly on public roads 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 15: ...e hydraulic hoses In case of normal wear replace the hydraulic hoses every 5 years Damaged or worn hoses must immediately be replaced When replacing the hydraulic hoses only use hoses with the specification recommended by the manufacturer of the machine To locate a leak use appropriate means Protect body and hands from liquid under pressure Any liquid under pressure particularly oil from hydraulic...

Page 16: ...us or even a lethal accident Do not wear loose clothing that could be caught in the rotating PTO shaft Before attaching or removing a PTO shaft or before doing any work on the machine disengage the PTO drive turn off the engine remove ignition key and wait for all moving parts have come to a complete stop If the primary PTO shaft is equipped with a torque limiter or a free wheel these must be fitt...

Page 17: ...lap the end of the splined shaft and the added adaptor device as outlined in the table When uncoupling the machine rest the PTO shaft on the support specially provided and replace protective shield on the PTO stub of the tractor Read and follow the instructions in the operator s manual provided with the PTO shaft A PTO type Diameter X splines A 5 mm 0 20 1 35 mm 1 378 6 85 mm 3 35 2 35 mm 1 378 21...

Page 18: ...g can exist when components are operated by hydraulic or pneumatic controls Keep away from these danger zones Tyres Regularly check the tyre pressure Respect manufacturers recommendations on pressure Assembly disassembly and repair of wheels and tyres must only be carried out by competent persons who are equipped with standardized tools Before any work is performed on the wheels ensure that the ma...

Page 19: ...d accidents Always keep the safety decals clean and readable and replace them when they are worn damaged missing or illegible Waste disposal Respect the environment Never spill pollutants oil grease filters etc on the ground never pour them down the drain and never discard them in any other place where they could pollute the environment Never throw away or burn a tyre Always take waste to speciali...

Page 20: ... done on the electric circuit or before any electric welding is carried out on the attached machine disconnect the machine from the tractor electrical circuit Also disconnect alternator and battery terminals Repairs on elements under pressure or tension springs pressure accumulators etc must only be carried out by competent persons with regulation equipment Wear the appropriate protective clothing...

Page 21: ...ease the cutting height to avoid contact with stones or rocks 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 Keep all persons and animals away from the danger zone The protection covers help reducing ris...

Page 22: ...e any worn damaged or missing cover Before engaging the PTO rest the cutterbar on the ground Make sure all the guards are in place Keep all persons and animals away from the danger zone Stay a safe distance from the machine when the cutting tools are in movement Never work in reverse After disengaging the PTO drive cuttings tools can continue rotating for some time Stay away from the machine until...

Page 23: ...Safety Mower conditioner FC3160TCD 3560TCD 4060TCD 21 KN284BGB A 3 Location and description of safety decals on the machine Location of safety decals 1 2 7 3 4 6 599011001 59900300 3 6 6 6 4 59900300 ...

Page 24: ...Working on the machine 2 Before leaving the tractor or before adjusting maintaining or repairing the machine disengage the PTO drive turn off the engine remove ignition key and wait until all moving parts have come to a complete stop and apply park brake Projections 3 Stones and other debris projected by the moving parts can travel a long distance The protection covers must always be in position a...

Page 25: ...crushing risk before all moving parts have come to a complete stop Manoeuvring area 5 Stay a safe distance from the machine Crushing hazard Rotating cutting tools 6 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 59900300 59900600 ...

Page 26: ... KN284BGB A Cutting tools 7 The cutting tools and their attachment hardware meet safety and reliability criteria set by standards and by the manufacturer For your own safety and for correct machine operation only use original manufacturer parts 599011001 ...

Page 27: ...ep to the legal speed limit for driving a tractor machine assembly on public roads Whatever the speed we recommend for everyones safety not to exceed a maximum speed of 40 km h The rear safety device comprises 2 signalling panels 1 2 signalling lights 2 red light stop light turn signal light 4 red triangular reflectors 3 1 identification plate light 4 The side device comprises 3 amber reflectors 1...

