Kersten HyCut Installation instructions

Order number: B00108
From mach. no.:
Rev.: R01
Date: 2021-01-27
original operating
manual
tracked mower
HyCut

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All rights reserved. This documentation is protected by copyright. Kersten Arealmaschinen GmbH reserves
all rights that have not been expressly granted. This documentation may not be duplicated, disseminated or
made publicly accessible in any other way without prior written consent and except in cases permitted by the
law.
We reserve the right to make changes without prior notification. The original document was written in
German. All translations are copies of the original document.
Copyright 2021 Kersten Arealmaschinen GmbH
Kersten Arealmaschinen GmbH
Empeler Straße 95
46459 Rees
Germany
Telephone: [phone]
Fax: [phone]
[e-mail]
http://www.kersten-maschinen.de/

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Information about this operating manual
This manual enables the safe and efficient handling of the machine. This manual
forms part of the machine and must be kept close to the machine and within easy
reach at all times.
All operating personnel must have carefully read through and fully understood this
manual before using the machine. A basic requirement for safe working is
adherence to all the safety and handling instructions in this operating manual.
There is a risk of accidents and material damage if the machine is used
improperly!
Because the improper use of self-propelled equipment can result in accidents or
pose other potential hazards, the initial commissioning of this Kersten machine
requires mandatory training by competent, authorised personnel. Familiarise
yourself with the machine’s basic functions and the handling by choosing an even,
level area free of any obstacles when using the machine for the first time.
•For further information, or if you have any problems, please contact your
dealer, the importer or the manufacturer directly.
•Make sure to pass the safety instructions on to all other users.
In addition, all local occupational health and safety regulations and general safety
regulations for the machine's area of application apply.
Further applicable documents
In addition to this operating manual, the following documents and the safety
instructions that they contain must also be observed:
•Operating manual for the wireless remote control
•Operating manual for the combustion engine
Manufacturer customer service
For any technical information, please contact the machine manufacturer’s
customer service team:
Manufacturer’s address
Kersten Arealmaschinen GmbH
Empeler Straße 95
46459 Rees
Germany
Service telephone
+ 49 2851 9234-10
Fax
+ 49 2851 9234-44
Email
[e-mail]
Website
http://www.kersten-maschinen.de
Please have the following information at hand when making any queries:
•Machine / device type
•Machine order number
•If you are experiencing a problem: precise description or exact error
message

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1Preface 6
2Safety 7
2.1 Symbols in this operating manual ...................................................................................................... 7
2.2 Pictograms ......................................................................................................................................... 9
2.3 Intended use..................................................................................................................................... 11
2.4 Work areas and danger zones......................................................................................................... 11
2.5 Safety during the work processes.................................................................................................... 12
2.6 Mowing on slopes............................................................................................................................. 14
2.7 Safety devices.................................................................................................................................. 15
2.7.1 Emergency shutdown with the emergency stop button .............................................................. 16
2.8 Safety markings................................................................................................................................ 16
2.9 Residual risks................................................................................................................................... 17
2.10 Environmental protection.................................................................................................................. 20
3Functional description 22
3.1 Overview........................................................................................................................................... 22
4Transport, packaging and storage 25
4.1 Safety instructions............................................................................................................................ 25
4.2 Transport inspection......................................................................................................................... 25
4.3 Packaging......................................................................................................................................... 25
4.4 Transportation of the machine ......................................................................................................... 26
4.5 Towing / Recovery............................................................................................................................ 28
5Assembly, setting up, installation, initial commissioning 30
5.1 Safety instructions............................................................................................................................ 30
6Operation 31
6.1 Safety instructions............................................................................................................................ 31
6.2 Wireless remote control.................................................................................................................... 31
6.3 Turning on the tracked mower ......................................................................................................... 35
6.4 Moving off / turning on the mowing unit ........................................................................................... 36
6.5 Turning off the tracked mower ......................................................................................................... 37
7Maintenance 39
7.1 Safety instructions............................................................................................................................ 39
7.2 Spare parts....................................................................................................................................... 39
7.3 Maintenance work ............................................................................................................................ 39
7.3.1 Checking that the safety devices are functioning correctly......................................................... 39
7.3.2 Daily inspection........................................................................................................................... 40
7.3.3 Maintenance after 20 operating hours / Longer periods of downtime......................................... 41
7.3.4 Maintenance after 100 operating hours / Longer periods of downtime....................................... 42
7.4 Changing the blades of the mowing unit.......................................................................................... 43
7.4.1 Changing a disc and all the blades on it ..................................................................................... 44
7.4.2 Changing opposite blades........................................................................................................... 45
7.5 Cleaning the air filter ........................................................................................................................ 46
7.6 Lifting up the chain........................................................................................................................... 47

