Kemper 460 User manual

460
Rotary Harvesting Unit
OPERATOR’S MANUAL
460 Rotary Harvesting Unit
OMKM99164 ISSUE E9 (ENGLISH)
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
If this product contains a gasoline engine:
WARNING
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
The State of California requires the above two warnings.
Kemper
European Edition
PRINTED IN GERMANY

Introduction
KM00321,0000169 1914MAY091/1
Foreword
READ THIS MANUAL carefully to learn how to operate
and service your machine correctly. Failure to do so
could result in personal injury or equipment damage.
This manual and the safety signs on your machine may
also be available in other languages (see your KEMPER
dealer to order).
THIS MANUAL SHOULD BE CONSIDERED a permanent
part of your machine and should remain with the machine
when you sell it.
MEASUREMENTS IN THIS MANUAL are given in metric
units. The customary U.S. unit equivalents are also
quoted. Use only correct replacement parts and fasteners.
Metric and inch fasteners may require a specific metric
or inch wrench.
RIGHTHAND AND LEFTHAND sides are determined
by facing in the direction the implement will travel when
going forward.
THE TERM "TRANSPORT" refers to a rotary harvesting
unit mounted on a forage harvester and transported from
A to B on the forage harvester.
THE TERM "HAULAGE" refers to a rotary harvesting unit
loaded on a flatbed carrier and transported from A to B
on the flatbed carrier.
WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)
in the Specification or Identification Numbers section.
Please note all numbers exactly. In the event of theft,
these numbers may prove vital in tracing your property.
Your KEMPER dealer also needs these numbers when
you order parts. File the identification numbers in a secure
place off the engine or machine.
BEFORE DELIVERING THIS MACHINE, your dealer
performed a predelivery inspection.
THIS ROTARY HARVESTING UNIT IS DESIGNED
SOLELY for use in customary agricultural or similar
operations ("INTENDED USE"). Use in any other way
is considered as contrary to the intended use. The
manufacturer accepts no liability for damage or injury
resulting from this misuse, and these risks must be borne
solely by the user. Compliance with and strict adherence
to the conditions of operation, service and repair as
specified by the manufacturer also constitute essential
elements for the intended use.
THIS ROTARY HARVESTING UNIT SHOULD BE
operated, serviced and repaired only by persons familiar
with all its particular characteristics and acquainted
with the relevant safety rules (accident prevention).
The accident prevention regulations, all other generally
recognized regulations on safety and occupational
medicine and the road traffic regulations must be observed
at all times. Any arbitrary modifications carried out on this
rotary harvesting unit will relieve the manufacturer of all
liability for any resulting damage or injury.
070909
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Contents
Page
Predelivery Inspection
Predelivery Checklist ...................................CLIST1
Delivery Checklist.........................................CLIST1
AfterSale Checklist......................................CLIST2
Identification View
Identification View...............................................001
Safety
Recognize Safety Information ............................051
Follow Safety Instructions...................................051
Understand Signal Words...................................051
Observe Road Traffic Regulations......................052
Use Safety Lights and Devices...........................052
Prepare for Emergencies....................................052
Wear Protective Clothing....................................053
Check Machine Safety........................................053
Guards and Shields............................................053
Stay Clear of Harvesting Unit .............................053
Keep Hands Away From Knives.........................054
Store Attachments Safely...................................054
Practice Safe Maintenance.................................055
Stay Clear of Rotating Drivelines........................055
Service Machines Safely ....................................056
Support Machine Properly..................................056
Avoid HighPressure Fluids ................................056
Transport with Harvesting Unit Installed.............057
Ballasting for Safe Ground Contact....................057
Remove Paint Before Welding or Heating..........057
Dispose of Waste Properly .................................058
Safety Decals
Pictorial Safety Signs..........................................101
Operator’s Manual..............................................101
Repair and Maintenance ....................................101
Rotary Harvesting Unit .......................................102
Rotating Blade....................................................102
Folding Area .......................................................103
Rotating Drums...................................................103
Hydraulic System................................................104
Hanging Points ...................................................104
Haulage
Prepare the Rotary Harvesting Unit for
Haulage..........................................................151
Transport Pallet ..................................................152
Page
Loading with a Crane..........................................152
Prepare the Rotary Harvesting Unit
Unpacking...........................................................201
Remove Tensioner Strap ....................................201
Removing the Transport Pallet ...........................201