Page 28: ... FC3160TCD 3560TCD 4060TCD Safety KN284BGB A The front safety device comprises 2 signalling panels 1 2 white lights 2 2 white reflectors 3 Tyre pressure Tyre pressure 1 5 bar 22 5 psi 3 2 1 1 3 2 1 5 bar 22 5 psi 09969200 ...

Page 29: ... legal speed limit of 25 km h for driving a tractor machine assembly on public roads Coupling device Couple the machine to a tractor that is equipped with a system for locking the lift arms laterally and vertically To drive on roads respect the attachment height specified in the operator s manual and lock the lift linkage 1 ...

Page 30: ...fications KN284BGB A Machine specifications 1 Description and glossary 0 0 1 Check chain Optional equipment 2 Drawbar 3 Drawbar shift cylinder 4 Front guard 5 Side guard 6 Wheel 7 Wide spreading system 8 Side gearbox 9 Intermediate PTO shaft 2 1 2 3 4 5 6 7 8 9 ...

Page 31: ...Machine specifications Mower conditioner FC3160TCD 3560TCD 4060TCD 29 KN284BGB A 0 0 1 Intermediate PTO shaft 1 2 Cutterbar 3 Pitch angle adjustment rod 4 Conditioning lever adjustment 1 4 2 3 ...

Page 32: ...60TCD Machine specifications KN284BGB A 0 0 1 Parking stand 2 Hitch pin category 2 3 Hitch pin category 3 4 PTO shaft support 5 Gyrodine gearbox 6 Gyrodine hitch tube 7 Toolbox 8 Special tool 9 Wheel chocks 10 Document box 1 2 4 5 6 7 8 3 10 9 ...

Page 33: ...ion 5 71 m 18 9 5 71 m 18 9 6 27 m 20 7 Width in transport position 3 00 m 9 10 3 50 m 11 6 4 02 m 13 2 Height in transport position 1 78 m 5 10 1 78 m 5 10 1 78 m 5 10 Length in transport position 6 74 m 22 1 6 74 m 22 1 7 29 m 23 11 Disc rotational speed 2900 min 1 Rotor speed 780 and 1000 min 1 Rotor width 2 46 m 8 1 2 87 m 9 5 2 87 m 9 5 PTO speed 1000 min 1 Weight 2340 kg 5159 lb 2477 kg 5461...

Page 34: ...achine under control in case of linkage breakage during transport 4 Sound levels Sound levels have been measured in accordance with the measuring methods as defined in NF EN ISO 4254 1 Agricultural machinery Safety Part 1 General requirements Weighted equivalent continuous acoustic pressure level at the driver s seat closed cabin L A eq Tractor only 72 4 dB A Tractor machine 76 2 dB A ...

Page 35: ...s The machine is supplied with a 13 mm spanner 1 for unlocking the greasing covers The machine is supplied with an 18 mm box wrench 2 to carry out certain adjustment and maintenance tasks The machine is supplied with a 30 mm wrench 3 to adjust the ground pressure The machine is supplied with a tool for replacing the knives 1 1 1 2 3 ...

Page 36: ... Two hydraulic hoses controlling the drawbar shift cylinder A 7 pin electric plug for the electrical signalling equipment Preparing the tractor The machine adapts to tractors fitted with a 3 point hitch coupler category 2 or 3 The tractor PTO stub must rotate at a speed of 1000 min 1 The tractor must be equipped with 1 double acting hydraulic outlet 1 single acting hydraulic outlet The tractor mus...

Page 37: ...Putting into service Mower conditioner FC3160TCD 3560TCD 4060TCD 35 KN284BGB A Hitch pin parallelism Adjust tractor lift rods so that hitch pins are parallel to the ground A A ...

