Kemper 490plus User manual

Rotary harvesting unit
490plus
*OMKM121433*
OPERATOR'S MANUAL
490plus Rotary Harvesting Unit
OMKM121433 ISSUE K9 (ENGLISH)
Maschinenfabrik Kemper GmbH & Co. KG
European Edition
PRINTED IN U.S.A.

Introduction
KM00321,000070F -19-20DEC17-1/1
Foreword
READ THIS OPERATOR'S 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 rotary harvesting unit may be installed and
operated on a forage harvester only. The user must be
entitled to drive a forage harvester on public roads. This
manual and safety signs on your machine are available in
other languages. To order, see your KEMPER dealer.
THIS MANUAL SHOULD BE CONSIDERED a permanent
part of your machine and must 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. Only use components and bolts that fit. 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.
LOADING AND HAULAGE of this rotary harvesting unit
must be performed only by persons familiar with how the
load is secured, and who can provide evidence of this.
WRITE PRODUCT IDENTIFICATION NUMBERS (P.I.N.)
in the Specification or Identification Numbers section.
Record all numbers exactly. In the event of theft, these
numbers may prove vital in tracing your property. Your
KEMPER dealer needs these numbers when you order
parts. File the identification numbers in a secure place
away from machine.
BEFORE DELIVERING THIS MACHINE, your dealer
performed a predelivery inspection.
INTENDED USE: THIS ROTARY HARVESTING UNIT
may be used ONLY for harvesting:
•thick-stemmed, flexible types of plant such as corn,
elephant grass or bamboo
•thin-stemmed types of plant such as grain crop, mustard
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.
THIS ROTARY HARVESTING UNIT MUST NOT be
used to manually transfer materials of any sort and is not
suitable for the transfer and chopping of:
•woody plants with a diameter greater than 1 mm
•wood intended for chipping
•animal feed such as beets
•metallic objects
•materials that include stones
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 MUST be serviced
and repaired ONLY by industrial mechanics, fitters or
persons with comparable qualifications. The electrical
system must be repaired only by electricians. 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. It
is not permitted to alter the machine to accept materials
other than those permitted in its intended use. Any
arbitrary modifications carried out on this rotary harvesting
unit will relieve the manufacturer of all liability for any
resulting damage or injury.
THIS ROTARY HARVESTING UNIT MUST NOT be
operated in the United States and Canada.
120519
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Contents
Page
Pre-delivery Inspection
Predelivery Checklist....................................CLIST-1
Delivery Checklist.........................................CLIST-1
After-Sale Checklist......................................CLIST-2
Identification View
Identification View...............................................00-1
Safety Measures
Recognize Safety Information ............................05-1
Follow Safety Instructions...................................05-1
Understand Signal Words...................................05-1
Observe Road Traffic Regulations......................05-2
Operator Ability...................................................05-2
Use Safety Lights and Devices...........................05-2
Prepare for Emergencies....................................05-3
Wear Protective Clothing....................................05-3
Check Machine Safety........................................05-3
Guards and Shields............................................05-3
Stay Clear of the Intake Area .............................05-4
Stay Clear of Harvesting Unit .............................05-4
Keep Hands Away From Knives.........................05-4
Store Attachments Safely...................................05-5
Practice Safe Maintenance.................................05-5
Stay Clear of Rotating Drivelines........................05-6
Service Machines Safely ....................................05-6
Support Machine Properly..................................05-6
Avoid High-Pressure Fluids ................................05-7
Driving on Roads with Rotary
Harvesting Unit Attached ...............................05-7
Ballasting for Safe Ground Contact....................05-7
Remove Paint Before Welding or Heating..........05-8
Avoid High-Pressure Jet on Safety Decals.........05-8
Decommissioning — Proper Recycling
and Disposal of Fluids and Components .......05-9
Protect Against Noise.........................................05-9
Park Machine Safely.........................................05-10
Safety Decals
Pictorial Safety Signs..........................................10-1
Replace Safety Signs .........................................10-1
Operator's Manual ..............................................10-1
Repair and Maintenance ....................................10-2
Rotating Blades ..................................................10-2
Folding Area of the Rotary Harvesting Unit ........10-3
Stay Clear of Rotary Harvesting Unit..................10-3
Page
Rotating Drums...................................................10-4
Crushing Danger Area........................................10-4
Foldable Feed Bars ............................................10-5
Hydraulic Lines...................................................10-5
Driveshaft ...........................................................10-5
Input Transmission .............................................10-6
Haulage
Haulage of the rotary harvesting unit -
General Notes ................................................15-1
Loading with a crane (rotary harvesting
units up to serial no 135629)..........................15-1
Loading with a Crane (rotary harvesting
unit starting with Serial No. 135630) ..............15-3
Secure the Rotary Harvesting Unit for
Transport (Lashing Points).............................15-5
Preparing the Rotary Harvesting Unit
Unpacking...........................................................20-1
Remove the Transport Pallet..............................20-1
Bring the shipping stands to the parking
position...........................................................20-2
Attaching to a CLAAS Forage Harvester
Compatibility Chart (Forage
Harvesters, Types 498) ..................................25-1
Ballasting Harvester ...........................................25-1
Adjust additional headlights on forage
harvester ........................................................25-1
Attaching to a type 498 forage
harvester with variable header drive ..............25-2
Install additional wiring harness (only
forage harvesters of the types 498) ...............25-5
Attaching to CLAAS Forage Harvesters .............25-7
Rotary Harvesting Units with