Align Drive Case (Rotary Harvesting
Units for NEW HOLLAND Forage
Harvesters Only) ............................................202
Adapt the Scrapers to the Feed Passage...........202
Installation on a CLAAS Forage Harvester
Compatibility Chart (Forage
Harvesters, Types 491, 492,
493 and 494) ..................................................251
Installation on the CLAAS Forage Harvester......252
Connect Hydraulic Hoses...................................252
Connect the Drive (Type 492).............................253
Connect the Drive (Types 493 and 494).............254
Installation on NEW HOLLAND and CASE Forage
Harvesters
Compatibility Chart (NEW HOLLAND
and CASE Forage Harvesters) ......................301
Install Mounting Rail ...........................................301
Installation on NEW HOLLAND and
CASE Forage Harvesters...............................302
Connect Drive Shaft ...........................................302
Install Guards for U.J. Shaft on Forage
Harvester........................................................303
Install Guard for U.J. Shaft on Rotary
Harvesting Unit...............................................303
Connect Hydraulic Hoses...................................304
Removal of the Rotary Harvesting Unit
Detach the Rotary Harvesting Unit .....................351
Transport
Transport Information .........................................401
Fold the Rotary Harvesting Unit .........................401
Close Safety Relief Valve (Rotary
Harvesting Units for CLAAS Forage
Harvesters Only) ............................................401
Accident Prevention............................................402
Lock/Unlock Tilt Frame.......................................403
Driving on Public Road.......................................404
Continued on next page
Original Instructions. All information, illustrations and specifications in this
manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2009
All rights reserved.
i070909
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Contents
Page
Operation of the Rotary Harvesting Unit
Method of Operating the Rotary
Harvesting Unit...............................................451
Put Outer Dividers into Operating Position.........452
Adjusting the Feed Bars .....................................453
Gathering Drum Operating Speeds....................454
LengthofCut Adjustment with NEW
HOLLAND Forage Harvester .........................454
Length of Cut and Drum Speeds with
NEW HOLLAND Forage Harvesters
FX 50 and FX 60 ............................................456
LengthofCut Adjustment with CLAAS
Forage Harvester ...........................................456
Length of Cut and Drum Speeds with
CLAAS Forage Harvester 860880
(Type 491) ......................................................457
Length of Cut and Drum Speeds with
CLAAS Forage Harvester 830900
(Type 492) ......................................................457
Length of Cut and Drum Speeds with
CLAAS Forage Harvester 830900
(Type 493) ......................................................458
Length of Cut and Drum Speeds with
CLAAS Forage Harvester 930980
(Type 494) ....................................................4510
Harvesting ........................................................4510
Clear Blockages ............................................... 4511
Accessories
Short Crop Dividers ............................................501
Troubleshooting
460 Rotary Harvesting Unit ................................551
Lubrication and Maintenance
Service Intervals.................................................601
Lubricants...........................................................601
Transmission Oil.................................................602
Coolant for Main Drive Friction Clutch................602
Alternative and Synthetic Lubricants ..................603
Mixing Lubricants................................................603
Lubricant Storage ...............................................603
At the Start of Every Harvesting Season............603
At the Start of Every Harvesting
Season—Spherical Collar Bolts .....................604
At the Start of Every Harvesting
Season—Gearbox Mounting Flange
Attaching Screws ...........................................605
General View of Drives and Oil Levels
in the Rotary Harvesting Unit .........................606
After Every 10 Hours in Service .........................607
After Every 50 Hours in Service .........................609
Every 3 Years—Change Coolant of
Main Drive Friction Clutch ..............................609
After Each Harvesting Season .........................6010
Maintenance
Metric Bolt and Screw Torque Values.................651
Page
Relieve Pressure on the Main Drive
Slip Clutches ..................................................652
Disassemble Slip Clutch.....................................653
Install New Rotating Blades................................654
Checking the Drive for the DownCrop Auger ....655
Adjusting Gatherer Points...................................655
Check End Switches of Folding Mechanism ......656
Checking Scrapers Adjustment ..........................656
Adjusting Cleaners .............................................657
Storage
Storage at End of Harvesting Season ................701
Start of New Season...........................................701
Specifications
460 Rotary Harvesting Unit ................................751
Declaration of Conformity...................................751
EU Declaration of Conformity .............................752
Serial Numbers
Serial Number Plate of the Rotary
Harvesting Unit...............................................801
Serial Number.....................................................801
ii 070909
PN=2