Page 38: ...r the tractor three point linkage Place the lower links as close as possible under the hitch pins Attach lower links to the hitch pins on the inside of the yokes The machine adapts to tractors fitted with a 3 point hitch coupler category 2 a or 3 b Secure with lynch pins Do not lose spacers 1 a b 1 1 1 1 ...

Page 39: ...ree point linkage Fold parking stand and lock it in place a 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 machine 7 pin plug on the tractor 7 pin socket a 1 2 1 ...

Page 40: ...Mower conditioner 38 FC3160TCD 3560TCD 4060TCD Putting into service KN284BGB A Fit check chain See section Frame height adjustment to position the check chain ...

Page 41: ...d tubes should not butt against the yokes As a safety measure a clearance L of at least 25 mm 1 must be maintained When the PTO shaft is in its maximum extended position the tube overlap must be more than 250 mm 10 If this is not the case Mark length H to cut when the transmission is the maximum overlap position Shorten the guard tubes and the transmission tubes by the same length Bevel and clean ...

Page 42: ...ft at an angle X exceeding 30 Attach PTO shaft guard chain in hole 1 on machine side To avoid serious accidents the PTO drive shaft guards must be properly in place and fixed with the chains provided Do not attach the drive guard chain to the guard cone Immediately replace any worn or damaged guard X X 1 ...

Page 43: ...aft is fitted with a friction slip clutch Remove 4 bolts 1 Remove guard plate 2 Before adjusting maintaining or repairing the machine turn off ignition key and wait until all moving parts have come to a complete stop 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 1 2 ...

Page 44: ...friction discs slip for a few seconds b FC3160 3560 Tighten nuts until distance L is 34 mm 1 34 FC4060 Tighten nuts until distance L is 33 mm 1 3 The friction slip clutch is ready to function Do not fully tighten springs to prevent damage on drive elements The springs must never be coil bound Loosen at least by 1 2 turn a c b L ...

Page 45: ...Putting into service Mower conditioner FC3160TCD 3560TCD 4060TCD 43 KN284BGB A Reinstall guard plate 2 Reinstall the 4 screws 1 1 2 ...

Page 46: ...justing 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 650 mm 2 1 6 from the ground L H ...

Page 47: ...top link attachment clevis Lower the tractor lift until check chains are tensioned Uncoupling the machine Lower the mowing unit on the ground using mowing unit lift cylinders Lower and lock parking stand a Remove and store check chains Lower the tractor three point linkage to rest the machine on the ground Park the machine on an even fairly level ground Preferably park the machine in transport pos...

Page 48: ...BGB A Block machine with wheel chocks 1 Uncouple and place PTO shaft in support 1 Disconnect and store hydraulic hoses on holder 2 Disconnect and store 7 pin plug in its holder 3 Release the lower links Lower the tractor three point linkage The machine is uncoupled 1 1 1 3 2 ...

Page 49: ...ders to fully raise the machine Operate drawbar shift cylinder to put the drawbar in transport position Shut off drawbar shift cylinder lock valve 1 Shut off mowing unit lift cylinder lock valves 2 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 pers...

Page 50: ...e guard using 18mm box spanner supplied with the machine The side guard automatically locks in raised position Repeat procedure on the second side guard The machine is in transport position Opened position 1 Closed position 2 Never engage the tractor PTO drive when the machine is in transport position 1 2 ...

Page 51: ...ic roads ensure that the machine complies with current highway code regulations Check that the drawbar shift cylinder and mowing unit lift cylinder lock valves are shut off Immediately replace any worn or damaged signalling panels or lights Regularly check the tyre pressure In certain countries the machine exceeds the maximum legal size to drive on public roads If the machine is over the maximum l...

Page 52: ...ock valves Activate the transport work cylinder control valve in the pivot into work position Lower the mowing unit using the machine lift cylinders Pull on handles 1 to unlock the side guards Lower and lock side guards The machine is in working position Before placing the machine in working position Check that nobody is within the machine pivoting area If there is someone make sure the person mov...