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7.7 Setting the chain tension.................................................................................................................. 49
7.8 Charging the batteries...................................................................................................................... 51
7.8.1 48-volt charging device ............................................................................................................... 52
7.8.2 24-volt charging device ............................................................................................................... 53
7.8.3 12-volt charging device ............................................................................................................... 54
7.9 Cleaning the machine....................................................................................................................... 55
7.10 Measures after maintenance has been performed .......................................................................... 55
7.11 Storage............................................................................................................................................. 56
8Malfunctions / Troubleshooting 57
8.1 Safety instructions............................................................................................................................ 57
8.2 Warning codes ................................................................................................................................. 57
8.3 Causes of malfunctions and how to remedy them........................................................................... 57
8.4 Petrol engine malfunction table........................................................................................................ 57
8.5 Control system malfunction table..................................................................................................... 59
8.6 Drive malfunction table..................................................................................................................... 59
8.7 Mowing unit drive malfunction table................................................................................................. 60
9Dismantling, disposal 61
9.1 Safety instructions............................................................................................................................ 61
9.2 Dismantling....................................................................................................................................... 61
9.3 Disposal............................................................................................................................................ 61
10 Technical Data 63
10.1 General information.......................................................................................................................... 63
10.2 Electric motors / batteries................................................................................................................. 63
10.3 Wireless remote control.................................................................................................................... 64
10.4 Engine type ...................................................................................................................................... 64
10.5 Declaration of Conformity................................................................................................................. 65

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1 Preface
Dear Customer,
Thank you for choosing a quality product from Kersten.
This product was manufactured according to the most up-to-date production
processes and using comprehensive quality assurance measures as our target is
only achieved when you are satisfied with your machine.
Please read this manual thoroughly and carefully before using the machine or
attachment for the first time.
If there is any information in the safety data sheet or in the product-specific
assembly or operating manual that you do not understand, please contact your
vendor or the machine manufacturer directly.
Please keep this manual at hand at all times. You can then read the important
information and instructions it contains when necessary.
We hope you enjoy using your new Kersten machine!
Dipl. Ing. (FH) Robert Bosch
Managing Director

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2 Safety
2.1 Symbols in this operating manual
Safety instructions
The following occupational safety symbols are used with all information regarding
occupational safety that indicate a risk to life and limb and usually consist of a
pictogram, a signal word and a signal colour.
In this documentation, you will find an explanation of hazardous situations at the
relevant points.
Please follow the information provided!
Ensure that you also follow all locally applicable safety and accident prevention
regulations!
DANGER
Type and source of the danger
This symbol warns users of an imminent danger to the life and health of
personnel.
Failure to follow the instructions and information provided can have a serious
impact on the health of personnel, including life-threatening injuries, and may
cause extensive material damage.
•Action that must be avoided so that the danger does not occur.
WARNING
Type and source of the danger
This symbol warns users of an impending danger to the life and health of
personnel that may also cause environmental and material damage.
Failure to follow the instructions and information provided can have a serious
impact on the health of personnel, including life-threatening injuries, and may
cause extensive environmental and material damage.
•Action that must be avoided so that the danger does not occur.
CAUTION
Type and source of the danger
This symbol warns users of an impending danger to the health of personnel that
may also cause environmental and material damage.
Failure to follow the instructions and information provided can have a minor or
moderate impact on the health of personnel, including injuries, and may cause
extensive environmental and material damage.
•Action that must be avoided so that the danger does not occur.