Predelivery Inspection
OUCC002,0002814 1914OCT071/1
OUCC002,0002815 1914OCT071/1
Predelivery Checklist
After the 460 rotary harvesting unit has been completely
assembled, inspect it to be sure it is in good running order
before delivering it to the customer. Check off each item
when found satisfactory or after making the necessary
adjustments.
□ All shields open and close freely.
□ Rotary harvesting unit has been properly assembled.
□ Parts delivered separately have been properly installed.
□ All screws and nuts have been tightened to specified
torque. Pay particular attention to the screws that hold on
the knives. Comply with the tightening torques quoted in
the “Service” section.
□ All grease fittings have been lubricated.
□ All the gear cases have been filled with the correct
quantity of the correct oil/grease/coolant (see “Lubrication
and Periodic Service” section).
□ Shipping bracket removed (see also “Haulage” section).
□ Rotary harvesting unit can be folded correctly.
□ Rotary harvesting unit has been cleaned and touched
up wherever paint is nicked or scratched.
□ All moving parts are working freely.
□ Check all slip clutches as shown in the “Service” section.
□ All decals are in place and in good condition.
□ This rotary harvesting unit has been tested and, to
the best of my knowledge, is ready for delivery to the
customer.
(Date Tested) (Signature of Technician)
Delivery Checklist
The following checklist is a reminder of very important
information which should be conveyed directly to the
customer when delivering the machine.
□ The customer has been advised that the life expectancy
of this or any other machine depends on regular lubrication
as described in this operator’s manual.
□ Proper harvesting management practices have been
discussed; these are required for good silage.
□ This operator’s manual has been handed over to the
customer and all the operating adjustments have been
fully explained.
□ The customer has been advised that the only tire sizes,
fluids and pressures that may be used are those quoted
in the cutterhead specifications and forage harvester
documents.
□ The customer has been advised of the necessity to
check the tension of the downcrop auger drive belts after
the first 20 hours of operation and to check their tension
regularly after that.
□ The customer has been advised of the safety
precautions that must be observed while using the rotary
harvest unit.
□ The customer has been invited to come in and discuss
any problems that may be encountered while operating
the rotary harvest unit.
□ The customer has been told to record the serial number
of his rotary harvesting unit in the space provided in the
“Serial Number” section.
□ The shipping bracket has been handed over to the
customer.
□ This page has been filled out and removed for filing.
(Signature of Technician) (Signature of Customer)
CLIST1 070909
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Predelivery Inspection
OUCC002,0002816 1914OCT071/1
AfterSale Checklist
The following items should be checked on the new rotary
harvesting unit at the start of the harvesting season.
□ All screws and nuts have been tightened to specified
torque. Pay particular attention to the screws that hold on
the knives. Comply with the tightening torques quoted in
the “Service” section.
□ All safety shields are in place and fastened securely.
□ Check for broken or damaged parts. Replace any
broken or damaged parts with genuine spare parts.
□ If possible, run the rotary harvesting unit to see if it is
functioning properly.
□ Check for worn rotary knives.
□ Once again discuss proper harvesting management
practices; these are required for good silage.
□ Review the entire operator’s manual together with your
customer and stress the importance of proper and regular
lubrication, as well as safety precautions.
(Signature of Technician) (Signature of Customer)
CLIST2 070909
PN=6

Identification View
KM00321,000016A 1914MAY091/1
Identification View
KM1000857 —UN—14MAY09
001 070909
PN=7

Safety
DX,ALERT 1929SEP981/1
KM00321,000016B 1914MAY091/1
DX,SIGNAL 1903MAR931/1
Recognize Safety Information
This is a safetyalert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe operating
practices.
T81389 —UN—07DEC88
Follow Safety Instructions
Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
available from your KEMPER dealer.
Before you start working with the machine, learn how to
operate the machine and how to use controls properly. Do
not let anyone operate without instruction.
Keep your machine in proper working condition.
Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need
assistance, contact your KEMPER dealer.
TS201 —UN—23AUG88
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is
used with the safetyalert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187 —19—30SEP88
051 070909
PN=8