Page 53: ...k 2 Turn clockwise to reduce cutting height a Turn counter clockwise to increase the cutting height b Lower lock 2 Before making any adjustment Check that nobody is within the machine pivoting area If there is someone make sure the person moves away Wait until the rotating parts have come to a complete stop Place the machine on flat ground The cutting height is adjusted with the machine attached h...

Page 54: ...GB A The maximum cutting height L1 85 mm 3 3 is obtained when the discs are parallel to the ground The minimum cutting height must not be below L2 25 mm 1 Too low a cutting height can lead to Excessive disc and knife wear Crop being contaminated by soil Delay in regrowth L1 L2 ...

Page 55: ... F must equal approximately 60 daN 135 lbf on each side To adjust the suspension Move the locking plate upwardly to release the rotation of the adjustment screw The ground pressure is adjusted independently on each side of the mower unit The pressure must be adapted to the nature and moisture degree of the ground Raise the mowing unit for easier ground pressure adjustment Adjust both sides to the ...

Page 56: ...ssure Turn clockwise to increase the ground pressure 30 1 wrench 5 rotations of the adjustment screw corresponding to a variation of 15 20 daN Should you have difficulties in adjusting the mowing unit ground pressure it may be necessary to adjust the ground pressure system s torsion bars See maintenance and storage chapter a b 1 ...

Page 57: ... 1000 min 1 Rotor speed adjustment To change the speed use lever 1 Select the rabbit position to obtain a rotor speed of 1000 min 1 Select the turtle position to obtain a rotor speed of 780 min 1 Always place the machine in working position before making rotor speed rotational frequency adjustments Turn off the engine remove ignition key and wait until all moving parts have come to a complete stop...

Page 58: ...distance between the conditioning hood and the conditioning rotor To reduce the conditioning intensity for mowing leguminous for example increase the distance between the conditioning hood and the conditioning rotor Before adjusting maintaining or repairing the machine turn off ignition key and wait until all moving parts have come to a complete stop Refer to the pictorial applied on the machine t...

Page 59: ...duce the swath width a Pivot swath shields outwards to increase the swath width b Lower the handle 2 as far as it will go Reinstall R clip 1 Proceed the same way on the other side FC3160TCD The swath width can be adjusted of approximately 0 90 m 2 11 to 2 30 m 7 7 FC3560TCD FC4060TCD The swath width can be adjusted of approximately 1 10 m 3 7 to 2 70 m 8 10 Stop 1 enables preventing interferences ...

Page 60: ... required result is obtained Wide spreading system The wide spreading equipment comprises 9 spreading fins To switch from swathing mode to wide spreading mode Remove R clip 1 Lift handle 2 Pivot swath shield until lock engages in hole 3 The spreading fins pivot automatically when activating the drawbar shift cylinder The wide spreading kit is used to spread out crop in even layers The spreading fi...

Page 61: ...drawbar Insert shield hood in the hole a Lift handle to lock the shield to the drawbar holder b Reinstall R clip 1 Proceed the same way on the other side Loosen the wing nut 1 Slide the screw along oblong hole a to unlock the wide spreading device Pivot the wide spreading device 2 Lock the wide spreading device using the screw and tighten wing nut 1 1 1 a b 2 3 1 a b 2 ...

Page 62: ... 1 over the wide spreading device The machine is in wide spreading configuration To switch from wide spreading mode to swathing mode Carry out the procedure in reverse This step allows preventing premature wear of the cover as well as a reduction of the wide spreading system s efficiency 1 ...

Page 63: ...oundspeed Before mowing and to reduce risks of projections lower side guards and front guards Check guard locking Check that latches 1 are attached Check that nobody is within the machine pivoting area If there is someone make sure the person moves away The machine is lifted from working position into headland turn position by means of the mowing unit lift cylinders 1 Adapt the forward speed to th...

Page 64: ...uipment 1 Check chains Check chains allow tractor lift linkage stabilization and ensure a fixed frame height The check chain enables maintaining the machine under control in case of linkage breakage during transport 2 Lifters The lifters allow improving forage transport to the conditioner ...