Multi-Speed Gearbox and Quick Coupler ......25-8
Connect the wiring harness................................25-9
Connect Hydraulic Hoses...................................25-9
Replace CLAAS Tray with KEMPER Tray..........25-9
Detaching the Rotary Harvesting Unit
Detach the Rotary Harvesting Unit .....................30-1
Transport
Driving on Public Roads .....................................35-1
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 © 2019
John Deere GmbH & Co. KG Mannheim Regional Center
Zentralfunktionen
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
i120519
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Contents
Page
Fold the Rotary Harvesting Unit .........................35-1
Apply Decal (Rotary Harvesting Units
with Support Wheel).......................................35-1
Driving on Public Roads (Rotary
Harvesting Units with Comfort
Support Wheel) ..............................................35-2
Driving on Public Roads (Rotary
Harvesting Units without Comfort
Support Wheel) ..............................................35-3
Operating the Rotary Harvesting Unit
Rotary Harvesting Unit Method of Operation......40-1
Operating the Rotary Harvesting Unit -
General Use ...................................................40-2
Clear Blockages .................................................40-2
Clear Blockages on CLAAS Forage
Harvesters......................................................40-2
Feeder House Drum Operating Speeds .............40-3
Adjusting Gear Selection with
Multi-Speed Gearbox for CLAAS
Forage Harvesters .........................................40-4
Lengths of Cut and Gear Selection
with Multi-Speed Drive for CLAAS
Forage Harvesters .........................................40-5
Harvesting ..........................................................40-6
Hydraulic System................................................40-6
Troubleshooting
490plus Rotary Harvesting Unit............................45-1
Lubrication and Periodic Service
Service Intervals.................................................50-1
Fluid Grease for Drives.......................................50-1
Transmission Oil.................................................50-1
Coolant for Main Drive Friction Clutch................50-2
Alternative and Synthetic Lubricants ..................50-2
Mixing Lubricants................................................50-2
Lubricant Storage ...............................................50-2
At the Start of Every Harvesting Season............50-3
Use Genuine KEMPER Parts ............................50-3
At the Start of Every Harvesting
Season—Spherical Collar Bolts .....................50-3
At the Start of Every Harvesting
Season—Transmission Mounting
Flange Attaching Screws ...............................50-4
At the beginning of each harvesting
season — adjust latch of the chassis.............50-5
General View of Drives and Oil Levels
on the Rotary Harvesting Unit ........................50-6
Overview of Oil Levels in Input Transmission.....50-7
Every 10 Hours of Operation—Clean-
ers and Blade Rotor Segments ......................50-7
Every 10 Operating Hours—Balance Weights ...50-8
Every 50 Hours—Claw Clutch ............................50-8
Every 50 Hours—Lower Pin of
Hydraulic Cylinder and Pivots of the
Outer Units .....................................................50-9
Page
Every 50 hours of operation—Upper
rollers of the tilt frame (rotary
harvesting units for CLAAS forage
harvesters) .....................................................50-9
Every 50 hours of operation—Lower
rollers of the tilt frame (rotary
harvesting units for CLAAS forage
harvesters) .....................................................50-9
Every 50 hours of operation—Spring-
loaded pins...................................................50-10
Every 50 hours of operation—Axle pins
of the outer units ..........................................50-10
Every 50 operating hours—Fold cylinders........ 50-11
Every 50 operating hours—Latch jaws.............50-12
Every 3 Years—Change Coolant of
Main Drive Friction Clutch ............................50-13
After each harvesting season...........................50-14
Service
Metric Bolt and Screw Torque Values.................55-1
Check Main Drive Slip clutches ..........................55-2
Disassemble Slip Clutch.....................................55-3
Installing New Rotating Blades...........................55-4
Adjusting the Dividers.........................................55-5
Checking Adjustment of Scrapers
(Inner Drums) .................................................55-6
Checking Adjustment of Scrapers
(Outer Drums) ................................................55-6
Check Condition of Cleaners..............................55-7
Cleaning Rotary Harvesting Unit ........................55-8
Storage
Storage at End of Harvesting Season ................60-1
Start of New Season...........................................60-1
Technical specifications
Machine Design Life...........................................65-1
Rotary Harvesting Unit 490plus............................65-1
Sound level.........................................................65-1
EU Declaration of Conformity .............................65-2
Serial Number
Rotary Harvesting Unit Serial Number Plate ......70-1
Serial Number.....................................................70-1
ii 120519
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Pre-delivery Inspection
KM00321,00003C7 -19-12MAR15-1/1
KM00321,00008BF -19-01MAR19-1/1
Predelivery Checklist
After the 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).
□ 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 can move 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.
□ Advise the customer that the life expectancy of this
or any other machine depends on regular lubrication as
described in this operator's manual.
□ Discuss proper operation of the rotary harvesting unit
as well as the procedures and methods required for the
best harvest.
□ Give the Operator's Manual to the customer and explain
all operating settings.
□ Advise the customer of the proper weights and fluids
that must be used in the tires, depending upon the
individual forage harvester.
□ Rotary harvesting units for Claas forage harvesters
with variable header drive only: Programming A130FAM
Module.
□ Advise the customer of safety precautions that must be
observed while using the rotary harvesting unit.
□ Tell the customer to record the serial number of his
rotary harvesting unit in the space provided at the end
of this manual.
□ Remove this page and file it safely.
(Signature of Technician) (Signature of Customer)
CLIST-1 120519
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Pre-delivery 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 120519
PN=6