Safety
FX,ROAD 1901MAY911/1
KM00321,000016C 1914MAY091/1
DX,FIRE2 1903MAR931/1
Observe Road Traffic Regulations
Always observe local road traffic regulations when using
public roads.
H28930 —UN—30JUN89
Use Safety Lights and Devices
Prevent collisions with other road users. Slow moving
tractors with implements or drawn equipment, as well
as selfpropelled machines are especially dangerous on
public roads. Always pay attention to traffic approaching
from behind, particularly when changing direction. Provide
for safe traffic conditions by using turn signals.
Use headlights, hazard warning lights, turn signals and
other safety devices according to the local regulations.
Keep safety devices in good condition. Replace missing
or damaged items.
TS951 —UN—12APR90
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.
TS291 —UN—23AUG88
052 070909
PN=9

Safety
DX,WEAR 1910SEP901/1
FX,READY 1928FEB911/1
FX,DEVICE 1904DEC901/1
ZX,CUT688 1910FEB981/1
Wear Protective Clothing
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
TS206 —UN—23AUG88
Check Machine Safety
Always check the road and general operating safety of
the machine before using.
Guards and Shields
Keep guards and shields in place at all times. Ensure that
they are serviceable and installed correctly.
Always disengage main clutch, shut off engine and
remove key before removing any guards or shields.
Keep hands, feet and clothing away from moving parts.
ES118703 —UN—21MAR95
Stay Clear of Harvesting Unit
Due to their function, the cutting rotors as well as
gathering, cross and feed drums cannot be completely
shielded. Stay clear of these moving elements during
operation. Always disengage main clutch, shut off engine
and remove key before servicing or unclogging harvesting
unit.
ES118704 —UN—21MAR95
053 070909
PN=10

Safety
FX,KNIFE 1921DEC901/1
DX,STORE 1903MAR931/1
Keep Hands Away From Knives
Never attempt to clear obstructions in front of or on
harvesting unit unless main clutch is disengaged, engine
shut off and key removed.
Everyone must be clear of the forage harvester before
starting the engine.
TS254 —UN—23AUG88
Store Attachments Safely
Stored attachments such as dual wheels, cage wheels,
and loaders can fall and cause serious injury or death.
Securely store attachments and implements to prevent
falling. Keep playing children and bystanders away from
storage area.
TS219 —UN—23AUG88
054 070909
PN=11

Safety
DX,SERV 1917FEB991/1
DX,PTO 1912SEP951/1
Practice Safe Maintenance
Understand service procedure before doing work. Keep
area clean and dry.
Never lubricate, service, or adjust machine while it is
moving. Keep hands, feet , and clothing from powerdriven
parts. Disengage all power and operate controls to relieve
pressure. Lower equipment to the ground. Stop the
engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be
raised for service work.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On selfpropelled equipment, disconnect battery ground
cable () before making adjustments on electrical systems
or welding on machine.
On towed implements, disconnect wiring harnesses from
tractor before servicing electrical system components or
welding on machine.
TS218 —UN—23AUG88
Stay Clear of Rotating Drivelines
Entanglement in rotating driveline can cause serious
injury or death.
Keep tractor master shield and driveline shields in place
at all times. Make sure rotating shields turn freely.
Wear close fitting clothing. Stop the engine and be sure
PTO driveline is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
TS1644 —UN—22AUG95
055 070909
PN=12

Safety
DX,LOOSE 1904JUN901/1
DX,LOWER 1924FEB001/1
KM00321,000016D 1914MAY091/1
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
TS228 —UN—23AUG88
Support Machine Properly
Always lower the attachment or implement to the ground
before you work on the machine. If the work requires
that the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
TS229 —UN—23AUG88
Avoid HighPressure Fluids
Escaping oil under pressure can have sufficient pressure
to penetrate the skin, causing serious personal injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Check and tighten
all connections before applying pressure.
Hydraulic oil escaping from pinholes is difficult to detect,
so use a piece of cardboard to search for leaks. Protect
hands and body from highpressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source.
X9811 —UN—23AUG88
056 070909
PN=13