Page 65: ... FC3160TCD 3560TCD 4060TCD 63 KN284BGB A 3 Swath shields for offset swathing The swathing shield for offset swathing enables bringing two swaths closer to each other for easier pick up 4 1 3 8 21 spline yoke For a pto speed of 1000 min 1 ...

Page 66: ... adjusting maintaining or repairing the machine turn off ignition key and wait until all moving parts have come to a complete stop After the first 30 hours of use Every 20 hours Every 200 hours or at the end of the season Lubrication Oil change Gearbox Side gearbox Gyrodine gearbox Grease Drawbar pivot point Drawbar shift cylinder ...

Page 67: ... 4060TCD 65 KN284BGB A 2 Cleaning the machine Regularly clean the build up between the conditioning hood and the support tube Unlock and lift front guard using 18 box spanner supplied with the machine Raise protection cover 1 Clean Lower and lock front guards 1 ...

Page 68: ...ours universal joints 1 transmission tube 2 Guide rings 3 Universal joint assembly b Every 50 hours universal joints 1 Intermediate PTO shaft 1 c Every 20 hours universal joints 1 transmission tube 2 Guide rings 3 Intermediate PTO shaft 2 d Every 20 hours universal joints 1 transmission tube 2 Guide rings 3 Lubricate with multi purpose grease grade NLGI 2 a b c d 1 1 3 3 2 ...

Page 69: ...en screw 1 Pivot cover 2 to access greaser Grease PTO shaft U joint Reinstall guard Intermediate PTO shaft 1 c Loosen bolts 1 Pivot cover 2 to access greaser Grease Grease PTO shaft U joint Drive shaft tubes Reinstall cover plate Step on the self adhesive non slip patches 1 to access the other greasers 1 2 1 2 1 1 ...

Page 70: ...storage KN284BGB A Grease the U joints Intermediate PTO shaft 2 d Loosen screw 1 Pivot cover 2 to access greaser Grease Grease PTO shaft U joint Drive shaft tubes Reinstall cover plate Step on the self adhesive non slip patches 1 to access the other greasers 1 2 1 ...

Page 71: ...Maintenance and storage Mower conditioner FC3160TCD 3560TCD 4060TCD 69 KN284BGB A Grease the U joints Grease The drawbar pivot pin Drawbar shift cylinder ...

Page 72: ...f necessary Reinstall skid shoe 1 Lower and lock side guards The cutterbar is lubricated for life and requires no periodic maintenance If in doubt as to the oil quantity contained in the cutterbar fully drain and refill cutterbar respecting recommended oil quantity and quality Following all service operations or in case of an oil leak empty an refill cutterbar Before draining oil operate the machi...

Page 73: ...corresponds to the end of the dipstick plug Clean and reinstall filler plug 1 and its washer Replace if necessary Before draining oil operate the machine for a few minutes so that the oil warms up 1 2 The angle gearbox is lubricated with 1 2 L 0 32 US gal of extreme pressure oil for mechanical transmissions with viscosity grade SAE 80W and API grade GL4 When draining and refilling it is recommende...

Page 74: ...n and reinstall filler plug 1 and its washer Replace if necessary Before draining oil operate the machine for a few minutes so that the oil warms up The angle gearbox is lubricated with extreme pressure gear oil with viscosity grade SAE 80W and API grade GL4 FC3160 TCD 2 L 0 53 US gal FC3560 TCD 2 L 0 53 US gal FC4060 TCD 2 3 L 0 61 US gal When draining and refilling it is recommended to use eithe...

Page 75: ...ck plug The MIN level corresponds to the end of the dipstick plug Clean and reinstall filler plug 1 and its washer Replace if necessary Before draining oil operate the machine for a few minutes so that the oil warms up 1 1 The Gyrodine gearbox is lubricated with 2 75 L 0 73 US gal of extreme pressure gear oil with SAE 80W viscosity grade API and GL4 When draining and refilling it is recommended to...