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NOTICE
Type and source of the machine or system damage
This symbol warns of a hazardous situation and identifies a notice on how to
handle the machine or system.
Failure to follow the instructions and information provided may lead to extensive
material damage.
•Action that must be avoided to prevent damage to the machine or system.
Tips and recommendations
This symbol draws users attention to useful tips and recommendation, as well as
information on how to operate the machine efficiently and without any
malfunctions.
Other types of identification
The following types of identification are used in this manual to identify instructions,
results, lists, references and other elements:
Identification
Explanation
1., 2., 3. ...
Step-by-step instructions
➔
Results of actions taken
•
List in no particular order
[Button]
Operating elements (e.g. button, switch), display elements
(e.g. signal lights)
“Display”
Display screen elements (e.g. buttons, assignment of
function keys)

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Pictograms
2.2 Pictograms
Follow the instructions in the operating manual
Only use the identified machine after having read the operating manual.
Wear protective workwear
This sign indicates that protective workwear must be worn in the area concerned.
Protective workwear is close-fitting work clothes with a low tensile strength, close-
fitting sleeves and without any protruding parts.
Wear safety shoes
This sign indicates that safety shoes must be worn in the area concerned.
Safety shoes protect the feet from being crushed and from falling parts and stops
the user from slipping on slippery surfaces.
Wear protective gloves
This sign indicates that protective gloves must be worn in the area concerned.
Protective gloves protect the hands against friction, abrasions, punctures, cuts or
deeper injuries and they protect the hands if they come into contact with hot
surfaces.
Wear protective eyewear
This sign indicates that protective eyewear must be worn in the area concerned.
Protective eyewear protects the eyes against flying parts and fluid splashes.

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Operating manual and safety instructions
Read and observe the operating manual and all safety instructions before starting
up the machine for the first time.
Never open or remove any protective devices while the engine is running.
Observe the information provided in the technical manual.
Note the lubrication points!
Do not touch any components until they have stopped moving completely.
Beware of parts flung from the machine while the engine is running.
Keep at a safe distance at all times!

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2.3 Intended use
WARNING
Risk of injury / risk of environmental damage caused by improper use of the
machine!
If the machine is used improperly, it may result in injury and can cause
environmental and material damage (to the machine or system)!
•The HyCut tracked mower has been designed for usual or common
mowing applications in the agricultural and forestry sectors, such as for the
maintenance of green spaces and parks.
•Any use going beyond this is deemed to be improper use. The
manufacturer does not assume liability for damage arising from such use.
The operator bears the sole risk.
•Adhering to the intended use includes complying with the manufacturer’s
operating, maintenance and repair specifications.
•The HyCut tracked mower may only be used, maintained and repaired by
people who are familiar with it and who have been instructed about the
associated hazards.
•All applicable accident prevention regulations and any applicable general
regulations regarding safety and occupational health must be observed
and followed.
•Any damages caused as a result of unauthorised modifications made to
the machine will be excluded from the manufacturer’s liability.
2.4 Work areas and danger zones
Fig.
1
: Danger zones (view from above)

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1 Ejection area of the cutting unit, max. 10 m
2 HyCut tracked mower
•RED ➔Danger zone (staying in this zone is prohibited / forbidden)
•GREEN ➔Work area (the entire area that needs to be cultivated)
WARNING
Risk of injury / risk of environmental damage from working / staying in the
danger zone!
There is a risk of injury and environmental damage (to the machine and system)
from working / staying in the danger zone!
•The user is responsible for protecting others present in the danger zone of
the machine.
•Staying within the danger zone of the machine is forbidden! Ensure that all
people leave the danger zone.
•If anyone approaches the danger zone, the machine must be stopped
immediately.
•The operator must ensure that there are no people or material assets in the
potential ejection area.
•Check the danger zone before turning on the mower and starting off. Pay
particular attention to children and animals. The operator must ensure that
they have sufficient visibility!
•In areas with poor visibility, stop the machine and ensure that nobody is in
the danger zone.
•Remove any obstacles or debris from the area to be cultivated before
starting work. Look out for and remove obstacles or debris during work to
avoid collisions.
•When working in the immediate vicinity of public streets and roads, ensure
that the ejection area of the mower is within the work area in order to
reduce the risk of injury to others.
•When working in, or in the immediate vicinity of, public spaces, set up the
relevant information and warning signs to make others in the area aware of
the work being performed.
2.5 Safety during the work processes
WARNING
Risk of injury / Risk of environmental damage due to non-compliance with
safety measures!
If the safety measures are not complied with, this can result in injury and
environmental and material damage (to the machine)!
•Never leave the HyCut tracked mower unattended when it is moving.
•Follow the information and instructions in this operating manual and
comply with all general occupational safety and accident prevention
regulations.