Safety
ZX,HEADER676 1920JAN951/1
ZX,WEIGHT676 1920JAN951/1
DX,PAINT 1924JUL021/1
Transport with Harvesting Unit Installed
Before driving forage harvester on public roads, harvesting
unit must be raised and secured in the raised position. It
must not, however, obstruct operator’s view of the road.
ZX007219 —UN—21MAR95
Ballasting for Safe Ground Contact
Operating, steering and braking performance of forage
harvester can be considerably affected by attachments
which alter the center of gravity of the machine. To
maintain safe ground contact, ballast the harvester at the
rear end as necessary. Observe the maximum permissible
axle loads and total weights.
ZX007220 —UN—21MAR95
Remove Paint Before Welding or Heating
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:
•Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
•If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
•If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding
will take place.
TS220 —UN—23AUG88
Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
Dispose of paint and solvent properly.
057 070909
PN=14

Safety
KM00321,000016E 1914MAY091/1
Dispose of Waste Properly
If waste disposal is carried out improperly, this may
damage the environment and ecological systems.
Potentially harmful waste used with KEMPER equipment
include such items as oil, fuel, coolant, brake fluid, filters,
and batteries.
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down the drain, or
into any water source.
Airconditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified airconditioning service center to
recover and recycle used airconditioning refrigerants.
TS1133 —UN—26NOV90
058 070909
PN=15

Safety Decals
FX,WBZ 1919NOV911/1
OUCC002,0002839 1916OCT071/1
OUCC002,000283A 1916OCT071/1
Pictorial Safety Signs
At several important places of this machine safety signs
are affixed intended to signify potential danger. The
hazard is identified by a pictorial in a warning triangle.
An adjacent pictorial provides information how to avoid
personal injury. These safety signs, their placement on
the machine and a brief explanatory text are shown below.
TS231 —19—07OCT88
Operator’s Manual
This operator’s manual contains all important information
necessary for safe machine operation. Carefully observe
all safety rules to avoid accidents.
KM1000172 —UN—16OCT07
Repair and Maintenance
Before carrying out repair and maintenance work, shut
off engine and remove key.
KM1000173 —UN—16OCT07
101 070909
PN=16

Safety Decals
OUCC002,000283B 1916OCT071/1
OUCC002,000283C 1916OCT071/1
Rotary Harvesting Unit
Stay clear of rotary harvesting unit to avoid personal injury.
Arms, legs or loose clothing might become caught in the
rotary harvesting unit when in operation.
Always keep the required safety distance from the rotary
harvesting unit.
KM1000178 —UN—16OCT07KM1000179 —UN—16OCT07
Rotating Blade
Do not touch any moving machine parts. Wait until all
moving parts have stopped.
The rotating blades are not immediately stopped when
the machine is shut down.
KM1000174 —UN—16OCT07KM1000175 —UN—16OCT07
102 070909
PN=17

Safety Decals
OUCC002,000283D 1916OCT071/1
OUCC002,000283E 1916OCT071/1
Folding Area
Stay clear of the folding area of the rotary harvesting unit.
When folding or unfolding the rotary harvesting unit,
ensure that no persons are standing within the folding
area.
Before folding or unfolding, ensure that all persons keep
the required safety distance from the rotary harvesting
unit.
KM1000176 —UN—16OCT07KM1000177 —UN—16OCT07
Rotating Drums
Stay clear of rotating drums to avoid personal injury.
Arms, legs or loose clothing might become caught by the
rotating drums when in operation.
Always keep the required safety distance from the rotating
drums.
Wait until all moving parts have stopped.
KM1000180 —UN—16OCT07KM1000181 —UN—16OCT07
103 070909
PN=18

Safety Decals
OUCC002,000283F 1916OCT071/1
OUCC002,0002840 1916OCT071/1
Hydraulic System
The hydraulic pressure must not exceed 21000 kPa (210
bar; 3046 psi).
KM1000182 —UN—16OCT07
Hanging Points
Should the rotary harvesting unit be moved without
attaching to the forage harvester, always use the hanging
points.
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Haulage
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Prepare the Rotary Harvesting Unit
for Haulage
Install Tensioner Strap
Install tensioner strap (A) to prevent the outer sections
from lowering.
A—Tensioner strap
KM1000858 —UN—14MAY09
Swing Drive Case for Haulage (Rotary Harvesting
Units for NEW HOLLAND Forage Harvesters Only)
Before loading the unit, make it more compact by folding
up the drive case (B).
1. Slacken off the attaching screws on drive case (B) and
remove them.
2. Swing drive case (B) up.
3. Reinstall the attaching screws on drive case (B) and
tighten them.
KM1000859 —UN—14MAY09
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