Page 76: ...odine gearbox Check Gyrodine gearbox level The MAX level corresponds to the mark on the dipstick plug A The MIN level corresponds to the end of the dipstick plug B Gearbox Check gearbox oil level The MAX level corresponds to the mark on the dipstick plug A The MIN level corresponds to the end of the dipstick plug B B A B A ...

Page 77: ...Maintenance and storage Mower conditioner FC3160TCD 3560TCD 4060TCD 75 KN284BGB A Side gearbox Check side bevel gearbox oil level The oil level must reach lower part of level plug hole ...

Page 78: ...ace knives in the following cases Damaged knives Very rough conditions can cause knives to crack and become deformed Worn knives Knife length C must exceed 80 mm 3 15 Knife width B measured at a distance A of 10 mm 0 39 from the disc edge must exceed 34 mm 1 34 The hole L for the securing bolt must not become oval by more than 22 mm 0 87 Immediately replace worn or damaged parts with genuine KUHN ...

Page 79: ...Maintenance and storage Mower conditioner FC3160TCD 3560TCD 4060TCD 77 KN284BGB A Disc direction of rotation FC3160TCD FC3560TCD FC4060TCD ...

Page 80: ...the following cases 2 When there is visible distortion When the locking compound is worn or inoperational When the bolt head wear reaches the center line of the bolt When diameter D of the bolt shoulder is less than 11 mm 0 43 See section Disc replacement Slightly hit all ground residues between the knife and the screw with a mallet to remove them The radial play between a worn bolt and a new knif...

Page 81: ...t A 20 mm 0 8 must exceed 60 mm 2 4 Knife replacement Check the condition of the fixing elements regularly and also the torque of the knife fixing bolt Torque 12 daN m 89 lbf ft See section Spring plate replacement 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 apply park brak...

Page 82: ...ool between disc and spring plate Pivot special tool downwards to free spring plate from screw head Make sure that the securing nut and bolt are in good condition and if necessary replace them Torque 12 daN m 89 lbf ft Dull knives require more horse power and have a negative effect on the cut quality Slightly hit all ground residues between the knife and the screw with a mallet to remove them ...

Page 83: ...ation Pivot special tool downwards to free spring plate from screw head Insert the new knife on the screw head Refer to self adhesive fitted on the machine to check the codes and dimensions of the knives Press knife upwards and pull it towards yourself before releasing the special tool a b c Checking the full locking and free rotation of the knife on the screw head a b K9C064TL 0 OPTIDISC 2011 116...

Page 84: ...late hole 3 Remove special tool Rotate disk by half a turn Repeat previous tasks Repeat previous tasks on the other disks Disc replacement Place a wooden wedge 1 between two discs to stop them from moving Remove the 4 bolts 2 and their conical washers After replacing the last knife check that the tool has been removed and put away 1 2 ...

Page 85: ...isk Reinstalling Refit the disc 2 Respect disc direction of rotation according to fitting of knives Make sure the arrow on the knife upper face is pointing in the disc s direction of rotation Reinstall disc cover 1 Respect an X of 90 between neighboring discs Reinstall bolts 1 and their conical washers Position conical centre of washers at the top 1 2 X X A A 1 ...

Page 86: ...dge 1 between two discs to stop them from moving Torque bolts to 2 Torque 12 daN m 89 lbf ft Remove locking piece Check that there is a minimum play of X 1 mm 0 04 between the spring plate and the cutter bar skids Otherwise position spacer s two maximum between the housing and the spring plate 1 2 X ...

Page 87: ...KN284BGB A Spring plate replacement Inner disc Intermediate discs Remove the disc See section Disc replacement Remove spring plate 1 Refit the disc See section Disc replacement The replacement of the inner disc spring plate must be carried out by a Kuhn authorized dealer 1 ...