Identification View
KM00321,0000710 -19-21DEC17-1/1
Identification View
KM336547 —UN—24JAN18
00-1 120519
PN=7

Safety Measures
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—28JUN13
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—15APR13
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 120519
PN=8

Safety Measures
FX,ROAD -19-01MAY91-1/1
DX,ABILITY -19-07DEC18-1/1
KM00321,000016C -19-14MAY09-1/1
Observe Road Traffic Regulations
Always observe local road traffic regulations when using
public roads.
H28930 —UN—30JUN89
Operator Ability
•Machine owners must make sure that operators
are responsible, trained, have read the operating
instructions and warnings, and know how to operate the
machine properly and safely.
•Age, physical ability, and mental capacity can be factors
in machine-related injuries. Operators must be mentally
and physically capable of accessing the operator station
and/or controls, and operating the machine properly
and safely.
•Never allow a child or an untrained person to operate
the machine. Instruct all operators not to give children a
ride on the machine or an attachment.
•Never operate machine when distracted, fatigued,
or impaired. Proper machine operation requires the
operator’s full attention and awareness.
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
05-2 120519
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Safety Measures
DX,FIRE2 -19-03MAR93-1/1
DX,WEAR -19-10SEP90-1/1
FX,READY -19-28FEB91-1/1
FX,DEVICE -19-04DEC90-1/1
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—15APR13
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—15APR13
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
05-3 120519
PN=10