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•The HyCut tracked mower should never be operated by children under the
age of 16, even if they are being supervised by an adult! Never allow
children or teenagers to play with the machine.
•The machine should be used by authorised personnel only.
•Follow all applicable legal requirements when using the machine on public
roads!
•The HyCut tracked mower is not permitted for use on public roads.
•Users should always wear close-fitting clothing. Avoid wearing loose
clothing and wear sturdy footwear or safety shoes.
•Only work in good light and visibility!
•The information and warning signs attached to the machine contain
important instructions for safe operation. You must observe them for your
own safety!
•The machine must be turned off before being transported outside of the
work area on a vehicle or trailer!
•Pay special attention when using rotating mulching blades - Keep at a safe
distance!
•Pay special attention to trailing mulching blades. Before starting any work
on these, ensure that they have come to a complete stop!
•If the mulching blades become blocked by a foreign object, the emergency
stop button must be pressed immediately. Before cleaning the mowing unit
with a suitable tool, the tracked mower must be turned off. To do this, turn
the mower over and pull out the disconnect switch.
•Driven parts pose a risk of crushing and shearing!
•It is forbidden to use the machine to transport people and objects!
•The contours of the terrain / slopes may affect the machine’s handling,
steering, braking ability and stability. Always adjust your working speed to
the local conditions.
•Never make unauthorised modifications to the machine as they may
compromise its operational safety!
•If the tracked mower is damaged in any way, the emergency stop button
must be pressed immediately. Before repairing any damage, the tracked
mower must be turned off. To do so, turn the mower over and pull out the
disconnect switch.
•When working on slopes, the accompanying person must stand above the
vehicle at a sufficient distance from the HyCut tracked mower. We
recommend that the operator wears crampons if necessary.
•Always travel across slopes rather than up and down them wherever
possible.
•Do not use the machine on slopes in damp or rainy conditions.
•If the steering malfunctions, stop the HyCut tracked mower immediately
and turn off the engine. Repair the malfunction immediately.
•Check the machine’s operational safety before each use!
•If the HyCut tracked mower starts slipping when on a slope, press the
emergency stop button on the remote control immediately.

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2.6 Mowing on slopes
Fig.
2
: Mowing on slopes
1 Position above the slope above the tracked mower
2 Position above the slope next to the tracked mower
3 Position on the slope
4 Position below the slope next to the tracked mower
5 Position below the slope downhill from the tracked mower
The figures above show the recommended and prohibited positions for when the
tracked mower is being used on a slope.
•In any case, the position below the slope downhill from the tracked mower
(5) is prohibited.
•When travelling vertically on a slope, the position above the slope above the
tracked mower (1 in the left figure) is prohibited.
•The position on the slope (3) has a question mark next to it and should be
avoided whenever possible.
WARNING
Risk of injury / risk of environmental damage when on a slope!
There is a risk of injury and environmental and material damage (on the machine)
when mowing on a slope!
•Never leave the HyCut tracked mower unattended when it is moving.
•Follow the information and instructions in this operating manual and
comply with all general occupational safety and accident prevention
regulations.
•If the HyCut tracked mower starts slipping when on a slope, press the
emergency stop button on the remote control immediately.