Page 88: ...in adjusting the mowing unit ground pressure it may be necessary to adjust the ground pressure system s torsion bars Adjustment procedure Use mowing unit lift cylinder to lift the mowing unit Position 2 blocks between ground and cutterbar 1 Shut off mowing unit lift cylinder lock valves 2 Remove 4 bolts 1 Remove hood 2 Remove circlip 1 2 1 1 2 1 ...

Page 89: ... 1 screw in the threaded hole on the shaft end Rotate adjustment screw 1 to release pressure on the torsion bar Extract torsion bar 1 from its housing by pulling on screw 2 This screw will facilitate extracting and inserting the torsion bar in its housing Mark position of the torsion bar 1 1 2 1 ...

Page 90: ...te adjustment screw while pushing on the torsion bar until reaching the following spline Rotate in direction a if the cutter bar is too light and in direction b if the cutter bar is too heavy Remove screw 1 Reinstall retaining ring 1 The splines are spaced at approximately 17 17 a b 1 1 ...

Page 91: ...conditioner FC3160TCD 3560TCD 4060TCD 89 KN284BGB A Reinstall hood 2 Reinstall the 4 bolts 1 Remove wedges 1 Open the mowing unit lift cylinder lock valves 2 Repeat procedure on the other side of the moving unit if necessary 1 2 2 1 ...

Page 92: ...acement Respect mounting order Fit roll pins at 180 to each other with slots lined up in the direction of the main load FC3160TCD FC3560TCD FC4060TCD Immediately replace worn or damaged parts with original manufacturer parts Respect the position of short and long fingers to avoid interference with the cutter bar ...

Page 93: ... the mowing unit Position 2 blocks between ground and cutterbar 1 Shut off mowing unit lift cylinder lock valves 2 The rotor safety system is fitted with 3 nuts Nuts are spaced at 120 If all 3 nuts have been used replace them See chapter Maintenance and storage Maintenance Rotor safety system Replacement of the rotor safety system nuts Immediately replace worn or damaged parts with original manufa...

Page 94: ...aintenance and storage KN284BGB A Release and lift side guard using 18mm box spanner supplied with the machine Remove the 3 nuts 1 Remove guard 2 Stop rotor from rotating Intervene on the pitch angle adjustment rod for easier access to the guard 2 1 ...

Page 95: ...ter bar by hand to place hole 2 opposite the next nut Fit the new screw Torque 2 5 daNm 18 5 lbf ft Use exclusively KUHN original parts 5 spare M8 x 31 bolts are supplied with the machine Check the shearing bolt class Machine Shearing bolt class FC3160TCD 10 9 FC3560TCD FC4060TCD Make sure to release the rotor rotation 2 1 ...

Page 96: ...60TCD 4060TCD Maintenance and storage KN284BGB A Reinstall guard 2 Reinstall the 3 nuts 1 Pull on handles 1 to unlock the side guards Lower and lock side guards Remove wedges 1 Open the mowing unit lift cylinder lock valves 2 2 1 2 2 1 ...

Page 97: ...eplace them Use mowing unit lift cylinder to lift the mowing unit Position 2 blocks between ground and cutterbar 1 Shut off mowing unit lift cylinder lock valves 2 Release and lift side guard using 18mm box spanner supplied with the machine Remove the 3 nuts 1 Remove guard 2 Immediately replace worn or damaged parts with original manufacturer parts 2 1 2 1 ...

Page 98: ...wer conditioner 96 FC3160TCD 3560TCD 4060TCD Maintenance and storage KN284BGB A Stop rotor from rotating Remove screw 1 and washer 2 Place a wooden wedge 1 between two discs to stop them from moving 2 1 1 ...

Page 99: ...A Remove bolts 1 Remove the rotor safety system Remove bolts 2 Remove flange 3 Remove the 3 pieces of damaged bolt Replace the 3 self locking nuts 4 Use exclusively KUHN original parts 3 self locking nuts M8 are supplied with the machine Place nut locks on the flange side 3 1 3 2 4 ...