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•The operator must always be familiar with the local conditions, particularly
the slopes, and change their position accordingly. The distances in relation
to the danger area described must be observed (see Chapter 2.4 Work
areas and danger zones on Page 11).
•Do not mow on slopes with a gradient of more than 50° (120%). The
mower can travel on slopes with a maximum gradient of 50° under optimal
conditions.
•Mowing damp grass or dry sand must be avoided if possible. The tracked
mower may start to slip uncontrollably depending on how damp the grass
is, the grain size of the sand and the slope inclination. The machine can
usually not be stopped in such situations. As such, uncontrollable slipping
must be avoided at all costs.
•Check the area to be mowed for any foreign objects.
•Check the area to be mowed for any steps or holes that may destabilise
the tracked mower.
•Always manoeuvre the mower carefully and drive it downhill slowly.
•When on a slope, mow horizontally in one direction and then use the drive
lever to reverse the direction of travel at the end of each row.
•Set the speed on the rotary potentiometer on the remote control. This
prevents an “oversteering” of the drive lever.
•Never leave the mower on a slope with the engine running.
•Never stand below the tracked mower.
•Never drive the tracked mower outside of your field of vision. When driving
over hills, the tracked mower must be stopped near the hilltop. Change
your position so that you have a clear view of the other side of the hill.
•Do not start or stop the engine suddenly when moving uphill or downhill.
Take particular care when changing direction on slopes.
2.7 Safety devices
DANGER
Risk of death or injury due to non-functioning safety devices!
With non-functioning or overridden safety devices, there is a risk of severe
injuries or even death.
•Before starting the work, ensure that all safety devices are fully functional
and have been installed correctly.
•Never override or disable safety devices.
•Take care to ensure that all safety devices are always accessible.

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2.7.1 Emergency shutdown with the emergency stop button
Fig.
3
: Emergency stop button
1 Tracked mower emergency stop button
2 Remote control emergency stop button
There is an emergency stop button on the top of the tracked mower (1) and on the
remote control (2). In an emergency, press the emergency stop button on the
tracked mower (1) or remote control (2) immediately.
•The HyCut tracked mower will come to a complete stop
•The power supply to the engine controllers remains
•The combustion engine will shut down
•The blade drive will stop
Perform the following steps before starting up the mower again!
•Remedy the cause of the malfunction / dangerous situation.
•Make sure that the emergency stop button is back in its starting position.
2.8 Safety markings
The following symbols and signs can be found in the work area. They refer to the
immediate environment in which they are installed.

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WARNING
Risk of injury due to illegible or missing signage!
Missing and illegible stickers and signs can have serious health consequences or
even cause fatal injuries.
•All safety, warning and operating signs must always be legible.
•Replace any damaged signs or stickers immediately.
2.9 Residual risks
The machine has been designed and built according to the latest state of the art
and in accordance with all currently applicable safety requirements. Nevertheless,
there are residual risks that mean that you must still act carefully. We have listed
the residual risks and the resulting behaviours and measures below.
Improper transport
NOTICE
Material damage caused by improper transport
If transported improperly, transported objects may fall or overturn. This can result
in significant material damage.
•Proceed carefully when unloading the transported objects upon delivery
and during internal transport and observe the symbols and information on
the packaging.
•Only use the attachment points provided.
•Only remove the packaging from the machine shortly before assembling.
Debris and objects lying around
CAUTION
Risk of injury caused by debris and objects lying around!
Debris and objects left lying around may cause personnel to slip and trip. Tripping
can cause injuries.
•Keep the work area clean at all times.
•Remove any objects that you no longer need from the work area and, in
particular, from the ground.
•Remove all tools and parts from the work area.
Cleaning agents
WARNING
Risk of injury caused by cleaning agents and substances being handled
improperly
The improper handling of cleaning agents or substances may have serious health
effects or can even cause fatal injuries.

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•Read the applicable material safety data sheets and manufacturer
instructions for the cleaning agents and substances
•Wear corresponding personal protective equipment (e.g. gloves, safety
shoes, protective suit, respirator, protective eyewear, etc.)
•Ensure that the surrounding environment is sufficiently ventilated
•Handle any warm cleaning agents and substances carefully Coming into
contact with them can cause burns and scalding
•Clean any parts, assemblies and components to remove any adhering oil,
grease and other contaminants
•Avoid skin contact with cleaning agents and substances
•Do not inhale any vapours produced by cleaning agents and substances
•Do not handle close to open flame and do not smoke
Noise level
Like the warning information provided in the documentation, all applicable noise
protection regulations must be observed. The noise level on site depends on the
local ambient noise. The operator must check the noise level at regular intervals.
WARNING
Risk of injury due to noise!
The noise levels occurring in the work area can cause severe hearing damage.
•Covers, insulating materials and other insulating parts should not be
removed and should be replaced if damaged.
•If the daily noise exposure level of 85 dB(A) is exceeded, the operator must
wear hearing protection.
•Only stay in the danger zone for as long as is necessary.

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Moving parts
DANGER
Risk of death and injury due to moving parts!
If moving parts are handled improperly, there is a risk of death and injury, as well
as material damage to the machine and system.
•Do not reach into or handle moving parts when the machine is in operation.
•Never open the covers when the machine is in operation.
•Observe the follow-up time: before opening the covers, take care to ensure
that all parts have stopped moving.
•Wear close-fitting protective clothing with low tensile strength in the danger
zones.
Sharp edges and corners
CAUTION
Risk of injury due to sharp edges and corners!
Sharp edges and corners can cause skin abrasions and cuts.
•Be careful when working in the vicinity of sharp edges and corners.
•If in any doubt, wear protective gloves.
Operating materials / Resources / Lubricants / Oils
WARNING
Risk of injury due to the improper handling of operating materials and
resources!
The improper handling of operating materials and resources can have serious
health consequences or can even cause fatal injuries.
•Read the applicable material safety data sheets and manufacturer
instructions for the operating materials and resources.
•Wear corresponding personal protective equipment (e.g. gloves, safety
shoes, protective suit, respirator, protective eyewear, etc.).
•In the event of accidental eye contact, rinse the eyes thoroughly with plenty
of water and consult a doctor.
•If any materials or resources come into contact with the skin, clean
thoroughly with plenty of water.
•Ensure that the surrounding environment is sufficiently ventilated.
•Handle any warm materials and resources carefully. Coming into contact
with them can cause burns and scalds.
•Clean any parts, assemblies and components to remove any adhering oil,
grease and other contaminants.
•Avoid skin contact with operating materials and resources.
•Do not inhale any vapours produced by operating materials and resources.
•Do not handle close to an open flame and do not smoke.

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2.10 Environmental protection
WARNING
Risk of environmental damage due to the improper handling of operating
materials and resources, as well as cleaning agents and substances!
Handling operating materials, resources, cleaning agents and substances
improperly can cause extensive environmental and material damage.
•Read the applicable material safety data sheets and manufacturer
instructions for the operating materials, resources, cleaning agents and
substances.
•Store any operating materials and resources that are hazardous for the
water or soil, such as parts, assemblies and components contaminated
with oil, in secured areas or collecting basins.
•Bind any emitted operating materials, resources, cleaning agents and
substances with a binding agent and dispose of them according to local
regulations.
•Clean any parts, assemblies and components to remove any adhering oil,
grease and other contaminants.
•Do not let any emitted operating materials and resources and cleaning
agents and substances seep into the soil or flow into the sewage system.
The following environmentally hazardous substances are used:
Lubricants
Lubricants such as greases and oils contain toxic substances. These should not be
released into the environment. They must be disposed of by a specialist waste
disposal company.
Oils
Oils (such as lubricating, hydraulic or cleaning oils) should not be released into the
environment. Oils can have long-term harmful effects when released into water.
They must be disposed of by a specialist waste disposal company.
Observe the safety data sheets provided by the manufacturers.
Electronic parts
Electronic parts can contain toxic substances. These should not be released into
the environment. They must be disposed of by a specialist waste disposal
company.
Accumulators and batteries
Accumulators and batteries contain toxic heavy metals. They are classed as toxic
waste and must either be disposed of at municipal collection points or by a
specialist waste disposal company.