Page 100: ... 2 Torque 13 5 daNm 100 lbf ft Prior to reassembly coat surface 4 with graphite grease Fit the new screw 5 Torque 2 5 daNm 18 5 lbf ft Use exclusively KUHN original parts 5 spare M8 x 31 bolts are supplied with the machine Check the shearing bolt class Machine Shearing bolt class FC3160TCD 10 9 FC3560TCD FC4060TCD 3 2 4 5 ...

Page 101: ...0TCD 4060TCD 99 KN284BGB A Reinstall the rotor safety system Reinstall the 3 bolts 3 Torque 13 5 daNm 100 lbf ft Reinstall screw 1 and washer 2 Torque 8 5 daNm 63 lbf ft Make sure to release the rotor rotation Do not forget to remove the wooden wedge 2 3 1 ...

Page 102: ...60TCD 4060TCD Maintenance and storage KN284BGB A Reinstall guard 2 Reinstall the 3 nuts 1 Pull on handles 1 to unlock the side guards Lower and lock side guards Remove wedges 1 Open the mowing unit lift cylinder lock valves 2 2 1 2 2 1 ...

Page 103: ...amaged fingers on the conditioning rotor Depressurize all hydraulic functions Grease the cylinder rods in contact with the outside At the start of each season Pressurize the hydraulic circuit Check the condition of the friction slip clutch see Secondary pto shaft chapter Inspect and replace worn knives and bolts See chapter Inspection of knives and securing elements Check that all nuts and bolts a...

Page 104: ...much cutterbar down pressure Adjust the mowing unit ground pressure Very wet working conditions Adjust the mowing unit ground pressure Adjust the cutting height Obstruction of conditioning rotor Insufficient rotor speed rotational frequency Adjust the finger conditioning rotor speed Too low PTO speed rotational frequency Check PTO speed Refer to the decal fitted on the machine Swath shields too cl...

Page 105: ...ssible to decrease or increase the mowing unit ground pressure sufficiently Soil build up on the machine and Maximum ground pressure reduction Adjust torsion bars of the ground pressure system See maintenance and storage chapter Insufficient ground pressure and Minimum ground pressure reduction The rotor is no longer driven The safety system shear bolt has sheared Replace screw See maintenance and...

Page 106: ...nt of the manufacturer concerned in as much as the latter justifies such a claim This Limited Warranty does not apply to failure through normal wear and tear to damage resulting from negligence or from lack of inspection from misuse from lack of maintenance and or if the machine has been involved in an accident lent out or used for purposes other than those for which it was intended by the Company...

Page 107: ...quality and quantity of lubricants used must always be in accordance with Company specifications The safety measures mentioned in the Operator s manual and on the machine itself have been followed and all the guards and protective elements of whatever nature have been inspected regularly and maintained in perfect working order The judgment of the Company in all case of claims under this Limited Wa...

Page 108: ...nforms to the requirements of following European harmonized standards conforms to the requirements of the European directive 2006 42 CE Brand Brand Machine Machine Type Model Type Model Serial no Serial no declares that the product described hereafter Manufacturer name and address The manufacturer Name and address of the person authorised to compile the technical file 2 y r o t a n g i S 1 y r o t...

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Page 112: ...2 40 21 30 24 Fax 33 0 2 40 64 80 11 Société par Action Simplifiée au Capital de 2 000 000 Euros KUHN HUARD S A B P 49 F 44142 CHATEAUBRIANT CEDEX FRANCE Tél 33 0 2 40 55 77 00 Fax 33 0 2 40 55 77 10 Société Anonyme au Capital de 4 800 000 Euros KUHN GELDROP B V P O Box 9 5660 AA GELDROP THE NETHERLANDS Tél 31 0 40 289 33 00 Fax 31 0 40 285 78 95 KUHN NORTH AMERICA INC P O Box 167 Brodhead WI 5352...